SM 20130101

Service Manual
T770 Compact Track Loader
S/N A3P811001 & Above

S/N A3P911001 & Above
Page 1 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6989476 (1-13) Printed in U.S.A. © Bobcat Company 2013

MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1711 NA1715

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
NA1714 NA1710 NA1712

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1722 NA1725 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW40-0609
1-1 T770 Service Manual

1-2
T770 Service Manual
CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01


1-4
T770 Service Manual
FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15


1-6
T770 Service Manual
SAFETY &
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
SYSTEM
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must DRIVE
hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

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

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

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

the work lights.
FW SSL-1008 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM

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

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

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

WARNING your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-0511 SM

SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
Call Before You Dig

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-0511 SM

FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

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

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

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-0511 SM

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

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.
Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-0511 SM

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-90641A
1
The engine serial number (Item 1) [Figure 3] is located

on the side of the engine above the oil filter.
P100390
The loader serial number plate (Item 1) [Figure 1] is

located on the outside of the loader frame.
Figure 2
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine

Combination P-90175
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 4
B-16315
The delivery report [Figure 4] must be completed by the

dealer and signed by the owner or operator when the
Bobcat loader is delivered. An explanation of the form
must be given to the owner.

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
[1] BUCKET
STEP
BUCKET
STEPS
[2] OPERATOR CAB
LIFT (ROPS AND FOPS)

CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR [3] UNDERCARRIAGE

TAIL LIGHT NA5370
DOOR AND TRACK NA5371
[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS - Roll-Over Protective Structure per ISO 3471 and FOPS - Falling-Object Protective Structure per ISO
3449, Level I. Level II is available.
[3] UNDERCARRIAGE and TRACK - Undercarriage and Track options are available.

1-16
T770 Service Manual
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-6
Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . 10-30-6
TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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

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

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

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

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

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3

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

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

External Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1


LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-85425
P-85423
Lift the rear of the loader and install jackstands in the

B-7023A notched area of the frame [Figure 10-10-2].
Figure 10-10-3
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s

Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807 P-85424
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the struts [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tracks. Make sure the tracks clear the floor or
any obstacles.
NOTE: The lift arms are raised for photo clarity.

WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
10-10-1 T770 Service Manual

10-10-2
T770 Service Manual
LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
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.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or P-85463A P100009
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
Put jackstands under the rear corners of the loader frame
(Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.
DANGER The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Remove attachment from the loader. (See Removal And

Installation on Page 50-40-1.) OR (See Removal And P-90567B
Installation on Page 50-41-1.)
Have a second person install the lift arm support device

over the rod of one of the lift cylinders [Figure 10-20-2].
The lift arm support device must be tight against the

cylinder rod.

LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) The operator must be in the operator’s seat, with the seat
belt fastened and seat bar lowered, until the lift arm
Figure 10-20-3 support device is removed and the lift arms are lowered
all the way.
Start the engine and raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
P100399
Return the lift arm support device to the storage position
and secure with clamping knobs.
Remove the jackstands.
P100398
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
of the lift arm support device must go past the end of the
cylinder (Inset) [Figure 10-20-3].

OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. The seat belt must be
worn for rollover protection.
Check the cab, mounting, and hardware for damage.

Never modify the cab. Replace the cab and hardware if
damaged. See your Bobcat dealer for parts.
ROPS - Roll-Over Protective Structure per ISO 3471 and

FOPS - Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
Level I
Protection from falling bricks, small concrete blocks,

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

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

OPERATOR CAB (CONT’D)
Raising
WARNING
Always stop the engine before raising or lowering the
operator cab.
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If
CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab,
INJURY OR DEATH
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.) • STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-1
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3
P-85463A
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
Hardware Installed Hardware Removed

P-90564A
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P100235A P100236A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONT’D) Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-4]. Remove your hand
Lowering from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Always stop the engine before raising or lowering the all the way down.
operator cab.
NOTE: Always use the grab handles to lower the

operator cab.
WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
Hardware Removed Hardware Installed
N-20120 P-90565A
Pull down on the bottom of the operator cab until it stops

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

when equipped with options and accessories P100236A P100235A
such as cab door, heater, air conditioning,
etc. In these cases, the operator cab may need
to be raised slightly from the latch to be able Install the washers and nuts (both sides) [Figure 10-30-
to release the latch. 5].
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.

OPERATOR CAB (CONT’D) Figure 10-30-8
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
P-76461Q
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] will be ON when the door is open, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
button is pressed.
[DOOR] will appear in the data display [Figure 10-30-8].

P-68116B
The cab door has a sensor (Item 1) [Figure 10-30-6]

installed which deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
1
P-90726J
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] will be OFF when the door is closed, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
button is pressed.

OPERATOR CAB (CONT’D) Special Applications Kit Inspection And Maintenance
Special Applications Kit • Inspect for cracks or damage. Replace if required.

• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
AVOID INJURY OR DEATH • Do not clean with metal blades or scrapers.
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-9
NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.5 in) thick
polycarbonate front door and polycarbonate rear window
[Figure 10-30-9].
Polycarbonate top window (standard item) must be

installed for special applications to restrict material from
entering cab openings.

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-10 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-11
NA1819
Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the
loader. Kit includes 19,1 mm (0.75 in) thick laminated
1
polycarbonate front door, polycarbonate side windows
and polycarbonate rear window [Figure 10-30-10].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Applications Kit to restrict
material from entering cab openings.
P-96030
• Inspect both emergency exit levers (Item 1) [Figure

10-30-11], linkages and hardware for loose or
damaged parts.
• Repair or replace if necessary.

TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2

Rear Tie Down Front Tie Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P-85616A
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1
P100727D
Alternate Rear Tie Down Alternate Front Tie Down
1
P100728D
P-85466
P-85717A P-85599B
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie down

positions [Figure 10-40-2]. (Lift arms shown raised
for clarity.) (Some models have two front tiedown
locations on the transmission.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.

10-40-2
T770 Service Manual
TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

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

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tracks will not turn.) There might be slight wear
to the tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)

10-50-2
T770 Service Manual
REMOTE START TOOL KIT- MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

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

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow / variable flow switch (Item 2) [Figure

10-60-2] is used to activate the auxiliary hydraulics.
P16114 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
The remote start tool (Item 1) [Figure 10-60-1] is when checking pressures and flow rate.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering NOTE: With the engine running; pushing and holding
linkage, and electrical diagnostics. the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.

REMOTE START TOOL - MEL1563 (CONT'D) Figure 10-60-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
2
2
1
1
P-85728
Loaders equipped with an attachment harness (Item 1)

P16114 must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Remove the service tool harness (Item 1) from the cover Connect the service tool harness to the ACD connector
(Item 2) [Figure 10-60-3]. and the loader harness connector.
Figure 10-60-4 NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.
1
P-85729
Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.
Connect the service tool harness control to the loader

harness connector.

REMOTE START TOOL-MEL1563 (CONT'D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The service tool harness communicator (Item 1) is P16115

required to connect remote start tool to the Service PC
(Item 2) [Figure 10-60-6].
The remote start tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

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

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
1
P-85728
Figure 10-60-11
P-85729
Figure 10-60-9
1
1
P-85726
Connect the remote start tool to the engine harness

P-85728
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the remote start tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-13
WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P16118
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock The traction lock switch (Item 1) [Figure 10-60-13] is
the keypad with a unique password (keyless) or used to turn traction lock ON or OFF. Push the switch to
otherwise disable the starter before working in the override position. The switch will illuminate to indicate
the engine area. traction lock OVERRIDE, in this position the wheels are
W-2457-1110 able to turn.
The maximum flow / variable flow switch (Item 2) [Figure

Figure 10-60-12
10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when checking pressures and flow rate.
NOTE: With the engine running; pushing and holding

the pressure release switch (Item 3) [Figure
1
10-60-13] will cause the engine to stop.
WARNING
P16116 AVOID INJURY OR DEATH
• Use traction lock override switch for service work
with seat bar raised.
The remote start tool (Item 1) [Figure 10-60-12] has • Traction lock is engaged when light is OFF.
three rocker switches. • Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

REMOTE START TOOL KIT-MEL1563 (CONT'D)
Figure 10-60-14
P-85311
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-14].

REMOTE START TOOL (SERVICE TOOL) KIT -
7217666
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool and
MEL1400B BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7217666,

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

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7217666 (CONT'D)
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps

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

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

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
The RUN button (Item 3) [Figure 10-61-2] is used to turn

the Remote Start Tool (Service Tool) on and activates the
loader electrical system. The button will illuminate to
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678 The traction lock button (Item 5) [Figure 10-61-2] is used

to turn traction lock ON or OFF. Push the button and the
button will illuminate indicating the traction lock is
The remote start tool (Item 1) [Figure 10-61-1] is disabled in which the wheels or tracks are able to turn.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering The auxiliary button (Item 6) [Figure 10-61-2] is used to
linkage, and electrical diagnostics. activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

7217666 (CONT'D)
Loader Service Tool Harness - 6689747

1
Figure 10-61-3
2 3
P-90972
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must remove the tie
P-76678 strap (Item 2) and disconnect the attachment harness
from the loader harness (Item 3) [Figure 10-61-5].
The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace
3] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].
Figure 10-61-4
P-90973
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
3 2
1 P-76450
P-90976 The computer service tool harness (Item 1) [Figure 10-

61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-
6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The key switch must be in the off position or

the Remote Start Tool (Service Tool) will not
operate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

REMOTE START TOOL (SERVICE TOOL) KIT - Open the rear door of the loader.
7217666 (CONT'D)
Figure 10-61-9
Remote Start Procedure
WARNING
UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
1
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit. P-90973
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in Loaders without an attachment control harness, remove
the engine area. the loader harness cap (Item 1) [Figure 10-61-9] and
W-2457-1110 connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
The tool listed will be needed to do the following
NOTE: When using a Remote Start Tool (Service tool)
procedure:
harness on loaders not equipped with an
attachment control device, the Remote Start
7217666: Remote Start Tool (Service Tool) Kit
Tool (Service Tool) harness attachment
Figure 10-61-8 control device connector must be capped.
Figure 10-61-10
P-76450
P-90974
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-8] is required when the operator cab is in the
raised position for service and the service technician Loaders with an attachment control harness (7 pin or 14
needs to turn on the loader or start the engine. Example: pin), the attachment harness (Item 1) must be
adjusting the steering linkage. disconnected from the loader harness (Item 2) [Figure
10-61-10].
Lift and block the loader.
Raise the lift arms (if required by the procedure) and When the remote start procedure is completed, replace
install an approved lift arm support device. the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
Raise the operator cab (if required by the procedure). harness.

7217666 (CONT'D)
2
Figure 10-61-11
5 3
6 4
2 1
P-76439
3
1
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-12] has five buttons.
P-90976
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when checking pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7217666 (CONT'D)
Figure 10-61-13
1 2
P-85311B
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to

and from the computer.
NOTE: To relieve the pressure at the rear or

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

10-61-8
T770 Service Manual
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
SERVICE SCHEDULE HOURS

[4] [4] [4]
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Check display panel. Service only when required. Check for leaks and
Engine Air Filter and Air System
damaged components.
Clean debris from oil cooler, radiator and grille. Check coolant level COLD and
Engine Cooling System
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Lift Links, Cylinders,
Lubricate with multipurpose lithium based grease.
Bob-Tach, Pivot Pins, Wedges
Check the condition of seat belt. Clean or replace seat belt retractors as
Seat Bar, Control Interlocks, Seat
needed. Check the seat bar and control interlocks for correct operation. Clean
Belt, Seat Belt Retractors
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS™) bar raised. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Check for damaged signs (decals) and safety treads. Replace any signs or
Safety Signs and Safety Treads
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and Air Conditioning
Clean or replace filters as needed.
Filters (If Equipped)
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Tracks Check for damaged and worn tracks and correct tension. [1]
Track Sprocket Nuts Check torque. Tighten as needed. See procedure in this manual.
Parking Brake, Foot Pedals,
Hand Controls and Steering Check for correct operation. Repair or adjust as needed.
Levers or Joysticks
Spark Arrester Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydrostatic Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, air
Check condition. Replace as needed.
conditioning, water pump)
Bobcat Interlock Control System
Check the function of the lift arm bypass control.
(BICS™)
Engine Oil and Filter Replace oil and filter. [2] [3]
Hydraulic Charge Filter,
Replace the charge filter and the reservoir breather.
Hydraulic Reservoir Breather
Hydrostatic Drive Motors Replace oil with high performance synthetic oil P/N 7024981.
Hydraulic / Hydrostatic Filter Replace the hydraulic / hydrostatic filter.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves.
Coolant Replace the coolant Every 2 years
[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Or every 12 months.

10-70-2
T770 Service Manual
AIR CLEANER SERVICE Figure 10-80-2
Replacing Filter Elements
Figure 10-80-1
2
1
1
P100229
Open the latches (Item 2) and remove the cover (Item 1)

NA3178 [Figure 10-80-2].
Figure 10-80-3
It is important to change the air filter element only when
necessary. The service indicator (Item 1) will FLASH.
Press the information button (Item 3) until the display
screen (Item 2) shows the service codes. Service code
[M0117] (Air Filter Plugged) will show in the display
screen (Item 2) [Figure 10-80-1] when air filter change is
necessary.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Outer Filter
1
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.) P-90647
NOTE: The coolant tank can be raised to facilitate

access to the air cleaner. Pull the outer filter element (Item 1) [Figure 10-80-3] out
and discard.
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new filter element. Push all the way in until it

contacts the base of the housing.
Install the cover and secure the latches [Figure 10-80-2].
NOTE: Ensure the intake hose is connected to the

fitting on the fan housing (Inset) [Figure 10-
80-5].
NOTE: Ensure the coolant tank is secured into the

coolant tank bracket.
Install the rear grille.

AIR CLEANER SERVICE (CONT’D) Figure 10-80-5
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

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

outer filter is replaced. 2
• After the outer element has been replaced, start the

engine and run at full rpm. If service code [M0117]
(Air Filter Plugged) is still displayed in the data 1
display, replace the inner filter element. P100229
P-90648A

60-1.) Install the cover (Item 1) and secure the latches (Item 2)
[Figure 10-80-5].
Remove the cover [Figure 10-80-2] and the outer filter
element [Figure 10-80-3]. NOTE: Ensure the intake hose is connected to the
fitting on the fan housing (Inset) [Figure 10-
Figure 10-80-4 80-5].
NOTE: Ensure the coolant tank is secured into the

coolant tank bracket.
1
P-90646
Remove the inner filter element (Item 1) [Figure 10-80-

4].
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new inner filter element. Push all the way in until it
contacts the base of the housing.
Install the outer filter element [Figure 10-80-3].

ENGINE COOLING SYSTEM Cleaning
Check the cooling system every day to prevent over- Remove the rear grille. (See REAR GRILLE on Page 50-
heating, loss of performance or engine damage. 60-1.)
Maintenance Platform Loaders With Air Conditioning
Figure 10-90-1 Figure 10-90-2
2
2
1 3
P100039A P107095
A maintenance platform (Item 1) [Figure 10-90-1] is Use low air pressure or water pressure to clean the top of
available from your Bobcat dealer to facilitate access the air conditioning condenser (Item 1) [Figure 10-90-2].
when cleaning the engine cooling system.
The area between the air conditioning condenser and the
oil cooler will require occasional cleaning. Remove the
bolts (Item 2) and the brackets (Item 3) [Figure 10-90-2].

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-2019-0907

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Unhook the two rubber straps (Item 2) [Figure 10-90-4].
Loaders With Air Conditioning (Cont’d) Figure 10-90-5
Figure 10-90-3
1
1
2
3
2
P107095A P100327
NOTE: Be careful when raising and lowering the air Raise the oil cooler (Item 1) until the bar (Item 2) drops
conditioning condenser so that the air into place to support the oil cooler. Use low air pressure
conditioning condenser does not fall on the or water pressure to clean the top of the radiator (Item 3)
oil cooler and damage the fins. [Figure 10-90-5].
Raise the air conditioning condenser (Item 1) and use Raise the bar (Item 2) [Figure 10-90-5] slightly and lower
low air pressure or water pressure to clean the top of the the oil cooler. Fasten the two rubber straps.
oil cooler (Item 2) [Figure 10-90-3].
Check the cooling system for leaks.
Lower the air conditioning condenser (Item 1) [Figure 10-
90-3]. Install the brackets (Item 3) [Figure 10-90-2] and Install the rear grille.
the bolts (Item 2) [Figure 10-90-2].
Loaders Without Air Conditioning
Figure 10-90-4
P100779
Use low air pressure or water pressure to clean the top of

the oil cooler (Item 1) [Figure 10-90-4].

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant
Checking Level For the service interval for replacing the engine
coolant. (See SERVICE SCHEDULE on Page 10-70-1.)
60-1.) Open the rear door and remove the rear grille.
Figure 10-90-6 Remove the coolant fill cap (Item 1) [Figure 10-90-6].
Figure 10-90-7
2
1
P100330
P-90657A
Check coolant level using the level markers (Item 2)
[Figure 10-90-6] on the tank. Coolant must be between
top and bottom level markers when the engine is cold. Attach a hose to the coolant drain petcock (Item 1)
[Figure 10-90-7] located to the left of the oil filter
NOTE: The loader is factory filled with propylene assembly. Open the petcock and drain the coolant into a
glycol coolant (purple color). DO NOT mix container. Close the petcock and remove the hose.
propylene glycol with ethylene glycol. Recycle or dispose of coolant in an environmentally safe
manner.
Use a refractometer to check the condition of propylene
glycol in your cooling system. Close the rear door.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-5.)
The correct mixture of coolant to provide a -37°C (-34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
IMPORTANT of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt

of water.
AVOID ENGINE DAMAGE Add premixed coolant, 47% water and 53% propylene
Always use the correct ratio of water to antifreeze. glycol to the coolant tank until the coolant level reaches
the lower marker on the tank [Figure 10-90-6].
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine Install the coolant fill cap.
damage.
NOTE: When installing the coolant fill cap, the cap
must be tightened until it clicks.
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the Run the engine until it is at operating temperature. Stop
boiling point and freeze protection of the system. the engine. Check the coolant level when cool. Add
coolant as needed.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature Install the rear grille.
engine damage.
I-2124-0497

10-90-4
T770 Service Manual
FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE NO. 2 NO. 1 corrosion and plugging of fuel system components.
-9°C (+15°F) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -29°C (-20°F) 50% 50% failure of fuel system components, such as plugged
Below -29°C (-20°F) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals may be required, such

At a minimum, low sulfur diesel fuel must be used in this
as cleaning the fuel system and replacing fuel filters
machine. Low sulfur is defined as 500 mg/kg (500 ppm)
and fuel lines.
sulfur maximum.
• Using biodiesel blended fuels containing more than
The following fuels may also be used in this machine:
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Ultra low sulfur diesel fuel. Ultra low sulfur is defined
pump and seals.
as 15 mg/kg (15 ppm) sulfur maximum.
Apply the following guidelines if biodiesel blend fuel is
• Biodiesel blend fuel - Must contain no more than five
used:
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
• Ensure the fuel tank is as full as possible at all times
marketed as B5 blended diesel fuel. B5 blended
to prevent moisture from collecting in the fuel tank.

diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,

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

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

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

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

stability and should not be stored for more
than 3 months.

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Open the rear door. NA1726
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1 1].
Close the rear door.
WARNING
P100035 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter. (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water
WARNING
Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
2
Figure 10-100-4
1
1
P-90653A
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter.
Replacing Element
2
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and P100780
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air
housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
WARNING Close the vent (Item 1) [Figure 10-100-4].

Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

10-100-4
T770 Service Manual
ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil ENGINE OIL

RECOMMENDED SAE VISCOSITY NUMBER
Check the engine oil level every day before starting the (LUBRICATION OILS FOR DIESEL ENGINE
engine for the work shift. CRANKCASE)
Figure 10-110-2
Figure 10-110-1
P-90654A
TEMPERATURE RANGE ANTICIPATED BEFORE

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

Remove the oil fill cap (Item 2) [Figure 10-110-1] to add Classification of CI-4 or better [Figure 10-110-2].
engine oil.
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Later Models
Removing And Replacing Oil And Filter Figure 10-110-4
For the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-70-1.)
Run the engine until it is at operating temperature. Stop

the engine.
P-90497B
Open the rear door.
Earlier Models
Figure 10-110-3 1 2
P109086A
The oil drain hose is located behind a cover under the

right rear corner of the loader (Inset) [Figure 10-110-6].
1
Remove the cover mounting bolts (Item 1) and remove
the cover (Item 2) [Figure 10-110-6].
Figure 10-110-5
2
3 P-90497A
P-90499A
The oil drain hose is located behind a cover under the

right rear corner of the loader (Inset) [Figure 10-110-3].
Remove two cover mounting bolts (Item 1) [Figure 10-

110-3].
Loosen one cover mounting bolt (Item 2) and slide the 2

1
cover (Item 3) [Figure 10-110-3] to the rear of the loader.
P109088
Remove the oil drain hose (Item 1) from the storage

location and route through the opening (Item 2) [Figure
10-110-5].

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-7
Removing And Replacing Oil And Filter (Cont’d)
All Models
2
Figure 10-110-6
P-90654A
Remove the oil filter (Item 2) [Figure 10-110-7] and clean

1 the filter housing surface.
P-90498A Use genuine Bobcat filter only.
Put clean oil on the new filter gasket, install the filter and
Remove the oil drain cap (Item 1) [Figure 10-110-6] from hand tighten.
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe Remove the oil fill cap (Item 3) [Figure 10-110-7].
manner.
Put oil in the engine and replace the fill cap. For the
Install and tighten the oil drain cap [Figure 10-110-6].
correct quantity. (See Capacities on Page SPEC-10-5.)

Do not overfill.
(Earlier Models) - Install the cover and the cover
mounting bolts [Figure 10-110-3]. Tighten all bolts. Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
OR
Remove the dipstick (Item 1) [Figure 10-110-7] and
(Later Models) - Remove the oil drain hose from the check the oil level.
opening and return to storage location [Figure 10-110-
5]. Install the cover and the cover mounting bolts [Figure Add oil as needed if it is not at the top mark on the
10-110-4]. Tighten all bolts. dipstick. Install the dipstick and close the rear door.
WARNING
explosion or fire.
W-2103-0508

10-110-4
T770 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid HYDRAULIC / HYDROSTATIC FLUID

RECOMMENDED ISO VISCOSITY GRADE (VG)
Check the hydraulic / hydrostatic fluid level every day AND VISCOSITY INDEX (VI)
before starting the work shift. Figure 10-120-3
Park the loader on a level surface, lower the lift arms and
place the attachment flat on the ground or tilt the Bob-
Tach fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
P100391 temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure Use only recommended fluid in the hydraulic system
10-120-1]. Keep the fluid level within the operating range. [Figure 10-120-3]. (See Hydraulic System on Page
SPEC-10-4.)
60-1.)
Figure 10-120-2
WARNING
1 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
P100055
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

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

the rear grille.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after 1

major repair.
Always replace the hydraulic / hydrostatic filter and the 2

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.) P100327

60-1.) Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into place to support the oil cooler. This
Figure 10-120-4 will aid in draining the hydraulic fluid.
Figure 10-120-6
1
1
P100055
P100907
Remove the right side access cover bolts (Item 1)

[Figure 10-120-6] and remove the cover. (Lift arms
shown raised for visual clarity.)
P100779
Remove the hydraulic fill cap (Item 1) and unhook the two
rubber straps (Item 2) [Figure 10-120-4].

Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-120-7
1
1 2
P-90506
Remove and clean the hydraulic fill screen (Item 1)

P100784 [Figure 10-120-8]. Use low air pressure to dry the
screen.
Remove the clamp (Item 1). Pinch off the hose (Item 2) Install hydraulic fill screen and add the correct fluid to the
[Figure 10-120-7] near the fitting and disconnect hose reservoir until the fluid level is within the operating range
from the fitting. Route the hose out the side of the loader of the sight gauge. (See Capacities on Page SPEC-10-
and drain the fluid into a container. 5.) and (See Checking And Adding Fluid on Page 10-
120-1.)
Connect the hose to the fitting when the fluid stops
draining. Install the hydraulic fill cap.
Recycle or dispose of used fluid in an environmentally Install the rear grille.

safe manner.
Start the engine and operate the loader hydraulic
controls.
WARNING Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)
explosion or fire.
W-2103-0508
Install the side access cover and bolts [Figure 10-120-6].
Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps [Figure 10-120-4].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new O-ring and lubricate with clean oil.
Removing And Replacing Hydraulic / Hydrostatic Install new filter element ensuring that element is fully
Filter seated in the housing.
For the correct service interval. (See SERVICE Install the filter cap and tighten to 25 N•m (18 ft-lb)
SCHEDULE on Page 10-70-1.) torque.

60-1.)
The filter housing is located behind the hydraulic fluid

WARNING
reservoir.
Clean the top of the filter housing. Always clean up spilled fuel or oil. Keep heat, flames,
Figure 10-120-9 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

controls.
1
WARNING
P100047 Diesel fuel or hydraulic fluid under pressure can
Remove the filter cap (Item 1) [Figure 10-120-9]. Use a piece of cardboard or wood to find leaks. Do
Figure 10-120-10 enters skin or eyes, get immediate medical attention
W-2072-0807
1
Stop the engine and check for leaks at the filter.

2 P100044 P100046
Remove the filter element (Item 1) [Figure 10-120-10]

and discard.
Remove the O-ring (Item 2) [Figure 10-120-10] and

discard.

Removing And Replacing Hydraulic Charge Filter
The hydraulic charge filter is located under the operator

cab. For the correct service interval (See SERVICE
Raise the operator cab. (See Raising on Page 10-30-2.) 1
Figure 10-120-11
1
P100785A
2 Remove and discard the filter element (Item 1) [Figure

10-120-13].
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.
1
Put clean oil on the seal of the new filter element. Install
P100275 the element on the filter base. Install and tighten the filter
housing to 65 - 70 N•m (48 - 52 ft-lb) torque.
Unhook the four rubber straps (Item 1) and remove the

lower fan duct (Item 2) [Figure 10-120-11].
Figure 10-120-12
WARNING
explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-120-11].
NOTE: Failure to install the lower fan duct correctly

may result in decreased cooling.
Lower the operator cab. (See Lowering on Page 10-30-

P100785 3.)

Place a suitable container below the filter housing and controls.
remove the filter housing (Item 1) [Figure 10-120-12]
using a socket wrench.
Recycle or dispose of used fluid in an environmentally

safe manner.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Removing And Replacing Hydraulic Charge Filter See the SERVICE SCHEDULE for the correct
(Cont’d) replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)

WARNING 60-1.)
Figure 10-120-14
not use your bare hand. Wear safety goggles. If fluid 1
W-2072-0807
Stop the engine and check for leaks at the filter.

P100055
Remove the breather cap (Item 1) [Figure 10-120-14]

and discard.
Install new breather cap.

BOB-TACH (HAND LEVER) Figure 10-130-2
Inspection And Maintenance

1
Figure 10-130-1
Wedge must contact lower

edge of hole in the
attachment mounting
frame.
P-31233A P-31233
The wedges (Item 1) [Figure 10-130-2] must extend

P-85513A through the holes in the attachment mounting frame.
The spring loaded wedges (Item 1) must contact the

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-130-1]. frame (Item 2) [Figure 10-130-2].
The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-130-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING

The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208

BOB-TACH (HAND LEVER) (CONT'D)
Inspection And Maintenance (Cont'd)
Figure 10-130-3
B-17460
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-130-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

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

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)

BOB-TACH (POWER) Figure 10-131-2
This machine may be equipped with a Power Bob-Tach.

1
Figure 10-131-1 2
1 Wedge must contact lower

edge of hole in the
attachment mounting
frame.
P-31233A P-31233
2 The wedges (Item 1) [Figure 10-131-2] must extend

through the holes in the attachment mounting frame.
P-85320A The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-131-2].
Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure [Figure 10-131-2], the attachment will be loose and can
10-131-1] until the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely.

WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208

BOB-TACH (POWER) (CONT'D)
Inspection And Maintenance (Cont'd)
Figure 10-131-3
B-17460
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-131-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

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

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)

LUBRICATING THE LOADER Figure 10-140-2
Lubrication Locations
Lubricate the loader as specified for the best

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

Bobcat loader.
2
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. P-90572A
Tilt the Bob-Tach forward until it contacts the ground. (Not

required on later models with Bob-Tach wedge grease 2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-
fittings that are accessible from the side.) 140-2].
Stop the engine. Figure 10-140-3
Lubricate the following:
Figure 10-140-1
3
P-90543A
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-140-3].

P100908
1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

140-1].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-6
Lubrication Locations (Cont’d)
Figure 10-140-4
P-85720
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-90542A
140-6].
Figure 10-140-7
4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-140-4].
Figure 10-140-5
7
P-85719
P-85484
7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-
7].
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

140-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-10
Lubrication Locations (Cont’d)
Earlier Models
9
Figure 10-140-8
8
P100393
9. Rear Control Link (Both Sides) (2) [Figure 10-140-

10].
P-85487
Figure 10-140-11
Later Models
Figure 10-140-9
10
8 P-90544A
10. Front Control Link (Both Sides) (2) [Figure 10-140-

11].
P-31308A
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-140-8]

or [Figure 10-140-9].

10-140-4
T770 Service Manual
SPARK ARRESTER MUFFLER Figure 10-150-1
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for

cleaning the spark arrester muffler. (See SERVICE
Do not operate the loader with a defective exhaust

system.
1
IMPORTANT P-90662A
This machine is factory equipped with a spark Remove the plug (Item 1) [Figure 10-150-1] from the
arrester exhaust system that must be maintained for bottom of the muffler.
proper function.
• WITH MUFFLER
If factory equipped with a muffler, the muffler is a
U.S.D.A. Forestry Service Approved spark
WARNING
arrester. The spark chamber must be emptied
every 100 hours of operation to keep it in working When the engine is running during service, the
condition. driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
• WITH DIESEL PARTICULATE FILTER (DPF) cause injury or death.
W-2006-1209
If factory equipped with a DPF, the DPF acts as a
spark arrester and engine exhaust emissions
device. The DPF must be maintained according Start the engine and run for about 10 seconds while a
to the instructions in the Operation & second person, wearing safety glasses, holds a piece of
Maintenance Manual for proper function as an wood over the outlet of the muffler. This will force
emissions and spark arrester device. contaminants out through the cleanout hole.
(If this machine is operated on flammable forest, Stop the engine. Install and tighten the plug. Close the
brush or grass cover land, the machine must be rear door.
equipped with a spark arrester attached to the
exhaust system and maintained in working order.
Failure to do so will be in violation of California state
law section 4442 PRC. Refer to local laws and
regulations for spark arrester requirements.)
WARNING
I-2350-0312
When an engine is running in an enclosed area, fresh
Stop the engine and open the rear door. (See REAR air must be added to avoid concentration of exhaust
DOOR (TAILGATE) on Page 50-70-1.) fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
WARNING
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285

SPARK ARRESTER MUFFLER (CONT’D)
Cleaning Procedure (Cont’d)
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

PIVOT PINS
Figure 10-160-1
P-90667
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-1].
Check that the lock nuts are tightened to 48 - 54 N•m (35

- 40 ft-lb) torque.

10-160-2
T770 Service Manual
LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
loader for an extend period of time. Below is a list of items
to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.
• Lubricate the loader. • Remove grease from exposed cylinder rods.
• Replace worn or damaged parts. • Check all belt tensions.
• Park the loader in a dry protected shelter. • Be sure all shields and guards are in place.
• Lower the lift arms all the way and put the bucket flat • Lubricate the loader.
on the ground.
• Check track condition and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tracks.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.
• Start the engine and let run for a few minutes while
• Put fuel stabilizer in the fuel tank and run the engine observing the instrument panels and systems for
a few minutes to circulate the stabilizer to the pump correct operation.
and fuel injectors.
• Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the

following: • Stop the engine and check for leaks. Repair as
needed.
Drain the fuel tank, refill with 100% petroleum diesel
fuel, add fuel stabilizer and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

premixed coolant.
• Replace all fluids and filters (engine, hydraulic /

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

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

condition.

10-170-2
T770 Service Manual
STOPPING THE ENGINE AND LEAVING THE LOADER NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Procedure Deluxe Instrumentation Panel allows
operation of the loader without using a
Stop the loader on level ground. password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Fully lower the lift arms and put the attachment flat on the Feature on Page 60-191-1.)
ground.
Figure 10-180-3
Figure 10-180-1
P-85737A P-85735A
Exit the loader using grab handles, safety tread and steps
P-90525B (maintaining a 3-point contact) [Figure 10-180-3].
Push the engine speed control fully down [Figure 10-

180-1] to decrease the engine speed.
WARNING
Engage the parking brake.

Figure 10-180-2
Before you leave the operator’s seat:
1 1 • Lower the lift arms and put the attachment flat on
the ground.
2 • Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
P-90688A P-90214C P-90214A
position to make sure the lift, tilt and traction
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) or The seat bar system must deactivate these functions
press the STOP button (Item 2) [Figure 10-180-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to

prevent operation of the loader by unauthorized
personnel.

10-180-2
T770 Service Manual
EMERGENCY EXIT Figure 10-190-3
The front opening on the operator cab and rear window

provide exits.
External Access
Figure 10-190-1
P-90676
Exit through the rear of the operator cab [Figure 10-190-

3].
Front Door
P-90669A
This machine may be equipped with a front door.
The rear window can be removed from outside the loader NOTE: Use this procedure to remove the front door
using a T40 TORX® driver. Turn both screws (Item 1) only under emergency conditions. Damage to
[Figure 10-190-1] in until the latches disengage from the machine may occur.
window frame. Pull the top of the window away from the
cab and lift up to remove.
Figure 10-190-4
Rear Window
NOTE: Use this procedure to remove the rear window

only under emergency conditions. Damage to
machine may occur.
Figure 10-190-2 1
P-90725
Turn both latches (Item 1) [Figure 10-190-4] down until

they disengage from the door frame.
Push the door out of the operator cab door frame.
P-85309A Exit through the opening.
Turn both latches (Item 1) [Figure 10-190-2] in until they

disengage from the window frame.
Push the rear window out of the rear of the operator cab.

EMERGENCY EXIT (CONT’D) Figure 10-190-7
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-190-5
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-190-7] on the door. (Bottom
hinge shown)
2
Figure 10-190-8
P-85781A
1
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 10-190-5].
2
Figure 10-190-6
2
3
P-90686A
Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
1 against door and rotate latch (Item 1) [Figure 10-190-8]
up to lock cast washer into place. (Bottom hinge shown)
Install door on loader.

P-85588A P-85589A
Install the gas spring socket on the ball stud fitting. Install
the clip into the hole in the gas spring socket. Rotate the
Rotate and pull the clip (Item 1) out of the gas spring clip to lock into place [Figure 10-190-6].
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 10-190-6]. Connect electrical connector (Item 2) and washer fluid
Remove the door hinges from the loader.

SEAT BELT Figure 10-200-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware or any other obvious
problem should be replaced immediately. B-22283
The items below are referenced in [Figure 10-200-1].

1. Check the webbing. If the system is equipped with a

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

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

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

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

parts for your machine.

10-200-2
T770 Service Manual
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-9
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
MAIN RELIEF VALVE (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
MAIN RELIEF VALVE (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-2
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-5
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-6

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY MODELS) . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-10
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-11
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-33

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS) . . . . . . . . . . . . . 20-42-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-8
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) . . . . . . . . . . . . . 20-43-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-6
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-19
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-28
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

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

20-06
T770 Service Manual
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
T770 (S/N A3P811001 – A3P813237)
(S/N A3P911001 – A3P912042)
(PRINTED FEBRUARY 2013)
V-1433legend
LEGEND
1 RESERVOIR: 16 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 33 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal)
PRESSURE RELEASE (SAPR)
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal)
17 SOLENOID ACTIVATED DIRECTIONAL
2 SIGHT GUAGE CONTROL VALVE - BICS CONTROL 34 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – BRAKE VALVE
18 FILTER - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH:
(SCREEN) 35 FILTER – BRAKE VALVE
103 kPa (1,03 bar) (15 psi)
Normally Closed 19 CHECK VALVE - With 100 kPa (1,0 bar) 36 CHECK VALVE
(14.5 psi) Spring
4 FILTER - HYDRAULIC (CANISTER)
20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 37 CHARGE PUMP -
5 SPRING LOADED FILTER BY-PASS 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
VALVE: 172 kPa (1,7 bar) (25 psi) 21 PULL BUTTON ACTIVATED
38 HYDRAULIC PUMP . . . . . . . Gear Type
6 DIAGNOSTIC COUPLER DIRECTIONAL CONTROL VALVE - LIFT
87,1 L/min (23.0 U.S gpm) at High Engine Idle
ARM BY-PASS
39 VARIABLE CAPACITY DISPLACEMENT
7 RELIEF VALVE - MAIN: 22 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers 23 PROPORTIONAL RELIEF VALVE –
40 RELIEF/REPLENISHING VALVE - HIGH
8 RELIEF/ANTICAVITATION VALVE - (Fan Speed Regulator): 10797 – 12300 kPa PRESSURE: 36500 kPa (365 bar) (5294 psi)
PORT: 27579 kPa (276 bar) (4000 psi) (108 - 123 bar) (1566 - 1784 psi)
41 RELIEF VALVE - CHARGE INLET:
9 RELIEF/ANTICAVITATION VALVE - 24 SPRING LOADED FILTER BY-PASS VALVE: 3206 kPa (32, bar) (465 psi)
PORT (OPTIONAL): 27579 kPa
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) at High Engine Idle
(276 bar) (4000 psi)
With 60 ° C (140 ° F) Fluid
10 SOLENOID ACTIVATED DIRECTIONAL 25 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR 42 CHECK VALVE – COLD WEATHER BY-PASS
CONTROL VALVE - AUXILIARY
With 345 kPa (3,45 bar) (50 psi) Spring
11 LOAD CHECK VALVE 26 FILTER - HYDRAULIC (CANISTER)
12 ANTICAVITATION VALVE 27 SENSOR – CHARGE PRESSURE –

Fan Filter
13 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – HYD. TEMPERATURE
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 29 RESTRICTION - 2,0 mm (0.079 inch)
14 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 30 CHECK VALVE - With 1400 kPa (14,0 bar)
(203 psi) Spring
15 PILOTED ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - TILT CONTROL
32 FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC NOTE: Unless otherwise specified
MOTOR springs have NO significant
pressure value.
Printed in U.S.A. V-1433legend (2-25-13)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR 14
Male
L
30
29
Female
31
HYDRAULIC CONTROL VALVE
32
9
Z
10
A
10
33 B
Auxiliary Spool
TILT CYLINDERS
8
11
6 BICS CONTROL VALVE
HYDROSTATIC PUMP
39 Tilt Spool
8
15
M4
M
11
3
D C 16 LIFT CYLINDERS)
12
40 40 Lift Spool
13
41 11 18 18
A
19
B
17 ?
IN 20
2
M2 M1 7
6
21
40 1
40 Oil Cooler
39 42
HYDRAULIC RESERVOIR
T 3 2 (VENTED)
4 1
38
37 5
VARIABLE SPEED HYDRAULIC

FAN MOTOR W/ INTEGRATED FILTER
HYDRAULIC FILTER
26
24
27 WORKING CIRCUIT
BRAKE VALVE -
SPRING APPLIED CHARGE
PRESSURE RELEASE
B
33 PRESSURE
(SAPR) A
DRAIN / RETURN
25 22
3
Z
P DR 23
36 2
35 32 Printable Version Click Here

35
DRAIN/RETURN MANIFOLD
1
34 HYDRAULIC/HYDROSTATIC SCHEMATIC
28
STANDARD WITH NO OPTIONS
31 29 T770 (S/N A3P811001 - A3P813237)
30
L
(S/N A3P911001 - A3P912042)
DRIVE MOTOR
7194314
PRINTED IN U.S.A.
WITH NO OPTIONS
T770 (S/N A3P813238 AND ABOVE)
(S/N A3P912043 AND ABOVE)
V-1550legend
LEGEND
1 RESERVOIR: 16 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 33 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal)
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal)
2 SIGHT GUAGE CONTROL VALVE - BICS CONTROL 34 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – BRAKE VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 18 FILTER - BICS CONTROL VALVE
103 kPa (1,03 bar) (15 psi) Normally Closed (SCREEN) 35 FILTER – BRAKE VALVE
4 FILTER - HYDRAULIC (CANISTER) 19 CHECK VALVE - With 100 kPa (1,0 bar) 36 CHECK VALVE
(14.5 psi) Spring
5 SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi) 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 37 CHARGE PUMP -
51,1 L/min (13.5 U.S. gpm) at High Engine Idle
6 DIAGNOSTIC COUPLER 21 PULL BUTTON ACTIVATED
RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE - LIFT
7 87,1 L/min (23.0 U.S gpm) at High Engine Idle
23787 - 24476 kPa (238 - 245 bar) ARM BY-PASS
(3450 - 3550 psi) at Front Quick Couplers 39 VARIABLE CAPACITY DISPLACEMENT
22 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
RELIEF VALVE – MAIN (OPTIONAL):
25511 – 26200 kPa (255 - 262 bar) 23 PROPORTIONAL RELIEF VALVE –
6 40 RELIEF/REPLENISHING VALVE - HIGH
(3700 - 3800 psi) at Diagnostic Coupler (Fan Speed Regulator): 10797 – 12300 kPa PRESSURE: 36500 kPa (365 bar) (5294 psi)
(108 - 123 bar) (1566 - 1784 psi)
7A RELIEF VALVE – AUXILIARY (OPTIONAL):
41 RELIEF VALVE - CHARGE INLET:
23787 – 24476 kPa (238 - 245 bar)
6 24 SPRING LOADED FILTER BY-PASS VALVE: 3206 kPa (32, bar) (465 psi)
(3450 - 3550 psi) at Diagnostic Coupler
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) at High Engine Idle
8 RELIEF/ANTICAVITATION VALVE - With 60 ° C (140 ° F) Fluid
PORT: 27579 kPa (276 bar) (4000 psi) HYDRAULIC MOTOR 42 CHECK VALVE – COLD WEATHER BY-PASS
9 RELIEF/ANTICAVITATION VALVE - With 345 kPa (3,45 bar) (50 psi) Spring
PORT (OPTIONAL): 27579 kPa
(276 bar) (4000 psi)
27 SENSOR – CHARGE PRESSURE –
10 SOLENOID ACTIVATED DIRECTIONAL Fan Filter
28 SENSOR – HYD. TEMPERATURE
11 LOAD CHECK VALVE
29 RESTRICTION - 2,0 mm (0.079 inch)
12 ANTICAVITATION VALVE
LIFT CYLINDER SPOOL - MADE TO 30 CHECK VALVE - With 1400 kPa (14,0 bar)
13
RESTRICT FLOW DURING BOOM (203 psi) Spring
DOWN BUT NOT DURING BOOM UP 31 DRIVE MOTOR SHUTTLE VALVE
BLEED-OFF VALVE 32 FIXED CAPACITY DISPLACEMENT
15 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC NOTE: Unless otherwise specified
CONTROL VALVE - TILT CONTROL MOTOR springs have NO significant
pressure value.
Male
DRIVE MOTOR 14
Male
L
30
29
Female
31
32
Z
10
A
10
33 B
Auxiliary Spool
TILT CYLINDERS
7A
6 11 BICS CONTROL VALVE
HYDROSTATIC PUMP 8
39 Tilt Spool
8 15
M4
M
11
3
D C 16 LIFT CYLINDERS)
12
40 40 Lift Spool
13
41 11 18 18
A
19
B
17 ?
M2 M1 7
IN
2 20
6
21
40 1
40 Oil Cooler
39 42
HYDRAULIC RESERVOIR
T 3 2 (VENTED)
4 1
38
37 5

HYDRAULIC FILTER
26
24
27 WORKING CIRCUIT
BRAKE VALVE -
SPRING APPLIED CHARGE
PRESSURE RELEASE
B
33 PRESSURE
(SAPR) A
DRAIN / RETURN
25 22
3
Z
P DR 23
36 2
35
35
32 Printable Version Click Here
1
28
STANDARD WITH NO OPTIONS
31 29 T770 (S/N A3P813238 AND ABOVE)
30
L
DRIVE MOTOR
7194314 (B)
PRINTED IN U.S.A.
WITH ALL OPTIONS
T770 (S/N A3P811001 – A3P813174)
(S/N A3P911001 – A3P912024)
V-1434legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) 57 DRIVE MOTOR SHUTTLE VALVE
36
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal) ARM BY-PASS 37 CHECK VALVE - With 552 kPa) (5,5 bar) 58 FIXED CAPACITY DISPLACEMENT
(80 psi) Spring BIDIRECTIONAL HYDROSTATIC MOTOR
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
38 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 59 HYDRAULIC BRAKE – SPRING APPLIED –
3 DIFFERENTIAL PRESSURE SWITCH: PRESSURE RELEASE (SAPR)
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) 21 ANTICAVITATION VALVE 60 PILOT ACTIVATED DIRECTIONAL
psi) Spring And With 0,40 mm (0.016 in) Orifice
Normally Closed CONTROL VALVE – 2 Speed
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,51 mm (0.020 in)
(Fan Speed Regulator): 10797 – 12300 kPa 41 SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC MOTOR
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 42 RESTRICTION - 0,51 mm (0.020 in) 62 CHARGE PUMP -
23 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
24 FIXED CAPACITY DISPLACEMENT 63 HIGH FLOW HYDRAULIC PUMP Gear Type
7 RELIEF VALVE - MAIN: 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
HYDRAULIC MOTOR 51,1 L/min (13.5 U.S. gal) at High Engine Idle
24132 kPa (241 bar) (3500 psi) 44 PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 25 FILTER - HYDRAULIC (CANISTER) 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - REAR AUXILIARY
8 RELIEF/ANTICAVITATION VALVE -
26 SENSOR – CHARGE PRESSURE – 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 65 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi)
Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
CONTROL VALVE - TWO COIL
PORT (OPTIONAL): 27579 kPa CONTROL VALVE - BUCKET POSITION 67 FRONT AUXILIARY MANUAL PRESSURE
(276 bar) (4000 psi) 47 RESTRICTOR - 0,8 mm (0.031 in)
VALVE (ON/OFF) BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28 FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF SENSOR – HYD. TEMPERATURE
68
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL 69
11 LOAD CHECK VALVE RIDE CONTROL VALVE
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - BASE
12 ANTICAVITATION VALVE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL 70 HIGH PRESSURE CHAMBER
30 CHECK VALVE - BUCKET POSITION CONTROL VALVE - ROD
13 PILOTED ACTIVATED DIRECTIONAL 71 LOW PRESSURE CHAMBER
VALVE 51 VARIABLE CAPACITY DISPLACEMENT
31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE – BRAKE
CONTROL VALVE - LIFT CONTROL
SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi) 73 FILTER – BRAKE VALVE
32 PILOT ACTIVATED DIRECTIONAL CONTROL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL 74 CHECK VALVE
VALVE – HYDRAULIC POWERED BOB-TACH 3206 kPa (32, bar) (465 psi)
16 FILTER - BICS CONTROL VALVE With Build-up Valve 207 kPa (2,07 bar) (30 psi) at High Engine Idle 75 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) With 60 ° C (140 ° F) Fluid
CHECK VALVE - With 100 kPa (1,0 bar) 33 FILTER - BOB-TACH VALVE CONTROL VALVE – 2 Speed Shift
17 54 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring 76 SOLENOID ACTIVATED DIRECTIONAL
34 RESTRICTION - 2,08 mm (0.08 in) With 345 kPa (3,45 bar) (50 psi) Spring
CONTROL VALVE – 2 Speed Make-up
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 55 RESTRICTION - 1,5 mm (0.06 in)
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1379 kPa 13,8 bar springs have NO significant
(200 psi) Spring pressure value.
Male
TWO SPEED DRIVE MOTOR (OPTIONAL)
L
56 67
Male
55
57 66
Female
RIDE CONTROL (OPTIONAL)

HYDRAULIC CONTROL VALVE (SPOOL VALVE)
X
71 70 LIFT CYLINDERS)
60
W
REAR AUXILIARY COUPLERS (OPTIONAL) 9

61 58
FEMALE MALE 69
10
10
Z Auxiliary Spool
? 48 ?
A B
59
50
49 8
46 11
? ? BICS CONTROL VALVE
BUCKET POSITIONING
HYDROSTATIC PUMP VALVE (OPTIONAL)
E1 E2 A1 A2
47 E3
Tilt Spool 27
51
B
8
45 13
28
M4
M
11 ? 29
3
44 30
REAR AUXILIARY
2-SPEED & SAPR D C VALVE (OPTIONAL) 14 D2
BRAKE VALVE P in P out T 12
(OPTIONAL) 75 76
B A D
72 30
73 T 52 52 Lift Spool
31
BOBTACH CYLINDER (OPTIONAL) 8 C2
C1 D1
P 20
53 11 16 16
B1 A1 C
A 37 80 psi 17
B
73
(5.5 bar) 41 15 ?
36
74 39 IN 18
74 M2 M1 7 2
6
35
38
19 TILT CYLINDERS
52 52 Oil Cooler
1
51 54 42
D
34 40
HYDRAULIC RESERVOIR
2 (VENTED)
T 3
33 4 1
43 POWER BOBTACH
VALVE (OPTIONAL)
32
62 5

HYDRAULIC FILTER
63 64
65
25
23
? WORKING CIRCUIT
26
CHARGE
PRESSURE
59 DRAIN / RETURN
B A
Z
24 21
P DR 22
61 58
W
60 DRAIN/RETURN MANIFOLD
X Printable Version Click Here
STANDARD WITH ALL OPTIONS
T770 (S/N A3P811001 - A3P813174)
57 55 (S/N A3P911001 - A3P912024)
56
L
Page 102 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194314 (0)
PRINTED IN U.S.A.
WITH ALL OPTIONS
T770 (S/N A3P813175 – A3P813237)
(S/N A3P912025 – A3P912042)
V-1464legend
LEGEND
36
(80 psi) Spring BIDIRECTIONAL HYDROSTATIC MOTOR
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
3 DIFFERENTIAL PRESSURE SWITCH: PRESSURE RELEASE (SAPR)
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) 21 ANTICAVITATION VALVE 60 HIGH PRESSURE SHUTTLE With INNER
psi) Spring And With 0,40 mm (0.016 in) Orifice
Normally Closed MAKE-UP SPOOL
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,51 mm (0.020 in)
(Fan Speed Regulator): 10797 – 12300 kPa 41 SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC MOTOR
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 42 RESTRICTION - 0,51 mm (0.020 in) 62 CHARGE PUMP -
23 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
24 FIXED CAPACITY DISPLACEMENT 63 HIGH FLOW HYDRAULIC PUMP Gear Type
7 RELIEF VALVE - MAIN: 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
24132 kPa (241 bar) (3500 psi) 44 PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 25 FILTER - HYDRAULIC (CANISTER) 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - REAR AUXILIARY
26 SENSOR – CHARGE PRESSURE – 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 65 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi)
Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
CONTROL VALVE - TWO COIL
PORT (OPTIONAL): 27579 kPa CONTROL VALVE - BUCKET POSITION 67 FRONT AUXILIARY MANUAL PRESSURE
(276 bar) (4000 psi) 47 RESTRICTOR - 0,8 mm (0.031 in)
VALVE (ON/OFF) BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28 FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF SENSOR – HYD. TEMPERATURE
68
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL 69
11 LOAD CHECK VALVE RIDE CONTROL VALVE
12 ANTICAVITATION VALVE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL 70 HIGH PRESSURE CHAMBER
13 PILOTED ACTIVATED DIRECTIONAL 71 LOW PRESSURE CHAMBER
31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE – BRAKE
CONTROL VALVE - LIFT CONTROL
SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi) 73 FILTER – BRAKE VALVE
32 PILOT ACTIVATED DIRECTIONAL CONTROL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL 74 NOT USED FOR THIS MODEL
VALVE – HYDRAULIC POWERED BOB-TACH 3206 kPa (32, bar) (465 psi)
16 FILTER - BICS CONTROL VALVE With Build-up Valve 207 kPa (2,07 bar) (30 psi) at High Engine Idle 75 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) With 60 ° C (140 ° F) Fluid
CHECK VALVE - With 100 kPa (1,0 bar) 33 FILTER - BOB-TACH VALVE CONTROL VALVE – 2 Speed Shift
17 54 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring With 345 kPa (3,45 bar) (50 psi) Spring
34 RESTRICTION - 2,08 mm (0.08 in)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 55 RESTRICTION - 1,5 mm (0.06 in)
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1379 kPa 13,8 bar springs have NO significant
Male
L
56 67
Male
55
57
66
Female

X
58
60 REAR AUXILIARY COUPLERS (OPTIONAL) 9
61 10
FEMALE MALE 69
10
Z Auxiliary Spool
? 48 ?
A 59 B 6
50
49 8
46 11
BUCKET POSITIONING
HYDROSTATIC PUMP VALVE (OPTIONAL)
E1 E2 A1 A2
47 E3
Tilt Spool 27
51
B
8
45 13
28
M4
M
11 ? 29
3
44 30
REAR AUXILIARY
D C VALVE (OPTIONAL) 14 D2
2-SPEED & SAPR
(OPTIONAL) 75
B A
72 30
T 52 52
73 Lift Spool
31
C1 D1
P 20
53 11 16
B1 A1 B A 37
41 15 ?
73 36
39 IN
2 18
M2 M1 7 16
6
35 17
38
19 TILT CYLINDERS
52 1
52 Oil Cooler
51 54 42
D
34 40
RESERVOIR
T 3 2 (VENTED)
33 4 1
43 POWER BOBTACH
VALVE (OPTIONAL)
32
62 5

HYDRAULIC FILTER
63
64
65
25
23
? WORKING CIRCUIT
26
CHARGE
PRESSURE
B
59 DRAIN / RETURN
A
Z
24 21
61 P DR 22
60
58
X
T770 (S/N A3P813175 - A3P813237)
56 55 (S/N A3P912025 - A3P912042)
57
L

Page 104 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194314 (A)
PRINTED IN U.S.A.
WITH ALL OPTIONS
V-1551legend
LEGEND
36
2 SIGHT GUAGE (80 psi) Spring BIDIRECTIONAL HYDROSTATIC MOTOR
20 LIFT CYLINDER SPOOL - MADE TO
3 DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM
103 kPa (1,03 bar) (15 psi) Normally Closed DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
4 21 ANTICAVITATION VALVE 60 HIGH PRESSURE SHUTTLE With INNER
FILTER - HYDRAULIC (CANISTER) psi) Spring And With 0,40 mm (0.016 in) Orifice
MAKE-UP SPOOL
5 SPRING LOADED FILTER BY-PASS 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,51 mm (0.020 in)
VALVE: 172 kPa (1,7 bar) (25 psi) (Fan Speed Regulator): 10797 – 12300 kPa 41 SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC MOTOR
6 DIAGNOSTIC COUPLER (108 - 123 bar) (1566 - 1784 psi)
23 SPRING LOADED FILTER BY-PASS VALVE: 42 RESTRICTION - 0,51 mm (0.020 in) 62 CHARGE PUMP -
7 RELIEF VALVE - MAIN:
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
23787 - 24476 kPa (238 - 245 bar) 43 HYDRAULIC PUMP . . . . . . . Gear Type
(3450 - 3550 psi) at Front Quick Couplers 24 FIXED CAPACITY DISPLACEMENT 63 HIGH FLOW HYDRAULIC PUMP Gear Type
87,1 L/min (23.0 U.S. gpm) at High Engine Idle
RELIEF VALVE – MAIN (OPTIONAL): 44 PILOT ACTIVATED DIRECTIONAL
25511 – 26200 kPa (255 - 262 bar) 25 FILTER - HYDRAULIC (CANISTER) 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
6 CONTROL VALVE - REAR AUXILIARY
(3700 - 3800 psi) at Diagnostic Coupler 65
26 SENSOR – CHARGE PRESSURE – 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) DUMP VALVE – ON / OFF
7A RELIEF VALVE – AUXILIARY (OPTIONAL): Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
23787 – 24476 kPa (238 - 245 bar)
6 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL (5.0 psi) Spring
CONTROL VALVE - BUCKET POSITION 47 RESTRICTOR - 0,8 mm (0.031 in) 67 FRONT AUXILIARY MANUAL PRESSURE
8 RELIEF/ANTICAVITATION VALVE - VALVE (ON/OFF) BLEED-OFF VALVE
PORT: 27579 kPa (276 bar) (4000 psi) FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF
28 68 SENSOR – HYD. TEMPERATURE
9 RELIEF/ANTICAVITATION VALVE - PORT
(OPTIONAL): 27579 kPa (276 bar) (4000 psi) 29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL 69 RIDE CONTROL VALVE
SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL 70 HIGH PRESSURE CHAMBER
11 LOAD CHECK VALVE 71 LOW PRESSURE CHAMBER
12 ANTICAVITATION VALVE 31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 72 SOLENOID ACTIVATED DIRECECTIONAL
13 CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE – BRAKE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi) 73 FILTER – BRAKE VALVE
14 PILOTED ACTIVATED DIRECTIONAL 32 PILOT ACTIVATED DIRECTIONAL CONTROL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - LIFT CONTROL VALVE – HYDRAULIC POWERED BOB-TACH 3206 kPa (32, bar) (465 psi) 74 NOT USED FOR THIS MODEL
15 SOLENOID ACTIVATED DIRECTIONAL With Build-up Valve 207 kPa (2,07 bar) (30 psi) at High Engine Idle 75 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL With 60 ° C (140 ° F) Fluid
33 FILTER - BOB-TACH VALVE CONTROL VALVE – 2 Speed Shift
16 FILTER - BICS CONTROL VALVE (SCREEN) 54 CHECK VALVE – COLD WEATHER BY-PASS
34 RESTRICTION - 2,08 mm (0.08 in) With 345 kPa (3,45 bar) (50 psi) Spring
17 CHECK VALVE - With 100 kPa (1,0 bar) 55 RESTRICTION - 1,5 mm (0.06 in)
(14.5 psi) Spring 35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1379 kPa 13,8 bar springs have NO significant
Male
L
56 67
Male
55
57
66
Female

X
74 60 58
REAR AUXILIARY COUPLERS (OPTIONAL)
61 9
10
FEMALE MALE 69
10
Z Auxiliary Spool
? 48 ?
A 59 B
6
50
49 7A
46
? ? 11 BICS CONTROL VALVE
BUCKET POSITIONING
HYDROSTATIC PUMP 8 VALVE (OPTIONAL)
E1 E2 A1 A2
47 E3
Tilt Spool 27
51
8 B
45 13
28
M4
M
11 ? 29
3
44 30
REAR AUXILIARY
D C VALVE (OPTIONAL) 14 D2
2-SPEED & SAPR
(OPTIONAL) 75
B A
72 30
T 52 52
73 Lift Spool
31
C1 D1
P 20
53 11 16
B1 A1 B A 37
41 15 ?
73 36
39 IN
2 18
M2 M1 7 16
6
35 17
38
19 TILT CYLINDERS
52 1
52 Oil Cooler
51 54 42
D
34 40
RESERVOIR
T 3 2 (VENTED)
33 4 1
43 POWER BOBTACH
VALVE (OPTIONAL)
32
62 5

HYDRAULIC FILTER
63
64
65
25
23
? WORKING CIRCUIT
26
CHARGE
PRESSURE
B
59 DRAIN / RETURN
A
Z
24 21
61 P DR 22
74 60 58
X Printable Version Click Here
56 55 (S/N A3P912043 AND ABOVE)
57
L

Page 106 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194314 (B)
PRINTED IN U.S.A.
SJC WITH NO OPTIONS
T770 (S/N A3P811001 – A3P813237)
(S/N A3P811001 – A3P912042)
V-1435legend
LEGEND
1 RESERVOIR: 14 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – CHARGE PRESSURE – 42 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal) RESTRICT FLOW DURING BOOM Fan Filter PRESSURE RELEASE (SAPR)
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal) DOWN BUT NOT DURING BOOM UP
29 HYDRAULIC PUMP . . . . . . . Gear Type 43 SOLENOID ACTIVATED DIRECECTIONAL
2 SIGHT GUAGE 15 PILOTED ACTIVATED DIRECTIONAL 87,1 L/min (23.0 U.S. gpm) at High Engine Idle CONTROL VALVE – BRAKE
CONTROL VALVE - TILT CONTROL 44 FILTER – BRAKE VALVE
30 CHARGE PUMP -
3 DIFFERENTIAL PRESSURE SWITCH: 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
16 PILOTED ACTIVATED DIRECTIONAL 45 CHECK VALVE
103 kPa (1,03 bar) (15 psi)
CONTROL VALVE - LIFT CONTROL 31 VARIABLE CAPACITY DISPLACEMENT
Normally Closed
17 BIDIRECTIONAL HYDROSTATIC PUMP
4 FILTER - HYDRAULIC (CANISTER) SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 32 RELIEF/REPLENISHING VALVE - HIGH
5 SPRING LOADED FILTER BY-PASS 18 FILTER - BICS CONTROL VALVE PRESSURE: 36500 kPa (365 bar) (5294 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) (SCREEN) 33 RELIEF VALVE - CHARGE INLET:
19 CHECK VALVE - With 100 kPa (1,0 bar) 2654 kPa (26,5 bar) (385 psi) at High
6 DIAGNOSTIC COUPLER
(14.5 psi) Spring Engine Idle With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 34 SERVO PISTON – Swash Plate
24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers 21 PULL BUTTON ACTIVATED 35 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE – FORWARD/REVERSE
ARM BY-PASS 36 FILTER
PORT: 27579 kPa (276 bar) (4000 psi)
22 SENSOR – HYD. TEMPERATURE
9 RELIEF/ANTICAVITATION VALVE - 37 CHECK VALVE – COLD WEATHER BY-PASS
PORT (OPTIONAL): 27579 kPa 23 ANTICAVITATION VALVE With 345 kPa (3,45 bar) (50 psi) Spring
(276 bar) (4000 psi)
10 SOLENOID ACTIVATED DIRECTIONAL 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
CONTROL VALVE - AUXILIARY 39 CHECK VALVE - With 1400 kPa (14,0 bar)
(108 - 123 bar) (1566 - 1784 psi)
(203 psi) Spring
11 LOAD CHECK VALVE
25 SPRING LOADED FILTER BY-PASS VALVE: 40 DRIVE MOTOR SHUTTLE VALVE
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
BLEED-OFF VALVE 26 FIXED CAPACITY DISPLACEMENT 41 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR BIDIRECTIONAL HYDROSTATIC
13 ANTICAVITATION VALVE MOTOR
NOTE: Unless otherwise specified

springs have NO significant
pressure value.

INTEGRATED COUPLER BLOCK
Male
12
DRIVE MOTOR Male
L
39
Female
38
40
OUT
HYDRAULIC CONTROL VALVE (SPOOL VALVE)
9
41
10
42
10
Z
Auxiliary Spool
A B
TILT CYLINDERS
8
6 11
BICS CONTROL VALVE
R
HYDROSTATIC PUMP 31
T
35
X1 36
34 8
X2
15
32 32 11
16 LIFT CYLINDERS
MA 36 13
MB
A B
MG
Lift Spool
33
8
G
A B
MB 14 18
18
MA
36 11 19 ?
17
IN
7 2 20
32 ? 6
32
X2
34
X1 ? Oil Cooler
1 21
36
31 35
37 HYDRAULIC RESERVOIR
T (VENTED)
3 2
R
4 1
29
30
5
HYDRAULIC FILTER
27
WORKING CIRCUIT
28 25 CHARGE
BRAKE VALVE - 42 PRESSURE
SPRING APPLIED DRAIN / RETURN
PRESSURE RELEASE B A
3
Z 23
26
2
45 24
P DR
44 44 41
1
DRAIN/RETURN MANIFOLD Printable Version Click Here
43
SJC WITH NO OPTIONS
22
40 T770 (S/N A3P811001 - A3P813237)
38
39 (S/N A3P911001 - A3P912042)
L
DRIVE MOTOR
Page 108 - OSS#IN6300032016
PRINTED U.S.A. - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194315
SJC WITH NO OPTIONS
V-1553legend
LEGEND
1 RESERVOIR: 14 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – CHARGE PRESSURE – 42 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal) RESTRICT FLOW DURING BOOM Fan Filter PRESSURE RELEASE (SAPR)
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal) DOWN BUT NOT DURING BOOM UP
29 HYDRAULIC PUMP . . . . . . . Gear Type 43 SOLENOID ACTIVATED DIRECECTIONAL
2 SIGHT GUAGE 15 PILOTED ACTIVATED DIRECTIONAL 87,1 L/min (23.0 U.S. gpm) at High Engine Idle CONTROL VALVE – BRAKE
CONTROL VALVE - TILT CONTROL 44 FILTER – BRAKE VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 30 CHARGE PUMP -
103 kPa (1,03 bar) (15 psi) Normally Closed 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
16 PILOTED ACTIVATED DIRECTIONAL 45 CHECK VALVE
CONTROL VALVE - LIFT CONTROL 31 VARIABLE CAPACITY DISPLACEMENT
17 BIDIRECTIONAL HYDROSTATIC PUMP
SOLENOID ACTIVATED DIRECTIONAL
5 SPRING LOADED FILTER BY-PASS CONTROL VALVE - BICS CONTROL 32 RELIEF/REPLENISHING VALVE - HIGH
VALVE: 172 kPa (1,7 bar) (25 psi)
18 FILTER - BICS CONTROL VALVE PRESSURE: 36500 kPa (365 bar) (5294 psi)
6 DIAGNOSTIC COUPLER (SCREEN) 33 RELIEF VALVE - CHARGE INLET:
7 RELIEF VALVE - MAIN: 19 CHECK VALVE - With 100 kPa (1,0 bar) 2654 kPa (26,5 bar) (385 psi) at High
23787 - 24476 kPa (238 - 245 bar) (14.5 psi) Spring Engine Idle With 60 ° C (140 ° F) Fluid
(3450 - 3550 psi) at Front Quick Couplers
20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 34 SERVO PISTON – Swash Plate
RELIEF VALVE – MAIN (OPTIONAL):
25511 – 26200 kPa (255 - 262 bar) 35 SOLENOID ACTIVATED DIRECTIONAL
6 21 PULL BUTTON ACTIVATED
(3700 - 3800 psi) at Diagnostic Coupler CONTROL VALVE – FORWARD/REVERSE
DIRECTIONAL CONTROL VALVE - LIFT
7A RELIEF VALVE – AUXILIARY (OPTIONAL): ARM BY-PASS 36 FILTER
23787 – 24476 kPa (238 - 245 bar) 22 SENSOR – HYD. TEMPERATURE
6
37 CHECK VALVE – COLD WEATHER BY-PASS
8 RELIEF/ANTICAVITATION VALVE - 23 ANTICAVITATION VALVE With 345 kPa (3,45 bar) (50 psi) Spring
PORT: 27579 kPa (276 bar) (4000 psi)
24 PROPORTIONAL RELIEF VALVE –
9 RELIEF/ANTICAVITATION VALVE - (Fan Speed Regulator): 10797 – 12300 kPa
PORT (OPTIONAL): 27579 kPa (108 - 123 bar) (1566 - 1784 psi) 39 CHECK VALVE - With 1400 kPa (14,0 bar)
(276 bar) (4000 psi) (203 psi) Spring
10 SOLENOID ACTIVATED DIRECTIONAL 25 SPRING LOADED FILTER BY-PASS VALVE: 40 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - AUXILIARY 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
11 LOAD CHECK VALVE 26 FIXED CAPACITY DISPLACEMENT 41 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR BIDIRECTIONAL HYDROSTATIC
27 FILTER - HYDRAULIC (CANISTER) MOTOR
BLEED-OFF VALVE
13 ANTICAVITATION VALVE
NOTE: Unless otherwise specified

springs have NO significant
pressure value.

Male
12
DRIVE MOTOR Male
L
39
Female
38
40 HYDRAULIC CONTROL VALVE
OUT
41
10
42
10
Z
Auxiliary Spool
A B
7A
TILT CYLINDERS
6
11
BICS CONTROL VALVE
R
HYDROSTATIC PUMP 31 8
T
35
X1 36
34
15
X2 8
32 32 11
16 LIFT CYLINDERS
MA 36 13
MB
A B
MG
Lift Spool
33
8
G
A B
MB 14 18
18
MA
36 11 19 ?
17
IN
7 2 20
32 ? 6
32
X2
34
X1 ? Oil Cooler
1 21
36
31 35
T (VENTED)
3 2
R
4
29 1
30
5
HYDRAULIC FILTER
27
WORKING CIRCUIT
BRAKE VALVE - 28 25 CHARGE
SPRING APPLIED
PRESSURE RELEASE 42 PRESSURE
(SAPR)
DRAIN / RETURN
B A
3
Z 23
26
2
45 24
P DR
44 44 41
1
43
SJC WITH NO OPTIONS
22
40 T770 (S/N A3P813238 AND ABOVE)
38
39 (S/N A3P912043 AND ABOVE)
L
DRIVE MOTOR
Page 110 - OSS#IN6300032016
PRINTED U.S.A. - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194315 (B)
SJC WITH ALL OPTIONS
T770 (S/N A3P811001 – A3P813174)
(S/N A3P911001 – A3P912024)
V-1436legend
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa) (5,5 bar) 62 CHECK VALVE - With 1379 kPa 13,8 bar
Capacity at sight gauge . . 9,8 L (2.6 U.S. gal) (80 psi) Spring (200 psi) Spring
System Capacity . . . . . . . 36,0 L (9.5 U.S. gal) 21 PULL BUTTON ACTIVATED 40 SHUTTLE VALVE 63 DRIVE MOTOR SHUTTLE VALVE
2 SIGHT GUAGE 41 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 64 FIXED CAPACITY DISPLACEMENT
ARM BY-PASS
3 22 RIDE CONTROL VALVE 42 BIDIRECTIONAL HYDROSTATIC MOTOR
DIFFERENTIAL PRESSURE SWITCH: CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 65 HYDRAULIC BRAKE – SPRING APPLIED –
23 ANTICAVITATION VALVE PRESSURE RELEASE (SAPR)
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE – 66 PILOT ACTIVATED DIRECTIONAL
(Fan Speed Regulator): 10797 – 12300 kPa 44 RESTRICTION - 0,51 mm (0.020 in) CONTROL VALVE – 2 Speed
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi) 67 FIXED CAPACITY DISPLACEMENT
VALVE: 172 kPa (1,7 bar) (25 psi) 45 SENSOR – HYD. TEMPERATURE
25 SPRING LOADED FILTER BY-PASS VALVE: BIDIRECTIONAL HYDROSTATIC
6 DIAGNOSTIC COUPLER 46 NOT USED FOR THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) MOTOR – 2 Speed
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT PILOT ACTIVATED DIRECTIONAL 68 HYDRAULIC PUMP . . . . . . . Gear Type
47
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR CONTROL VALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER) RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
8 48 69
RELIEF/ANTICAVITATION VALVE - 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR – CHARGE PRESSURE – 49 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter CONTROL VALVE - TWO COIL 70 HIGH FLOW HYDRAULIC PUMP Gear Type
SOLENOID ACTIVATED DIRECTIONAL 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 27579 kPa 29 50 RESTRICTOR - 0,8 mm (0.031 in)
(276 bar) (4000 psi) CONTROL VALVE - BUCKET POSITION 71 FILTER - BRAKE
10 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 51 LOAD SHUTTLE VALVE - BLEED OFF 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE – BRAKE
11 LOAD CHECK VALVE
31 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 73 CHECK VALVE
12 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL 53 SOLENOID ACTIVATED DIRECTIONAL 74 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
BLEED-OFF VALVE SPOOL CONTROL VALVE - ROD
13 ANTICAVITATION VALVE 32 CHECK VALVE - BUCKET POSITION 75 DUMP VALVE – ON / OFF
VALVE BIDIRECTIONAL HYDROSTATIC PUMP CHECK VALVE - With 34,5 kPa (0,34 bar)
14 LIFT CYLINDER SPOOL - MADE TO 76
RESTRICT FLOW DURING BOOM 33 PILOTED ACTIVATED DIRECTIONAL RELIEF/REPLENISHING VALVE - HIGH (5.0 psi) Spring
55
DOWN BUT NOT DURING BOOM UP CONTROL VALVE - UNLOADING PRESSURE: 36500 kPa (365 bar) (5294 psi) 77 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE – 2 Speed Shift
15 PILOTED ACTIVATED DIRECTIONAL 56 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 78 SOLENOID ACTIVATED DIRECTIONAL
PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC Engine Idle With 60 ° C (140 ° F) Fluid CONTROL VALVE – 2 Speed Make-up
16
CONTROL VALVE - LIFT CONTROL POWERED BOB-TACH 57 SERVO PISTON – Swash Plate 79 HIGH PRESSURE CHAMBER
17 SOLENOID ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE
CONTROL VALVE - BICS CONTROL 80 LOW PRESSURE CHAMBER
36 RESTRICTION - 2,08 mm (0.08 in) CONTROL VALVE – FORWARD/REVERSE
18 FILTER - BICS CONTROL VALVE 59 FILTER
(SCREEN) 37 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
19 CHECK VALVE - With 100 kPa (1,0 bar) CONTROL VALVE (TWO COIL) 60 CHECK VALVE – COLD WEATHER BY-PASS springs have NO significant
38 With 345 kPa (3,45 bar) (50 psi) Spring pressure value.
(14.5 psi) Spring RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
61 RESTRICTION – 1,5 mm (0.06 in)
TWO SPEED DRIVE MOTOR (OPTIONAL) Male
L
62 12
Male
61
63 75
Female
OUT
X HYDRAULIC CONTROL VALVE

LIFT CYLINDERS
66 80 79
W
67
9
64 REAR AUXILIARY COUPLERS (OPTIONAL)
MALE
10
FEMALE
65 22
10
Z
Auxiliary Spool
A
? 51 ?
B
53
LOAD CHECK
52
8
6 11
? ?
R BUCKET POSITIONING
T
E1 E2 A1 A2
50 E3
58
X1 59 DRIVE PUMP
Tilt Spool
CONTROLLER
B
57
8
X2
15
48 30
55 55 11 ?
REAR AUXILIARY 29 32
VALVE (OPTIONAL) 16
77 78 47
D2
B A D MA 59 P in P out T
13
72 MB 31
T A B
MG
32
Lift Spool
56 33 C2
8
G
C1 D1
P BOBTACH CYLINDER (OPTIONAL)
A B
MB 14 18
B1 18
MA
59 11 19 ?
71 17
73 39 IN
7 2 20
55 ?
38 42 6
55
X2
57 TILT CYLINDERS
X1 ? 41 Oil Cooler
1 21
59
54 58 37
60
T D 36 43 (VENTED)
3 2
R
4 1
68
35
POWER BOBTACH
VALVE (OPTIONAL) 34
69
5
HYDRAULIC FILTER
70 74
75
27
WORKING CIRCUIT
?
28 25 CHARGE
PRESSURE
DRAIN / RETURN
B
65
A
Z 23
26
P DR
24
67 64
W
66 DRAIN/RETURN MANIFOLD Printable Version Click Here

X
45 SJC WITH ALL OPTIONS
T770 (S/N A3P811001 - A3P813174)
(S/N A3P911001 - A3P912024)
63
61
62
L

Page 112 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7194315
PRINTED IN U.S.A.
T770 (S/N A3P813175 – A3P813237)
(S/N A3P912025 – A3P912042)
V-1465legend
LEGEND
2 SIGHT GUAGE 41 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 64 FIXED CAPACITY DISPLACEMENT
ARM BY-PASS
3 22 RIDE CONTROL VALVE 42 BIDIRECTIONAL HYDROSTATIC MOTOR
DIFFERENTIAL PRESSURE SWITCH: CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 65 HYDRAULIC BRAKE – SPRING APPLIED –
23 ANTICAVITATION VALVE PRESSURE RELEASE (SAPR)
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE – 66 HIGH PRESSURE SHUTTLE With INNER
(Fan Speed Regulator): 10797 – 12300 kPa 44 RESTRICTION - 0,51 mm (0.020 in) MAKE-UP SPOOL
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi) 67 FIXED CAPACITY DISPLACEMENT
VALVE: 172 kPa (1,7 bar) (25 psi) 45 SENSOR – HYD. TEMPERATURE
25 SPRING LOADED FILTER BY-PASS VALVE: BIDIRECTIONAL HYDROSTATIC
6 DIAGNOSTIC COUPLER 46 NOT USED FOR THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) MOTOR – 2 Speed
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT PILOT ACTIVATED DIRECTIONAL 68 HYDRAULIC PUMP . . . . . . . Gear Type
47
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR CONTROL VALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER) RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
8 48 69
RELIEF/ANTICAVITATION VALVE - 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR – CHARGE PRESSURE – 49 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter CONTROL VALVE - TWO COIL 70 HIGH FLOW HYDRAULIC PUMP Gear Type
SOLENOID ACTIVATED DIRECTIONAL 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 27579 kPa 29 50 RESTRICTOR - 0,8 mm (0.031 in)
(276 bar) (4000 psi) CONTROL VALVE - BUCKET POSITION 71 FILTER - BRAKE
10 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 51 LOAD SHUTTLE VALVE - BLEED OFF 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE – BRAKE
11 LOAD CHECK VALVE
31 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 73 NOT USED ON THIS MODEL
12 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL 53 SOLENOID ACTIVATED DIRECTIONAL 74 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
BLEED-OFF VALVE SPOOL CONTROL VALVE - ROD
13 ANTICAVITATION VALVE 32 CHECK VALVE - BUCKET POSITION 75 DUMP VALVE – ON / OFF
14 LIFT CYLINDER SPOOL - MADE TO 76
RESTRICT FLOW DURING BOOM 33 PILOTED ACTIVATED DIRECTIONAL RELIEF/REPLENISHING VALVE - HIGH (5.0 psi) Spring
55
DOWN BUT NOT DURING BOOM UP CONTROL VALVE - UNLOADING PRESSURE: 36500 kPa (365 bar) (5294 psi) 77 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE – 2 Speed Shift
15 PILOTED ACTIVATED DIRECTIONAL 56 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 78 NOT USED ON THIS MODEL
PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC Engine Idle With 60 ° C (140 ° F) Fluid
16
CONTROL VALVE - LIFT CONTROL POWERED BOB-TACH 57 SERVO PISTON – Swash Plate 79 HIGH PRESSURE CHAMBER
17 SOLENOID ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE
CONTROL VALVE - BICS CONTROL 80 LOW PRESSURE CHAMBER
18 FILTER - BICS CONTROL VALVE 59 FILTER
(SCREEN) 37 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
19 CHECK VALVE - With 100 kPa (1,0 bar) CONTROL VALVE (TWO COIL) 60 CHECK VALVE – COLD WEATHER BY-PASS springs have NO significant
38 With 345 kPa (3,45 bar) (50 psi) Spring pressure value.
(14.5 psi) Spring RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
61 RESTRICTION – 1,5 mm (0.06 in)
L
62 12
Male
61 63
75
Female
OUT
X HYDRAULIC CONTROL VALVE

LIFT CYLINDERS
80 79
66 9
67 REAR AUXILIARY COUPLERS (OPTIONAL)
FEMALE MALE
10
22
65 10
Z 64 Auxiliary Spool
A
? 51 ?
B
53
52 8
6 11
? ?
T
E1 E2 A1 A2
50 E3
58
X1 59 Tilt Spool TILT BICS VALVE
B
57 8
X2
15
48 30
55 55 11 ?
VALVE (OPTIONAL) 16
77 47
D2
B A MA 59 P in P out T
13
72 MB 31
T A B
MG
32
Lift Spool
56 33 C2
8
G
C1 D1
A B
MB 14
B1 A1 18
MA
59 11
?
71 17
39 IN
7 18 2 20
55 ?
38 42 6
55
X2 19
57 TILT CYLINDERS
X1 ? 41 Oil Cooler
1 21
59
54 58 37
60
T D 36 43 (VENTED)
3 2
R
4 1
68
35
POWER BOBTACH
VALVE (OPTIONAL) 34
69
5
HYDRAULIC FILTER
70 74
75
27
WORKING CIRCUIT
?
28 25 CHARGE
PRESSURE
DRAIN / RETURN
B 65 A
Z 23
26
P DR
24
67 64
66
X
T770 (S/N A3P813175 - A3P813237)
(S/N A3P912025 - A3P912042)
62 61
63 (PRINTED FEBRUARY 2013)

L

7194315 (A)
PRINTED IN U.S.A.
V-1552legend
LEGEND
2 DIRECTIONAL CONTROL VALVE - LIFT
SIGHT GUAGE 41 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 64
ARM BY-PASS FIXED CAPACITY DISPLACEMENT
3 DIFFERENTIAL PRESSURE SWITCH: BIDIRECTIONAL HYDROSTATIC MOTOR
22 RIDE CONTROL VALVE 42 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) Normally Closed 65
psi) Spring And With 0,33 mm (0.013 in) Orifice HYDRAULIC BRAKE – SPRING APPLIED –
4 FILTER - HYDRAULIC (CANISTER) 23 ANTICAVITATION VALVE PRESSURE RELEASE (SAPR)
5 SPRING LOADED FILTER BY-PASS 24 PROPORTIONAL RELIEF VALVE – 66 HIGH PRESSURE SHUTTLE With INNER
VALVE: 172 kPa (1,7 bar) (25 psi) (Fan Speed Regulator): 10797 – 12300 kPa 44 RESTRICTION - 0,51 mm (0.020 in) MAKE-UP SPOOL
6 DIAGNOSTIC COUPLER (108 - 123 bar) (1566 - 1784 psi)
45 SENSOR – HYD. TEMPERATURE 67 FIXED CAPACITY DISPLACEMENT
7 RELIEF VALVE - MAIN: 23787 - 24476 kPa (238 - 25 SPRING LOADED FILTER BY-PASS VALVE: BIDIRECTIONAL HYDROSTATIC
245 bar) (3450 - 3550 psi) at Front Quick Couplers 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 46 NOT USED FOR THIS MODEL MOTOR – 2 Speed
RELIEF VALVE – MAIN (OPTIONAL): 26 FIXED CAPACITY DISPLACEMENT PILOT ACTIVATED DIRECTIONAL 68 HYDRAULIC PUMP . . . . . . . Gear Type
47
25511 – 26200 kPa (255 - 262 bar) HYDRAULIC MOTOR CONTROL VALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
6
(3700 - 3800 psi) at Diagnostic Coupler 27 FILTER - HYDRAULIC (CANISTER) RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
48 69
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
23787 – 24476 kPa (238 - 245 bar) 28 SENSOR – CHARGE PRESSURE – 49 SOLENOID ACTIVATED DIRECTIONAL
6 Fan Filter CONTROL VALVE - TWO COIL 70 HIGH FLOW HYDRAULIC PUMP Gear Type
(3450 - 3550 psi) at Diagnostic Coupler 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
8 29 SOLENOID ACTIVATED DIRECTIONAL 50 RESTRICTOR - 0,8 mm (0.031 in)
RELIEF/ANTICAVITATION VALVE - 71 FILTER - BRAKE
CONTROL VALVE - BUCKET POSITION
PORT: 27579 kPa (276 bar) (4000 psi)
VALVE (ON/OFF) 51 LOAD SHUTTLE VALVE - BLEED OFF
9 RELIEF/ANTICAVITATION VALVE - PORT 72 SOLENOID ACTIVATED DIRECECTIONAL
30 FLOW DIVIDER ADJUSTMENT VALVE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – BRAKE
(OPTIONAL): 27579 kPa (276 bar) (4000 psi) 52
31 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 73 NOT USED ON THIS MODEL
CONTROL VALVE - AUXILIARY CONTROL VALVE - FLOW CONTROL 53 SOLENOID ACTIVATED DIRECTIONAL 74 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
11 LOAD CHECK VALVE SPOOL CONTROL VALVE - ROD
32 CHECK VALVE - BUCKET POSITION 75 DUMP VALVE – ON / OFF
12 FRONT AUXILIARY MANUAL PRESSURE 54 VARIABLE CAPACITY DISPLACEMENT
BLEED-OFF VALVE 76
13 ANTICAVITATION VALVE 33 PILOTED ACTIVATED DIRECTIONAL RELIEF/REPLENISHING VALVE - HIGH (5.0 psi) Spring
55
CONTROL VALVE - UNLOADING PRESSURE: 36500 kPa (365 bar) (5294 psi) 77 SOLENOID ACTIVATED DIRECTIONAL
14 LIFT CYLINDER SPOOL - MADE TO SPOOL CONTROL VALVE – 2 Speed Shift
RESTRICT FLOW DURING BOOM 56 RELIEF VALVE - CHARGE INLET:
DOWN BUT NOT DURING BOOM UP 34 PILOT ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 78 NOT USED ON THIS MODEL
15 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC Engine Idle With 60 ° C (140 ° F) Fluid
CONTROL VALVE - TILT CONTROL POWERED BOB-TACH 57 SERVO PISTON – Swash Plate 79 HIGH PRESSURE CHAMBER
16 PILOTED ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 58 80 LOW PRESSURE CHAMBER
59 FILTER
CONTROL VALVE - BICS CONTROL 37 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
18 FILTER - BICS CONTROL VALVE (SCREEN) CONTROL VALVE (TWO COIL) 60 CHECK VALVE – COLD WEATHER BY-PASS springs have NO significant
38 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) With 345 kPa (3,45 bar) (50 psi) Spring pressure value.
19 CHECK VALVE - With 100 kPa (1,0 bar) 61 RESTRICTION – 1,5 mm (0.06 in)
(14.5 psi) Spring V-1552legend (2-25-13)
Printed in U.S.A.
L
62 12
Male
61 63
75
Female

OUT
X
LIFT CYLINDERS
80 79
66
67 REAR AUXILIARY COUPLERS (OPTIONAL) 9
FEMALE MALE
10
22
65
Z 64 10
Auxiliary Spool
A
? 51 ?
B
6
53
52
7A
49 11
HYDROSTATIC PUMP 54 8 VALVE (OPTIONAL)
T
E1 E2 A1 A2
50 E3
58
X1 59 Tilt Spool TILT BICS VALVE
B
57
15
X2
8
48 30
55 55 11 ?
VALVE (OPTIONAL) 16
77 47
D2
B A MA 59 P in P out T
13
72 MB 31
T A B
MG
32
Lift Spool
56 33 C2
8
G
C1 D1
A B
MB 14
B1 A1 18
MA
59 11
?
71 17
39 IN
7 18 2 20
55 ?
38 42 6
55
X2 19
57 TILT CYLINDERS
X1 ? 41 Oil Cooler
1 21
59
54 58 37
60
T D 36 43 (VENTED)
3 2
R
4 1
68
35
POWER BOBTACH
VALVE (OPTIONAL) 34
69
5
HYDRAULIC FILTER
70 74
75
27
WORKING CIRCUIT
?
28 25 CHARGE
PRESSURE
DRAIN / RETURN
B 65 A
Z 23
26
P DR
24
67 64
66
X
62 61
63 (PRINTED FEBRUARY 2013)

L

7194315 (B)
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.
FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to

atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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


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

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is

OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
LOCK VALVE - hydraulic pressure is
applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

HYDRAULIC SYSTEM INFORMATION (CONT'D)
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm 1, 3, 4, 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 neutral position 4, 9, 10, 11
Lift Arm Bypass Control valve stuck 12
Lift Arm Bypass Control valve stem bent or broken 13
KEY TO CORRECT CAUSE
1. The fluid level is not correct.

2. The pedal linkage is disconnected.

3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-
40-1.)
8. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace Lift Arm Bypass Control valve assembly.

20-10-6
T770 Service Manual
CYLINDER (LIFT) Figure 20-20-2
Testing
Figure 20-20-1
P-90617
1
Install a cap (Item 1) [Figure 20-20-2] on the hose and
P-90616 tighten.
Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.
Operate the controls that lower the lift arms.
WARNING If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair. Repeat the procedure to check the other lift
Hydraulic fluid escaping under pressure can have cylinder.

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.

CYLINDER (LIFT) (CONT'D)
Removal And Installation

WARNING
Lift and block the loader. (See Procedure on Page 10-10-
1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
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
2
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-90824
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

container to collect the hydraulic oil as the lift arms are
raised.
Recycle or dispose of used fluid in an environmentally

safe manner.
1
WARNING
P-90616 AVOID INJURY OR DEATH
Mark and disconnect the two hydraulic hoses (Item 1) death. Fluid leaks under pressure may not be visible.
[Figure 20-20-3]. Use a piece of cardboard or wood to find leaks. Do
W-2072-0807

Removal And Installation (Cont’d)
Figure 20-20-5
P-90602A
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-5] from the pin on the rod end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 35 - 40

ft-lb (48 - 54 N•m) torque.
Figure 20-20-6
P-90611
With a slide hammer, remove the pin (Item 1) [Figure 20-

20-6] from the rod end of the lift cylinder.

CYLINDER (LIFT) (CONT'D) Figure 20-20-7
DANGER
1
P-90605
P-90328
AVOID DEATH Install a sling in the middle of the Bob-Tach as shown in

• Disconnecting or loosening any hydraulic (Item 1) [Figure 20-20-7].
can cause lift arms to drop. Using a chain hoist raise the lift arms and install an
• Keep out of this area when lift arms are raised approved lift arm support device on the cylinder that is
unless supported by an approved lift arm connected to the lift arm.
D-1009-0409 Figure 20-20-8
2 1
WARNING
W-2059-0598
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder

and install a strap (Item 2) [Figure 20-20-8] to secure the
cylinder.

Open the rear door.

1
NOTE: When removing the left side lift cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery (If required). (See Removal And

Figure 20-20-9
P-90827
1
20-11] from the base end of the lift cylinder.
Figure 20-20-12
P-90834

20-9] from the pin on the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54 1

N•m (35 - 40 ft-lb) torque.
Figure 20-20-10 P-90823
Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.
P-90825
Remove the grease fitting (Item 1) [Figure 20-20-10]

from the base end of the lift cylinder.
Installation: Tighten the grease fitting to 15 ft-lb (20

N•m) torque.

Parts Identification
1. Seal
2. Hydraulic Tubeline
3. Cylinder Case Tube
4. Plug
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring
9. Piston Assembly
10. Spacer
11. Head
12. Seal
13. Seal
14. Shaft 4
15. Grease Fitting
3
4
5
2
6
7
8
9
10
1
8
11
12
13
8
7 14
15
NA1413S

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

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.

3
Figure 20-20-13
P-48038
1
Remove the back-up ring (Item 1) and O-ring (Item 2)
[Figure 20-20-15] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-15]

on the piston, becomes damaged, the
complete piston must be replaced.
Figure 20-20-16
1
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-13] from the cylinder case.
Figure 20-20-14 2
4
3
2
P-48039
1
Remove the two O-rings (Item 1) and the back-up ring
(Item 2) [Figure 20-20-16] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].

Disassembly (Cont'd)
Figure 20-20-17
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-17] from

the cylinder head.
Figure 20-20-18
1
P-48042
Remove the rod seal (Item 1) [Figure 20-20-18] from the

cylinder head.

Assembly
Use the following tools to assemble the cylinder: 1
MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Figure 20-20-19
P-48038
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-20] on the cylinder piston.
Figure 20-20-21
P7424 1
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-20-21].
fits the piston [Figure 20-20-19].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-20-21] must be installed
on the piston. toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-21].

Assembly (Cont'd)
Figure 20-20-22 1
2
3
P-48036
NOTE: Clean and dry the rod threads. Install a NEW

P7425 NUT with pre-applied Loctite® included in the
seal kit or if a new nut is not available use
Loctite® #242 on threads.
Install the rod seal in the head [Figure 20-20-22].
Install the head (Item 1), spacer (Item 2) piston (Item 3),
Figure 20-20-23 and nut (Item 4) [Figure 20-20-24].
Tighten the nut (Item 4) [Figure 20-20-24] to 1491 N•m

(1100 ft-lb) torque.
2
Figure 20-20-25
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-
23].
P-48035
Put the base end of the hydraulic cylinder in a vise.
Using a spanner wrench, tighten the head (Item 1)

[Figure 20-20-25] to 373 N•m (275 ft-lb) torque.

CYLINDER (TILT) Figure 20-21-2
Testing
Remove the attachment. Roll the Bob-Tach fully back. 1

Stop the engine. Raise the seat bar. 2
Figure 20-21-1
P-85552
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

hose and tighten.
P-85553 engine and press the PTOL button.
Operate the controls that rolls the Bob-Tach back.

Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the base end of the cylinder. If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-21-2], remove the cylinder for repair.
Repeat procedure to test the other cylinder.

WARNING
Hydraulic fluid escaping under pressure can have
immediately.
W-2145-0290

CYLINDER (TILT) (CONT'D) Figure 20-21-5
Figure 20-21-3
3
2
1
1
P-85562
Disconnect the two hydraulic hoses (Items 1 and 2)

P-85554 [Figure 20-21-5] from the tilt cylinder.
Cap the hoses and plug the fittings on the cylinder.

Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Figure 20-21-6
Stop the engine. Raise the seat bar.
Remove the retainer bolt and nut (Item 1) [Figure 20-21-

3] from the rod end pivot pin.
1
Installation: Tighten the retainer nut to 35 - 40 ft-lb (48 -
54 N•m) torque.
Figure 20-21-4
P-85648
Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].
Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.
Installation: Tighten the retainer nut to 190 - 195 ft-lb

P-85649 (258 - 264 N•m) torque.
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

CYLINDER (TILT) (CONT'D)
Removal And Installation (Cont'd)
Figure 20-21-7
P-85564
Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-7].

Base End Pivot Pin Removal And Installation
Figure 20-21-8
P-85567
1
Inspect pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a punch (Item 1) [Figure 20-21-9] and a hammer to

remove the tilt cylinder base pin from the lift arms.

Parts Identification (Early Models)
1. Tubeline
2. Case
3. Plug
4. Grease Fitting
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring
9. Piston
10. Head
11. Seal
12. Wiper
13. Rod 4
14. Bushing
5
8 6
3
1 7
8
9
8
3
11
8
10
11
12
8
11 13
11
14
11
4
NA1210S

Parts Identification (Later Models)
1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston
10. Seal
5
11. Wiper
12. Rod
13. Bushing 6
4 2
3
7
1 8
4 9
3
10
8
4
10
8
11
12
13
NA6008S

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

Spanner Wrench
Figure 20-21-11
P106021
1
Use a spanner wrench to loosen the head (Item 1)

2
[Figure 20-21-12] from the cylinder case.
Figure 20-21-13
Early
Models
3
1
2
1
P-85651
Remove the seals (Item 1) [Figure 20-21-11] on both

sides of the pivot bushing.
Remove and replace bushing (Item 2) with a driver tool

and hammer [Figure 20-21-11]. P-48071
Figure 20-21-14
Later
Models
3 2
P106017
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13] and [Figure 20-21-14].

CYLINDER (TILT) (CONT'D) Remove the O-ring (Item 1). Remove the O-ring (Item 2)
and back-up ring (Item 3) [Figure 20-21-17].
NOTE: The O-ring (Item 2) and back-up ring (Item 3)
Figure 20-21-15 [Figure 20-21-17] are no longer available
parts. The seal kit will contain a one piece seal
Early
2 that is used in place of the O-ring and back-up
Models
ring.
Figure 20-21-18
1
P-48073
Figure 20-21-16
Later 2
Models P-48040
1 Remove the wiper seal (Item 1) [Figure 20-21-18] from

the cylinder head.
Figure 20-21-19
P106020
Remove the seal (Item 1), and O-ring (Item 2) [Figure 1

20-21-15] and [Figure 20-21-16] from the piston.
Figure 20-21-17
1
P-48042
Remove the rod seal (Item 1) [Figure 20-21-19] from the

cylinder head.
3
P-48039

Assembly Early
Models
1
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Spanner Wrench

P-48073
Lubricate all O-rings and seals with hydraulic oil during Figure 20-21-22
installation.
Later 1
Models
Figure 20-21-20
2
P106020
P7424
Install the O-ring (Item 1), and seal (Item 2) [Figure 20-
21-21] and [Figure 20-21-22] on the cylinder piston.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Cont'd)
Figure 20-21-23 2
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
25].
Install the rod seal on the rod seal tool [Figure 20-21-23]. Figure 20-21-26
NOTE: During installation the spring side of the seal 1

(Item 1) [Figure 20-21-23] must be installed
toward the inside of the cylinder. 2
21-23].
Figure 20-21-24
P101716
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-26] on the cylinder head.
P7425

Assembly (Cont'd)
1
Figure 20-21-27
Early
Models
1
2
P106021
Using a spanner wrench, tighten the head (Item 1)

P-48071 [Figure 20-21-29] to 373 N•m (275 ft-lb) torque.
Figure 20-21-30
Figure 20-21-28
Later
Models 2
1
2
3
P-85650
P106017
Install the bushing (Item 1) and seals (Item 2) [Figure 20-

NOTE: Clean and dry the rod threads. Install a NEW 21-30] using a driver tool and hammer.
NUT with pre-applied Loctite® included in the
seal kit or if a new nut is not available use
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-27] and [Figure 20-21-28].
Tighten the nut (Item 3) [Figure 20-21-27] and [Figure

20-21-28] to 1152 N•m (850 ft-lb) torque.

20-21-12
T770 Service Manual
CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING 1
enters skin or eyes, get immediate medical attention P-85570
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
WARNING Figure 20-22-3

Always clean up spilled fuel or oil. Keep heat, flames, 2
1
explosion or fire.
W-2103-0508
Figure 20-22-1
P-85568
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
P-85570
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the cylinder for repair.
[Figure 20-22-1].
Push and hold BOB-TACH “WEDGES UP” switch until

levers are in the unlocked position (Wedges fully raised).

CYLINDER (BOB-TACH) (CONT'D)
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Installation: Tighten the bolts to 29,8 - 32,5 N•m (22 - 24

ft-lb) torque.
Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-85569
Remove the bolts and washers (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

lb) torque.
Remove the cylinder from the lever pivots.

1. Tube
2. Nut
3. Piston
4. O-ring
5. Back-up Ring
6. Spacer
7. Head
8. Seal
9. Wiper
10. Rod
2
3
4
5
6
5
4
8
9
4
5
10
PE3954S

CYLINDER (BOB-TACH) (CONT'D) Figure 20-22-8
Disassembly 3 2 1
Figure 20-22-6
P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2)

P-85647 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook

Spanner Wrench 4
2
1
Use a spanner wrench to loosen the head [Figure 20-22-

5
6]. 3
Figure 20-22-7
N-20611
2
4 3 1
Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the O-ring (Item 4), and the
O-ring (Item 5) [Figure 20-22-9] from the head.
NOTE: The O-ring (Item 5) and back-up ring (Item 3)

[Figure 20-22-9] are no longer available parts.
The seal kit will contain a one piece seal that
is used in place of the O-ring and back-up
ring.
P16294
Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.

Assembly
3 1
2
Figure 20-22-10
P16295
Piston: Install the O-ring (Item 1) and seal (Item 2) on the

P7424 piston (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Spanner Wrench

Lubricate all O-rings and seals with hydraulic oil during

installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].
NOTE: During installation the spring side of the seal

must be toward the inside of the cylinder.

Assembly (Cont'd)
2
Figure 20-22-13 1
P106031
Install the O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) [Figure 20-22-15]
into the groove on the head.
22-13]. NOTE: Clean and dry the rod threads. Install a NEW
NUT with pre-applied Loctite® included in the
Figure 20-22-14 seal kit or if a new nut is not available use
Figure 20-22-16
3
2 4
1
P7425

P16294
Install the wiper seal with the wiper toward the outside of
the head. Install the head (Item 1), and spacer (Item 2) [Figure 20-
22-16].
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 190 N•m (140 ft-lb) torque.

Assembly (Cont'd)
Figure 20-22-17
P-85647
Tighten the head using a spanner wrench [Figure 20-22-

17], to 183 N•m (135 ft-lb) torque.

20-22-8
T770 Service Manual
MAIN RELIEF VALVE (EARLY MODELS)
Description
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader.

MAIN RELIEF VALVE (EARLY MODELS) (CONT’D) Figure 20-30-1
Testing
1
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-85571
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the
When the engine is running during service, the hydraulic tester to the bottom (female) quick coupler on
driving and steering controls must be in neutral and the loader.
cause injury or death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-1209 hydraulic tester to the top (male) quick coupler on the
loader.
Figure 20-30-2
WARNING
W-2017-0286
2
1
The tools listed will be needed to do the following
procedure:
TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) FLOW

METER
MEL10006 - Hydraulic Test Kit P-76460C
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and Start the engine and run at low idle.
loaders equipped with SJC option. The main
relief valve is located in the same place on all Press the AUXILIARY HYDRAULICS Button (Item 1)
of the loaders. [Figure 20-30-2] once to engage the auxiliary hydraulics.
Lift and block the loader. (See Procedure on Page 10-10- NOTE: The light (Item 2) [Figure 20-30-2] will be on.
1.)

MAIN RELIEF VALVE (EARLY MODELS) (CONT’D) With the engine at high idle and hydraulic oil at 60°C
(140°F) turn the restrictor control on the tester until the
Testing (Cont’d) flow through the tester drops to zero. Test the relief
pressure.
Figure 20-30-3
If the relief pressure is not correct, stop the engine and
Right
adjust the main relief valve.
Steering
Lever
Control
P-85572
Figure 20-30-4
Joystick Option Only

Right
Steering
1 Lever
Control
P-26697
Push the front switch (Item 1) [Figure 20-30-3] and

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

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

the flow is correct. Increase the engine speed to full rpm.
Refer to (See Hydraulic System on Page SPEC-10-4.) for

both flow and pressure specifications of the hydraulic
system.
Test the free flow specification.

MAIN RELIEF VALVE (EARLY MODELS) (CONT’D)
Adjusting

loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5
1
2
P-85573
If the pressure is not correct, adjust the main relief valve.
Loosen the lock nut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
Retest the main relief valve after adjusting.
NOTE: If the correct pressure can not be reached,

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

MAIN RELIEF VALVE (EARLY MODELS) (CONT’D) Figure 20-30-7
IMPORTANT
damage the system.
I-2003-0888
P-37689
Raise the operator cab. (See Raising on Page 10-30-2.)
Clean the area around the control valve. Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-7].
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.
relief valve is located in the same place on all
of the loaders. Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Test the pressure again. (See Testing on Page 20-30-2.)
P-85573
The main relief valve (Item 1) [Figure 20-30-6] is located

at the lower front of the control valve below the lift and tilt
spool connections.
Loosen and remove the main relief valve (Item 1) [Figure

20-30-6].

20-30-6
T770 Service Manual
MAIN RELIEF VALVE (LATER MODELS)
Description
The main relief valve and auxiliary relief valve limit the
hydraulic system pressure by opening at a certain
pressure and allowing the hydraulic oil to flow back to the
hydraulic reservoir. (See Hydraulic System on Page
SPEC-10-4.)
Figure 20-31-1
P107749A
The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve (Item 1)

[Figure 20-31-1] is located below the spool linkages,
facing the front of the machine. The auxiliary relief valve
(Item 2) (if equipped) [Figure 20-31-2] is located on the
top of the control valve facing the left side of the machine.

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Figure 20-31-2
Testing
1 3
WARNING
When the engine is running during service, the
driving and steering controls must be in neutral and
2
cause injury or death.
W-2006-1209
The tools listed will be needed to do the following P107936

procedure:
MEL1355-3 - Pressure gauge 34474 KPa (345 bar) Install the gauge (Item 1) and coupler (Item 2) to the test
(5000 psi) hose (Item 3) [Figure 20-31-2].
MEL1723 - Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased Raise the operator cab. (See Raising on Page 10-30-2.)
locally. Must be rated for pressures above 34474 kPa
(345 bar) (5000 psi). Figure 20-31-3
NOTE: This procedure is for loaders equipped with

ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
2
WARNING 1

physician familiar with this injury is not received P107935
immediately.
W-2145-0290
Connect the test coupler (Item 1) to the control valve
coupler (Item 2) [Figure 20-31-3].
Route the test gauge so it can be used in the operator

cab when lowered. Make sure the hose will not interfere
with any moving parts.
Lower the operator cab. (See Raising on Page 10-30-2.)
NOTE: Do not have any attachment connected to the

loader auxiliary quick couplers while testing.

Testing (Cont’d)
Enter the loader and engage the parking brake. Start the
engine.
Increase the engine speed to full rpm and make sure the
hydraulic oil is at 60°C (140°F).
2
Testing Main Relief Pressure without Auxiliary Relief 1
Valve
The main relief valve setting is 23,8 - 24, 5 MPa (238 -
245 bar) (3450 - 3550 psi).
Tilt the bucket backward and monitor the test gauge for
the relief pressure setting. NA3172
adjust the relief valve (See main Relief Valve Adjustment
on Page 20-31-4). Press the auxiliary hydraulics button (Item 1) [Figure 20-
31-4] to activate the auxiliary hydraulics.
Testing Main Relief Pressure if equipped with auxiliary
relief valve NOTE: The auxiliary indicator (Item 2) [Figure 20-31-
4] will illuminate when activated.
The main relief valve setting is 25,5 - 26,2 MPa (255 -
262 bar) (3700 - 3800 psi). Figure 20-31-5
Right
Tilt the bucket backward and monitor the test gauge for Steering
the relief pressure setting. Lever
Control

adjust the relief valve (See Main Relief Valve Adjustment
on Page 20-31-4.).
Testing Auxiliary Relief Pressure 1
The auxiliary relief valve setting is 23787 - 24476 kPa

(238 - 245 bar) (3450 - 3550 psi).
P107006B
Move the front auxiliary hydraulic switch (Item 1) [Figure

20-31-5] to the left or right and monitor the test gauge for
the relief pressure setting.

adjust the relief valve (See Auxiliary Relief Valve
Adjustment on Page 20-31-5.).
Stop the machine and exit the loader.

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Main Relief Valve Removal And Installation
Main Relief Valve Adjustment
Figure 20-31-6
IMPORTANT
damage the system.
I-2003-0888
2
Clean the area around the control valve.
1 NOTE: This procedure is for loaders equipped with

P107744 ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
Loosen the lock nut (Item 1) [Figure 20-31-6].
Figure 20-31-7
Turn the adjustment screw (Item 2) [Figure 20-31-6] in or
out until the pressure is correct. Turning the screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,
replace the main relief valve. Test the
pressure setting of the new relief valve. 1
P107743
Remove the main relief valve (Item 1) [Figure 20-31-7].

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Auxiliary Relief Valve Adjustment
Main Relief Valve Removal And Installation (Cont’d) NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve
Figure 20-31-8 is located in the same place on all of the
loaders.
Figure 20-31-9
1 2
P107745A 1
Remove the O-ring (Item 1) and back-up ring (Item 2)

P107747
[Figure 20-31-8] from the relief valve.
Clean the relief valve in clean solvent. Use air pressure to Loosen the lock nut (Item 1) [Figure 20-31-9].
dry the valve.
Turn the adjustment screw (Item 2) [Figure 20-31-9] in or
Install a new O-ring (Item 1) and back-up ring (Item 2) out until the pressure is correct. Turning the screw in will
[Figure 20-31-8]. Install the main relief valve and tighten. increase pressure.
Installation: Tighten the relief valve to 51 - 62 N•m (38 - NOTE: If the correct pressure can not be reached,
45 ft-lb) torque. replace the auxiliary relief valve. Test the
pressure setting of the new relief valve.
Test the relief valve (See Testing on Page 20-31-2.).

Auxiliary Relief Valve Removal And Installation
IMPORTANT 2
damage the system.
I-2003-0888 1
P107627
Clean the area around the control valve. Remove the O-rings (Item 1) and back-up washer (Item
2) [Figure 20-31-11] from the auxiliary relief valve.
NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve Clean the relief valve in clean solvent. Use air pressure to
is located in the same place on all of the dry the valve.
loaders.
Install the O-rings (Item 1) and back-up ring (Item 2)
Figure 20-31-10 [Figure 20-31-11]. Install the relief valve.
Installation: Tighten the relief valve to 51 - 62 N•m (38 -

45 ft-lb) torque.
Test the relief valve (See Testing on Page 20-31-2.).
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
P107746
Remove the auxiliary relief valve (Item 1) [Figure 20-31-

10].

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY
MODELS)
Description
Figure 20-40-1
P-90327
The hydraulic control valve is located inside the main

frame on the right hand side, below the operators cab.
The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.
The auxiliary function is operated by pilot pressure.

There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handle / lever. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.
The hydraulic control valve also contains a main relief

valve which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Drain the hydraulic reservoir. (See Removing And
MODELS) (CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the control linkage. (See Linkage Removal And

DANGER Installation on Page 50-90-2.)
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.
NOTE: Cap and plug all hydraulic connection points

when tubelines or hoses are removed.
Clean area around control valve.

P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2
• Keep out of this area when lift arms are raised 3
D-1009-0409 1
WARNING
the lift arms are secured by an approved lift arm 2
P-90187
to fall and cause injury or death. Remove the two bolts (Item 1), move the hose clamp
W-2059-0598 (Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-40-2] off to the side.
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm

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

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Figure 20-40-5
MODELS) (CONT’D)
Figure 20-40-3
2
1
P-90270
Disconnect the hose (Item 1) [Figure 20-40-5] that

routes from the control valve to the brake valve.
P-90267
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed Figure 20-40-6
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-40-3].
Figure 20-40-4 1
P-90271
2

1 routes from the top of the control valve to the hydraulic
filter.
P-90269
Disconnect the wire harness connectors (Item 1) [Figure

20-40-4] from the control valve.

routes from the control valve to the drain manifold.

routes from the control valve to the inlet fitting of the
hydraulic pump.

MODELS) (CONT’D)
Figure 20-40-7
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-40-9]

that route from the control valve to the junction block at
P-90272 the rear of the loader.
Figure 20-40-10
Remove the tubeline clamp (Item 1) [Figure 20-40-7].
Disconnect the two tubelines (Item 2) [Figure 20-40-7]

that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-40-8
2
P-90275

1 routes from the control valve to the junction block at the
rear of the machine.
P-90273 Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-40-10] from the control valve.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Mount Bracket Removal And Installation
MODELS) (CONT’D)
Figure 20-40-13
Figure 20-40-11
1
P-90280
P-90276 Support the mount bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14
routes from the bottom of the control valve to the outlet
2
fitting of the hydraulic pump.
Figure 20-40-12
P-90279
Remove the two control valve mount bolts (Item 1)

[Figure 20-40-14].
P-90278
Remove the two frame bolts (Item 2) [Figure 20-40-14].
Support the control valve and remove the two bolts (Item Installation: Torque the two frame bolts (Item 2) [Figure
1) [Figure 20-40-12]. 20-40-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve from the loader. Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY MODELS) (CONT'D)
Identification Chart
Figure 20-40-15
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307
ITEM DESCRIPTION ITEM DESCRIPTION
A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – 24132 kPa (241,3 bar)
(275,8 bar) (4000 psi) (3500 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (275,8 bar) (4000 psi) (Optional)

MODELS) (CONT'D)
Lift Load Check Valve Removal And Installation

1
Figure 20-40-16
3
1 P-90309
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-18].
P-90308
Check the free movement of the load check valve and
spring (Item 3) [Figure 20-40-18].
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS™ valve fitting on the top of the lift load
check valve.
Figure 20-40-17
P-90310
Remove the lift load check valve (Item 1) [Figure 20-40-

17] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

MODELS) (CONT'D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
1
Figure 20-40-19
2
3
4
2
1
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-20].
P-90311 Inspect the orifice (Item 3) [Figure 20-40-20] in the

poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section Installation: Install a new O-ring (Item 4) [Figure 20-40-
load check valve (Item 1) [Figure 20-40-19]. 20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
At the front side of the control valve locate the auxiliary torque.
section load check valve (Item 2) [Figure 20-40-19].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
IMPORTANT
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT'D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-23

Rod End)
Figure 20-40-21
P-90314
P-90314 Loosen the lift circuit port relief / anti-cavitation valve

(Item 1) [Figure 20-40-23].
At the back side of the control valve, remove the lift Figure 20-40-24
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
3 1
4
P-90315
P-90312 Replace the O-ring (Item 1) [Figure 20-40-24] before

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-40-22].
Inspect the orifice (Item 3) [Figure 20-40-22] in the

Installation: Install a new O-ring (Item 4) [Figure 20-40-

22] on the plug and lightly lubricate with oil before
torque.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT'D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-27

Installation (Tilt, Base End)
Figure 20-40-25
P-90314
P-90314 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-40-27] from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-40-28
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-40-26] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

MODELS) (CONT'D)
Port Relief Valve Removal And Installation 1
Figure 20-40-29
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-31].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-29] Figure 20-40-32
from the auxiliary circuit of the control valve.
Figure 20-40-30
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure

20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure


MODELS) (CONT'D)
Plug Removal And Installation
Figure 20-40-33
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-35].
P-68016
Figure 20-40-36
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-33].
Figure 20-40-34
1
P-51462

1 20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.
P-51460A

20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.

MODELS) (CONT'D)
Rubber Boot Removal And Installation
Figure 20-40-37
P-51506
Remove the three screws (Item 1) [Figure 20-40-37] on

the rubber boot retainer plate.
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-40-38
1
2
P-51701
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-38].

MODELS) (CONT'D)
End Cap Block Removal And Installation
Figure 20-40-39
1 1
1 1
P-51699A
1
Figure 20-40-42
P-51697
1
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-39] from the
end cap / spool lock block.
3
Figure 20-40-40
2
1
P-51701
Remove the four end cap / spool lock block mount screws
(Item 1) [Figure 20-40-41] and [Figure 20-40-42].
1
100 in-lb) torque.
P-90320 Remove the rubber boots and retainer plate (Item 2)

[Figure 20-40-42] from the lift and tilt spools.
Disconnect the tube line (Item 1) [Figure 20-40-40] from Remove the end cap / spool lock block (Item 3) [Figure
the end cap / spool lock block. 20-40-42] from the control valve.

MODELS) (CONT'D)
Lift Spool And Detent Removal And Installation
The tool listed will be needed to do the following 1

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap / spool lock block from the control
valve.
Figure 20-40-43
P-90321
Remove the end cap (Item 1) [Figure 20-40-45].
Figure 20-40-46
1
P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-43]. 2
Installation: Replace the O-ring, and lubricate the O-ring

lightly with grease or oil before installation of the end cap
P-51514
/ spool lock block.
Figure 20-40-44 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-46].
Remove the washer (Item 2) [Figure 20-40-46].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-44] from the lift spool.

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-47
1 P-51516
Put a rag around the detent assembly [Figure 20-40-48].

This will prevent the detent balls and spring from being
1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-40-49
Remove the screws (Item 1) [Figure 20-40-47] from the

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-47].
Installation: Lubricate the screws and tighten to 10,2 -
11,3 N•m (90 - 100 in-lb) torque.
2 1
3
IMPORTANT
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and

assembly.
Remove the detent sleeve (Item 1), detent balls (Item 2)
I-2012-0284
and spring (Item 3) [Figure 20-40-49].

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-50
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-52].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-53
Remove the lift spool assembly and seal (Item 1) [Figure
20-40-50] from the control valve. 2
Figure 20-40-51
1
3
1
N-18915
Install the spring tool (Item 1) [Figure 20-40-53] over the

P-51519 centering spring (Item 3).
NOTE: Be careful when removing the detent adapter

Remove the lift spool seal (Item 1) [Figure 20-40-51] (Item 2) [Figure 20-40-53] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

MODELS) (CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-54
N-19009
Remove spring tool (Item 1) [Figure 20-40-56] from the

1 spring assembly.
2
N-18916 Figure 20-40-57
Put a rag around the detent assembly [Figure 20-40-54]. 1

2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Allen wrench.
4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-54].
Figure 20-40-55
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-55]

from the spring assembly.

MODELS) (CONT'D)

(Cont'd)
2
Figure 20-40-58
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-60].
N-18918 NOTE: The lift spool will have an internal leak if there
is damage to this O-ring. Always replace the
O-ring and recheck the lift spool before the
Remove the stud from the end of the spool [Figure 20-
control valve is replaced.
40-58].
Figure 20-40-61
Figure 20-40-59
N-18920
N-18963
Removal of the plastic plug:

Install the plastic plug and O-ring in the spool [Figure 20-
Make a center point in the plug using a 1,6 mm (1/16 in) 40-61].
drill.
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-59] into the plug.

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

THREADS.

MODELS) (CONT'D)

(Cont'd)
2
Figure 20-40-62
O-ring
1 3
2
N-18958
Plastic
Plug
(15,2 mm) Apply grease on all the detent component surfaces
0.60 in before assembly [Figure 20-40-64].
B-14712 Install the spring (Item 1) [Figure 20-40-64] and detent

balls (Item 2) [Figure 20-40-64] into the adapter (Item 3)
[Figure 20-40-64] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-40-65].
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-62]. Figure 20-40-65
Figure 20-40-63
1
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-65].
Clamp the collar (Item 1) [Figure 20-40-63] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-66
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-68].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the

Install the spring tool (Item 1) [Figure 20-40-66] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).
Figure 20-40-67
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-68].
Figure 20-40-69
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-67].
CD-15051
Install the detent balls and spring [Figure 20-40-69].

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-70
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-72].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-72].
Install the mounting screws (Item 2) [Figure 20-40-72].

Hold the detent balls in place with the detent pliers
[Figure 20-40-70]. Installation: Lubricate the screws and tighten to 10 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-71
Figure 20-40-73
1
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-71] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-73].

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-74
1
1
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-76] on the lift spool.
P-90321 Figure 20-40-77
Install the end cap (Item 1) [Figure 20-40-74].
Figure 20-40-75
P-51511A
Install the O-ring (Item 1) [Figure 20-40-77] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-75] on the

linkage end of the valve.

MODELS) (CONT'D)

(Cont'd)
Figure 20-40-78
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap / spool lock block (Item 1) and the (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
mount bolt (Item 2) [Figure 20-40-78]. 45 ft-lb) torque [Figure 20-40-80].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-78].
100 in-lb) torque.
Figure 20-40-79
P-90320
Connect the tubeline (Item 1) [Figure 20-40-79].

MODELS) (CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap / spool lock block. (See
End Cap Block Removal And Installation on Page 20-40- 2
14.)
Figure 20-40-81
P-90323
Remove the spool centering block (Item 1) [Figure 20-

1 2
40-83] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

83] and lubricate the O-ring lightly with grease or oil
before installation of the end cap / spool lock block.
P-51521
Figure 20-40-84

20-40-81] from the tilt spool.
Figure 20-40-82
P-51544
2 1 Remove the tilt spool, centering spring, back-up washer

and spool seal [Figure 20-40-84].
P-90321
Assembly: Always use a new spool seal.

from the spool centering block.
Remove the three screws (Item 2) [Figure 20-40-82]

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

MODELS) (CONT'D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-85
3
4
1
N-18944A
N-18942
Figure 20-40-88
Put the linkage end of the spool in the vice [Figure 20-
40-85]. 2
1
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

N-19014
Remove the bolt (Item 1) [Figure 20-40-86] holding the

centering spring to the spool.

in-lb) torque.
Remove spring tool from the spring assembly.

MODELS) (CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-89
1
1
2 3 2
P-51547
2 1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-91] from the auxiliary spool.
P-90321
Figure 20-40-92
Remove the two tubelines (Item 1) [Figure 20-40-89]



in-lb) torque. 2
1
40-89] from the control valve.
Figure 20-40-90
P-51549A
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-92] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

2 20-40-92] must be replaced, replace the
1 retainer on the opposite end also.
P-51546A


20-40-90] must be replaced, replace the
retainer on the opposite end also.

MODELS) (CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-93
1
2
P-51550

Figure 20-40-94
1
P-51551
Remove the spool (Item 1) [Figure 20-40-94].

MODELS) (CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-95
1
2
P-85528
Remove the screws (Item 1) [Figure 20-40-95] from both

solenoids.
Remove the solenoids (Item 2) [Figure 20-40-95] from

the control valve.
Installation: Tighten the nut to 2,44 - 2,98 N•m (21.6 -

26.4 in-lb) torque.
Figure 20-40-96
P-85556
Remove the O-rings (Item 1) [Figure 20-40-96] from the

solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.1 - 6.1 ohm.

MODELS) (CONT'D)
Solenoid Removal And Installation
Figure 20-40-97 1
1
2
P-85528
Remove the solenoid stem (Item 1) [Figure 20-40-99].
P-90310 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-97] from the Figure 20-40-100
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-97]. 3
2
Figure 20-40-98
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-100] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-98] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-100] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-98] and

[Figure 20-40-100] and new back-up rings (Item 2)
[Figure 20-40-100] on the solenoid stem.

MODELS) (CONT'D)
Lock Valve Removal And Installation
Figure 20-40-101 1
1
1
1
2
2
1
2
2 P-51564

[Figure 20-40-103] from the lift lock valve, and replace
P-90310 with new.
Figure 20-40-104
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-101] is for the lift
circuit.
Figure 20-40-102
P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

104].
P-90321
Remove the lift lock valve (Item 1) [Figure 20-40-102]

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


MODELS) (CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105 1
1
1
2
1
2
2
1 2
P-51564

[Figure 20-40-107] from the tilt lock valve, and replace
P-90325 with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-105].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-105].
Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-106
P-90324
Remove the tilt lock valve (Item 1) [Figure 20-40-106]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) (EARLY Main Relief Valve Removal And Installation
MODELS) (CONT'D)
Figure 20-40-110
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-108
1
P-51707
P-90308 Remove the main relief valve (Item 1) [Figure 20-40-

110].
Remove the fitting (Item 1) [Figure 20-40-108] from the Figure 20-40-111
valve.
Figure 20-40-109
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 52 - 61
109]. N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve

casting.

MODELS) (CONT'D)
Check Valve Removal And Installation
Figure 20-40-112
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-40-115
Remove the tubeline (Item 1) [Figure 20-40-112].
Figure 20-40-113
1
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-40-115].
Remove the check valve fitting (Item 1) [Figure 20-40-

113] from the hydraulic control valve.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER
MODELS)
Description
Figure 20-41-1
P107871

frame on the right hand side, below the operators cab.

lift, tilt, and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.

the right side control handle / lever. The activated
The hydraulic control valve is designed with two relief

valve ports. The main relief valve is used on the 800, 700,
and 600 series loaders. The auxiliary relief valve is
standard on the 800 series and may be present on the
700 and 600 series.

hydraulic control valve. The main relief valve port is
adjacent to the spool linkages. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Drain the hydraulic reservoir. (See Removing And
MODELS) (CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the control linkage. (See Linkage Removal And

DANGER Installation on Page 50-90-2.)

connections for correct installation.
NOTE: Cap and plug all hydraulic connection points

when tubelines or hoses are removed.
Clean area around control valve.

P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-41-2
unless supported by an approved lift arm 3
D-1009-0409
1
WARNING
2
support device. Failure to use an approved lift arm P-90187
W-2059-0598 Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose and then place the fuel
IMPORTANT
damage the system.
I-2003-0888

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

MODELS) (CONT’D)
Figure 20-41-3
P-90267
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
1) [Figure 20-41-3].
Figure 20-41-4
P-90269


routes from the control valve to the drain manifold.

hydraulic pump.

MODELS) (CONT’D)
Figure 20-41-5
2
1
P-90270


Figure 20-41-6
1
P-90271

routes from the top of the control valve to the hydraulic
filter.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Figure 20-41-9
MODELS) (CONT’D)
Figure 20-41-7
1 1
2 2
1 1
P-90274

P-90272 the rear of the loader.
Figure 20-41-10

1
hydraulics.
Figure 20-41-8
P-90275

1 routes from the control valve to the junction block at the
P-90273 Disconnect the lift arm bypass drain hose (Item 2)


MODELS) (CONT’D)
Figure 20-41-11
P-90276

fitting of the hydraulic pump.
Figure 20-41-12
1
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-12].
Remove the control valve from the loader.

MODELS) (CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-13
P-90280
Support the mount bracket (Item 1) [Figure 20-41-13].
Figure 20-41-14
2
P-90279

[Figure 20-41-14].
Remove the two frame bolts (Item 2) [Figure 20-41-14]
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)
Figure 20-41-15
AR
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2
D2
A1
H3 E1
B1
F3 MR
F1 H1 J1 J3
C1
NA5826
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
(276 bar) (4000 psi)
J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
(276 bar) (4000 psi) J3 Lift Arm Bypass Orifice
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – Without Auxiliary Relief
(276 bar) (4000 psi) Valve 24132 kPa (241 bar) (3500 psi)
Tilt (Rod End) Main Relief Valve - With Auxiliary Relief Valve
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) MR 25511 - 26200 KPa (255 - 262 bar)
27579 kPa (276 bar) (4000 psi) (Optional) (3700 - 3800 psi)
D6 Port Relief / Anti-Cavitation Valve (Auxiliary) Auxiliary Relief Valve - If equipped 23787 -
27579 kPa (276 bar) (4000 psi) (Optional) AR
24476 KPa (238 - 245 bar) (3450 - 3550 psi)

MODELS) (CONT'D)
Lift Load Check Valve Removal And Installation
IMPORTANT 1
damage the system.
I-2003-0888
P107873
Figure 20-41-16
17] and fitting from the top of the control valve.

Figure 20-41-18
1
1
P107872
2
check valve. 3
4
P107716
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-18].
Inspect the spring (Item 3) and free movement load

check valve (Item 4) [Figure 20-41-18].
Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-41-18].

MODELS) (CONT'D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
Figure 20-41-19 1
2
1
3
2 P107624

20-41-20].
P107874 Inspect the orifice (Item 3) [Figure 20-41-20] in the

poppet to make sure it is not plugged.
At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-41-
the tilt section load check valve (Item 1) [Figure 20-41- 20] and lubricate with oil before installing. Tighten the
19]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

the auxiliary section load check valve (Item 2) [Figure
20-41-19].

interchangeable.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT’D) Installation (Lift, Base End)

Rod End)
Figure 20-41-21
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-calibration seat (Item 1) [Figure
20-41-23].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-21]. Figure 20-41-24
Figure 20-41-22
1
2
2
1
4
P107952
3
P107624
Remove the O-ring (Item 1) [Figure 20-41-24] from the
port relief / anti cavitation relief valve.
20-41-22]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-24] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-41-22] in the needed.
Installation: Tighten the port relief anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT'D) Installation (Tilt, Rod End)

Figure 20-41-25
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-calibration seat (Item 1) [Figure 20-41-
27] from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-25] from the base end of the tilt section. Figure 20-41-28
Figure 20-41-26
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve.
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

MODELS) (CONT'D)
Port Relief Valve Removal And Installation
Figure 20-41-29
P107628

P107628
Figure 20-41-30
1
1
P107629
2
P107630 Remove the O-ring (Item 1) [Figure 20-41-32] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
[Figure 20-41-30] from the port relief plug.

MODELS) (CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-33
P107628

P107628
Figure 20-41-34
1
1
2
P107629


MODELS) (CONT'D)
Figure 20-41-37
P107632

(Item 1) [Figure 20-41-39].
P107631
Figure 20-41-40
1) [Figure 20-41-37].
Figure 20-41-38
1
P107633

plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

plug.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER End Cap Block Removal And Installation
MODELS) (CONT'D)
Figure 20-41-43
Rubber Boot Removal And Installation
Figure 20-41-41
1
2
1
1 P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-41-43] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-41-41] on
the rubber boot retainer plate. Figure 20-41-44

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-42
1
2
1 P107666
Disconnect the tubeline (Item 1) [Figure 20-41-44] from

the end cap block.
P107664
Remove the rubber boots (Item 1) from the retainer plate

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

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Lift Spool And Detent Removal And Installation
MODELS) (CONT'D)
End Cap Block Removal And Installation (Cont’d) procedure:
Figure 20-41-45 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-46
2
1
1
P107773
Remove the end cap block mount screw (Item 1) [Figure

20-41-45].
P107776
11,6 N•m (95 - 105 in-lb) torque.
Remove the O-ring (Item 1) [Figure 20-41-46].
Remove the end cap block (Item 2) [Figure 20-41-45]
from the control valve. Installation: Replace the O-ring, and lubricate the O-ring
lightly with grease or oil before installation of the end cap
block.
Figure 20-41-47
P107775

20-41-47] from the lift spool.

MODELS) (CONT'D)

(Cont’d)
Figure 20-41-48
P107846
NOTE: Do not remove the sleeve detent (Item 1) or

1 retaining ring (Item 2) [Figure 20-41-50] from
the spool centering block. If removed, the
P107779 sleeve detent must be inserted with the
original orientation.
Remove the four screws (Item 1) [Figure 20-41-48] from Figure 20-41-51
the spool centering block.
Figure 20-41-49
1
2
2
P107845A
1
P107778 NOTE: If removed, use the following for correct

installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-41-51]
Remove the spool centering block (Item 1) [Figure 20- so it faces the opening of the spool centering
41-49]. block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
Remove the O-ring (Item 2) [Figure 20-41-49]. [Figure 20-41-51] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

MODELS) (CONT'D)

(Cont’d)
Figure 20-41-52
P107739
2
41-54].
1
P107790 NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly (Item 1) and O-ring (Item

2) [Figure 20-41-52] from the control valve.
Figure 20-41-53
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and

assembly.
I-2012-0284
Figure 20-41-55
2
1
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-41-53]

from the linkage end of the valve.
P107674A

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

(Item 2) [Figure 20-41-55] from the centering
spring, as it is under spring pressure.

MODELS) (CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-41-56
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly

2 (Item 2) [Figure 20-41-58].
P107674 Figure 20-41-59
Remove the spring assembly / spring tool (Item 1) from

the spool (Item 2) [Figure 20-41-56]. 2
3 1
NOTE: The detent adapter has two detent balls (Item 4
3) held under pressure from a detent spring
(Item 4) [Figure 20-41-58]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-41-57
P107677
1 Inspect the adapter (Item 1), collar (Item 2), spring (Item
P107675
Remove the detent adapter (Item 1) [Figure 20-41-57]

from the spring assembly.

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-60
1
N-18967
Clamp the collar (Item 1) [Figure 20-41-62] in a vice.
Figure 20-41-63
N-18918
Remove the stud from the end of the spool [Figure 20-
41-60]. 3
Figure 20-41-61 2
P107677
Apply grease on all the detent component surfaces

15,2 mm before assembly [Figure 20-41-63].
(0.60 inch)
Install the spring (Item 1) [Figure 20-41-63] and detent
B-14712B balls (Item 2) [Figure 20-41-63] into the adapter (Item 3)
[Figure 20-41-63] and compress with the detent pliers
(Item 1) [Figure 20-41-64].
Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-41-61].

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-64
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-41-66].
N-18968A Remove the spring tool.
Check the alignment of the detent adapter and the

Install the detent adapter to the collar [Figure 20-41-64]. washer.
NOTE: The collar and the detent adapter are held Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the NOTE: The adapter must fit in the center of the
detent adapter and collar together to prevent
washer.
the detent balls and spring from falling out.
Figure 20-41-67
Figure 20-41-65
2
P107790
P107675
Lubricate and install a new O-ring (Item 1) [Figure 20-41-

Install the spring tool (Item 1) [Figure 20-41-65] over the 67].
washer, spring, collar, and detent adapter.
Lubricate and install a new O-ring (Item 2) [Figure 20-41-
67].
Install the lift spool assembly (Item 3) [Figure 20-41-67]

in the spool bore.

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-68
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

2 20-41-70] on the lift spool.
P107779 Figure 20-41-71
Install the spool centering block (Item 1) [Figure 20-41-

68].
Install the four mounting screws (Item 2) [Figure 20-41-

68].
1

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-69
P107776
1
Install an O-ring (Item 1) [Figure 20-41-71] on the control

valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-41-69] on the

linkage end of the valve.

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-72
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
P107664A The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap block (Item 1) and the mount bolt (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
(Item 2) [Figure 20-41-72]. 45 ft-lb) torque [Figure 20-41-74].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-41-72].
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-73
P107666
Connect the tubeline (Item 1) [Figure 20-41-73].

MODELS) (CONT'D)
Remove the lift and tilt end cap block. (See End Cap
Block Removal And Installation on Page 20-40-14.) 2
Figure 20-41-75
1
P107778

1 41-77] from the control valve.

2
77] and lubricate the O-ring lightly with grease or oil
P107777 before installation of the spool centering block.
Figure 20-41-78
Installation: Install the spacer (Item 1) and an O-ring

2
(Item 2) [Figure 20-41-75].
Figure 20-41-76
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure

20-41-78].
1
P107779 78] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Remove the four screws (Item 1) [Figure 20-41-76] from


11,6 N•m (95 - 105 in-lb) torque.

MODELS) (CONT'D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-41-79
1
P107647

P107781
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-41-79].
Remove the spring tool from the spring assembly.
Figure 20-41-82
Figure 20-41-80
2 1
3
1 4
N-18944B
P107646
Put the linkage end of the spool in the vice [Figure 20- 3), and washer (Item 4) [Figure 20-41-82].
41-80].
NOTE: Protect spool before clamping in vise.

centering spring.

MODELS) (CONT'D)
Figure 20-41-83
1
3 2
4
1
2
4
P107783

3 (Item 2) [Figure 20-41-84] from the auxiliary spool.
P107782
(Item 2) [Figure 20-41-83] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure
Remove the spacer (Item 3) and O-ring (Item 4) [Figure retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
[Figure 20-41-84].
retainer on the opposite end also. Figure 20-41-85
Installation: Lubricate and install an O-ring (Item 4)

[Figure 20-41-83].
P107784
Remove the auxiliary spool (Item 1) [Figure 20-41-85].

MODELS) (CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-41-86 1
2
1
2
2
P107798
1

[Figure 20-41-87] from the solenoid stem.
P107876
resistance.
Remove the screws (Item 1) [Figure 20-41-86] from both
solenoids. The correct resistance for the coil is 5.1 ohm.
Remove the solenoids (Item 2) [Figure 20-41-86] from Installation: Lubricate and install new O-rings (Item 1)
the control valves. and back-up rings (Item 2) [Figure 20-41-87].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9
in-lb) torque.

MODELS) (CONT'D)
Figure 20-41-88
1
1
2
P107876
P107875 Installation: Lubricate the O-rings and tighten the stem

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

2
Figure 20-41-89
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.

MODELS) (CONT'D)
Figure 20-41-92
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure

20-41-94] is threaded for easier removal and installation.
P107785
Figure 20-41-95
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-
92]. 1 3
2
Figure 20-41-93
1
P107767
Remove and inspect the spring (Item 2) and BICS™

P107786 valve (Item 3) [Figure 20-41-95].

Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

MODELS) (CONT'D)
Figure 20-41-96
2
1
P107937

P107788
Figure 20-41-99
Remove the lift spool lock solenoid (Item 1) [Figure 20-

41-96].
1 3
Remove the tilt spool lock solenoid (Item 2) [Figure 20-
2
41-96].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-41-97
P107767

valve (Item 3) [Figure 20-41-99].
1
P107789

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) (LATER Main Relief Valve Removal And Installation
MODELS) (CONT'D)
Figure 20-41-102
Figure 20-41-100
P107787
1
P107693 Remove the main relief valve (Item 1) [Figure 20-41-

102].
Remove the fitting (Item 1) [Figure 20-41-100] from the Figure 20-41-103
valve.
Figure 20-41-101
1
1
P-51463
P-51437 Remove the O-rings (Item 1) [Figure 20-41-103] from the

main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-41- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
101].

casting.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Check Valve Removal And Installation
MODELS) (CONT'D)
Figure 20-41-106
NOTE: The auxiliary relief valve (Item 1) [Figure 20-

41-104] is an optional item and may not be
installed.
Figure 20-41-104
P107693
Figure 20-41-107
P107870

104].
Figure 20-41-105 1
P107786

P107627

[Figure 20-41-105] from the auxiliary relief valve.

MODELS) (CONT'D)
Check Valve Removal And Installation (Cont’d)
Figure 20-41-108
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-108].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
(EARLY MODELS)
Description
Figure 20-42-1 DANGER
P-90328
AVOID DEATH
P-90337 • Keep out of this area when lift arms are raised
NOTE: The 90° fitting (Item 1) [Figure 20-42-1] has D-1009-0409
been replaced with a tee fitting on late model
machines.

frame on the right hand side, below the operator’s cab. WARNING
The hydraulic control valve is the hydraulic component Never work on a machine with the lift arms up unless
that uses spools to direct the flow of hydraulic fluid to the the lift arms are secured by an approved lift arm
lift, tilt and auxiliary functions. support device. Failure to use an approved lift arm
The lift and tilt functions in the hydraulic control valve are to fall and cause injury or death.
operated using electronic control handles / levers that W-2059-0598
send an electronic signal to the electronic actuators to
move the lift and tilt spools in the control valve.

Only one solenoid at a time is activated by the switch on IMPORTANT
the right side control handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool When repairing hydrostatic and hydraulic systems,
and forces the spool to shift. clean the work area before disassembly and keep all
The hydraulic control valve also contains a main relief tubelines and ports to keep dirt out. Dirt can quickly
valve which is adjustable. damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-42-3
(EARLY MODELS) (CONT’D)

support device. (See LIFT ARM SUPPORT DEVICE on 1
Page 10-20-1.)
Drain the hydraulic reservoir. (See Removing And

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

on Page 50-100-2.)
P-90267

connections for correct installation. The fixed end main valve hose assembly is connected to
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
Clean area around control valve. 1)[Figure 20-42-3].
Open rear door. Figure 20-42-4
Figure 20-42-2
3
1
3
P-90269
2
P90187
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and then place the fuel Disconnect the hose (Item 2) [Figure 20-42-4] that
inlet assembly (Item 3) [Figure 20-42-2] off to the side. routes from the control valve to the drain manifold.

hydraulic pump.

Figure 20-42-5
1
Early Models
2
1
P-90271

3
P-90270 filter.
Figure 20-42-8

2 2
NOTE: The hose (Item 1) has been relocated to the
tee fitting on top of the load check valve (Item 1

3) [Figure 20-42-5] on late model machines.
Figure 20-42-6
Later Models
2 P-90272

1 that route from the control valve to the front auxiliary
hydraulics.
P107219




1
Figure 20-42-9
P-90275
1
routes from the control valve to the junction block at the
P-90273 rear of the machine.
Disconnect the lift arm bypass drain hose (Item 2)

Remove the tubeline clamp (Item 1) [Figure 20-42-9]. [Figure 20-42-11] from the control valve.
Figure 20-42-10 Figure 20-42-12
1 1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-42- Disconnect the hose (Item 1) [Figure 20-42-12] that
10] that route from the control valve to the junction block routes from the bottom of the control valve to the outlet
at the rear of the loader. fitting of the hydraulic pump.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
Figure 20-42-13
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-42-13].


Actuator Removal And Installation (In Loader)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-1.) Remove the two screws (Item 1) [Figure 20-42-15] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.
Figure 20-42-16
Figure 20-42-14
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-42-16] away from

Unplug the actuator connectors (Item 1) [Figure 20-42- the control valve.
14] from the loader harness.
Use a punch to remove the actuator pin (Item 2) [Figure
20-42-16] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)


(Cont’d)
Figure 20-42-17
1
2
P-54568
Inspect the O-ring (Item 1) [Figure 20-42-17] on the face

of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-42-17] and

replace as needed.

Actuator Removal And Installation (Out Of Loader)
Figure 20-42-18
P-54339
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-42-20] from the actuator
and the tilt spool.
P-54337 Remove the actuator and linkage pin from the valve.
Figure 20-42-21
Remove the two mount bolts (Item 1) [Figure 20-42-18]
from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-42-19
P-54340
1 Inspect the O-ring (Item 1) [Figure 20-42-21] on the face

of the actuator, and replace as needed.

P-54338 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-42-

19] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
42-19].

Actuator Removal And Installation (Out of Loader)

(Cont’d)
Figure 20-42-22
1 1
P-54343
Using a punch and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-42-24] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-42-22] Figure 20-42-25
from the lift actuator.

Figure 20-42-23
P-54340
Inspect the O-ring (Item 1) [Figure 20-42-25] on the face

1 of the actuator, and replace as needed.
P-54342 Inspect the linkage pin (Item 2) [Figure 20-42-25] and

replace as needed.

42-23].


(Cont’d)
Figure 20-42-26
4 3
1
3
P-90329
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-42-26] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-42-26].
N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-42-26]

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS) (CONT’D)
Figure 20-42-27
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307

D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24132 kPa (241,3 bar)
(3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (275,8 bar) (4000 psi) (Optional)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
Figure 20-42-30
Figure 20-42-28
P-90308
P-90280 Remove the charge tubeline (Item 1) [Figure 20-42-30]

check valve.
Support the mounting bracket (Item 1) [Figure 20-42-28].
Figure 20-42-31
Figure 20-42-29
2 1
P-90310
P100202

Remove the two control valve mount bolts (Item 1) 31] and fitting from the top of the control valve.
[Figure 20-42-29].
Remove the two frame bolts (Item 2) [Figure 20-42-29] tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

20-42-29] to 406 - 447 N•m (300 - 330 ft-lb).

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(EARLY MODELS) (CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-42-33

(Cont’d)
Figure 20-42-32
2
P-90311
3
P-90309 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-42-33].
Remove and install new O-rings (Item 1) and back-up At the front side of the control valve locate the auxiliary
ring (Item 2) [Figure 20-42-32]. section load check valve (Item 2) [Figure 20-42-33].
Inspect the free movement load check valve and spring NOTE: The tilt and auxiliary load check valves are
(Item 3) [Figure 20-42-32]. interchangeable.
Figure 20-42-34
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
parts clean. Always use caps and plugs on hoses, 2
damage the system. 3
I-2003-0888 4
P-90312

20-42-34].


torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(EARLY MODELS) (CONT’D) Installation (Lift, Base End)

Rod End)
Figure 20-42-35
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-42-37].
At the back side of the control valve, remove the lift Figure 20-42-38
section anti-cavitation valve (Item 1) [Figure 20-42-35].
Figure 20-42-36
1
3 1
4
P-90315

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-42-36].


torque.

(EARLY MODELS) (CONT’D) Installation (Tilt, Rod End)

Figure 20-42-39
P-90314
P-90314 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-42-41] from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-42-42
[Figure 20-42-39] from the base end of the tilt section.
Figure 20-42-40
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-42-40] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.

Port Relief Valve Removal And Installation 1
Figure 20-42-43
P-90318A

P-90314
Figure 20-42-44
1
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure



Figure 20-42-47
1
P-51461

(Item 1) [Figure 20-42-49].
P-68016
Figure 20-42-50
1) [Figure 20-42-47].
Figure 20-42-48
P-51462

1 20-42-50]. Tighten to 81,3 N•m (60 ft-lb) torque.
P-51460A

20-42-48]. Tighten to 81,3 N•m (60 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-42-6.) Remove the end cap block from the control valve.
Figure 20-42-51 Figure 20-42-53
1 2
P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-42-51] from Remove the O-ring (Item 1) [Figure 20-42-53].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-42-51].
Figure 20-42-54
100 in-lb) torque.
Figure 20-42-52
P-68047
1
P-90339 20-42-54] from the lift spool.

from the control valve.

Lift Spool Removal And Installation (Cont'd)
Figure 20-42-55
1
1
P-68045
1
Remove the lift spool assembly and seal (Item 1) [Figure

P-68043
Figure 20-42-58
Remove the two screws (Item 1) [Figure 20-42-55] from

the lift spool end cap.

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-42-56
P-68046
1 Remove the lift spool seal (Item 1) [Figure 20-42-58]

from the linkage end of the valve.
P-68044
Remove the lift spool end cap (Item 1) [Figure 20-42-56]


Lift Spool Disassembly And Assembly

1
Figure 20-42-59
N-190146

P-51772
in-lb) torque.
42-59]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-42-62
Figure 20-42-60
3
4 1
1
P-51776
P-51773
centering spring.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) NOTE: The lift spool will have an internal leak if there
(EARLY MODELS) (CONT’D) is damage to this O-ring. Always replace the
O-ring and plastic plug. Inspect the lift spool
Lift Spool Disassembly And Assembly (Cont,d) before the control valve is replaced.
Figure 20-42-63 Figure 20-42-65
N-18920
P-74184
Removal of the plastic plug:

Install the plastic plug and O-ring in the spool [Figure 20-
Make a center point in the plug using a 1,6 mm (1/16 in) 42-65].
drill.
Figure 20-42-66
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill.
Turn a 6-32 tap (Item 1) [Figure 20-42-63] into the plug. 2

1
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS. 1
Figure 20-42-64
P-68046 P-51775
2
1 washer (Item 2) [Figure 20-42-66].
P-74183
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-42-64].

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-42-18.)
2
Figure 20-42-67
P-90342

2 42-69] from the control valve.
1 Installation: Replace the O-ring (Item 2) [Figure 20-42-
69] and lubricate lightly with oil / grease before
P-68049 installation of the end cap block.
Figure 20-42-70
Figure 20-42-68
1 1
1 P-68052
2
Remove the tilt spool, centering spring, back-up washer
P-90321 and spool seal (Item 1) [Figure 20-42-70].

Disconnect the two tubelines (Item 1) [Figure 20-42-68].


in-lb) torque.

Tilt Spool Removal And Installation (Cont’d)

2 1
Figure 20-42-71
3
4
1
N-18944A
N-18942
Figure 20-42-74
Put the linkage end of the spool in the vice [Figure 20-
42-71]. 2
1
centering spring.
Figure 20-42-72
1
1
P-51545 N-18943

N-19014


in-lb) torque.
Remove spring tool from the spring assembly.

Figure 20-42-75
2
1
2
P-68054
1
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

P-90321
Figure 20-42-78


100 in-lb) torque.
2
1
Remove the spool centering block from the control valve.
Figure 20-42-76
P-68076


2 20-42-78] must be replaced, replace the
P-68053



HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
Figure 20-42-81
Auxiliary Spool Removal And Installation (Cont,d)
Figure 20-42-79
2
1
2
2 P-90337
P-68077 Remove the screws (Item 1) [Figure 20-42-81] from both

solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Remove the solenoids (Item 2) [Figure 20-42-81].
Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6
Figure 20-42-80 - 26.4 in-lb) torque.
Figure 20-42-82
P-68078
P-85556
Remove the auxiliary spool (Item 1) [Figure 20-42-80].
Inspect and remove the O-rings (Item 1) [Figure 20-42-

82] from the solenoid stem.

resistance.

Figure 20-42-83 1
P-90346
P-90337 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
solenoid stem.
2
Figure 20-42-84
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-42-84] and

[Figure 20-42-86] and new back-up rings (Item 2)
[Figure 20-42-86] on the solenoid stem.

Figure 20-42-87
1
2 P-51792

P-90310
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-42-87] is for the lift circuit. Figure 20-42-90
Figure 20-42-88
1
1
1
1
1
2
2
2
P-51564
P-90321
[Figure 20-42-90] from the valve, and replace with new.


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
Figure 20-42-93
Figure 20-42-91
1
P-51794
P-90308 Remove the main relief valve (Item 1) [Figure 20-42-93].
Figure 20-42-94
Remove the fitting (Item 1) [Figure 20-42-91] from the
valve.
Figure 20-42-92
1
1
P-90344
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-42-94].
Installation: Always use new O-rings. Tighten to 52 - 61

Inspect the lift arm bypass orifice (Item 1) [Figure 20-42- N•m (38 - 45 ft-lb) torque.
92].

casting.

Check Valve Removal And Installation
Figure 20-42-95
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-42-

97] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-42-98
Figure 20-42-96
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-42-98].


20-42-30
T770 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
(LATER MODELS)
Description
Figure 20-43-1 DANGER
P-90328
AVOID DEATH
P107847 • Keep out of this area when lift arms are raised
The hydraulic control valve is located inside the main D-1009-0409
frame on the right hand side, below the operator’s cab.

lift, tilt, and auxiliary functions.
WARNING
The lift and tilt functions in the hydraulic control valve are Never work on a machine with the lift arms up unless
operated using electronic control handles / levers that the lift arms are secured by an approved lift arm
send an electronic signal to the electronic actuators to support device. Failure to use an approved lift arm
move the lift and tilt spools in the control valve. support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. W-2059-0598
the right side control handles / levers. The activated
IMPORTANT
The hydraulic control valve is designed with two relief
valve ports. The main relief valve is used on the 800, 700, When repairing hydrostatic and hydraulic systems,
and 600 series loaders. The auxiliary relief valve is clean the work area before disassembly and keep all
standard on the 800 series and may be present on the parts clean. Always use caps and plugs on hoses,
700 and 600 series. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
hydraulic control valve. The main relief valve port is
adjacent to the actuator side. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

(LATER MODELS) (CONT’D)

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


on Page 50-100-2.)
P-90267

connections for correct installation. The fixed end main valve hose assembly is connected to
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
Clean area around control valve. 1) [Figure 20-43-3].
Open rear door. Figure 20-43-4
Figure 20-43-2
3
1
3 1
P-90269
2
P-90187
(Item 2) to the middle of the hose, and then place the fuel Disconnect the hose (Item 2) [Figure 20-43-4] that
inlet assembly (Item 3) [Figure 20-43-2] off to the side. routes from the control valve to the drain manifold.

hydraulic pump.

Figure 20-43-5
2 2
1
2
P-90272

1
P107219 Disconnect the two tubelines (Item 2) [Figure 20-43-7]
hydraulics.
routes from the control valve to the brake valve. Figure 20-43-8

Figure 20-43-6
1
1
P-90273
P-90271

filter.

Figure 20-43-9
1 1
1
P-90276
1 Disconnect the hose (Item 1) [Figure 20-43-11] that

P-90274 fitting of the hydraulic pump.
Figure 20-43-12
the rear of the loader.
Figure 20-43-10
1
1
2
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-43-12].
P-90275

routes from the control valve to the junction block at the
Disconnect the lift arm bypass drain hose (Item 2)


WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-1.) Remove the two screws (Item 1) [Figure 20-43-14] from
the actuator retainer.
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.
Figure 20-43-15
Figure 20-43-13
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-43-15] away from

Unplug the actuator connectors (Item 1) [Figure 20-43- the control valve.
13] from the loader harness.
Use a punch to remove the actuator pin (Item 2) [Figure
20-43-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out Of Loader)
(Cont’d) Figure 20-43-17
Figure 20-43-16 1
1
2
1
P107802
P-54568
from the tilt actuator.
Remove the O-ring (Item 1) [Figure 20-43-16] on the
face of the actuator. Installation: Tighten the mounting bolts to 10,2 - 11,3
replace as needed. Figure 20-43-18
NOTE: Repeat this procedure to remove the lift
actuator.
P107803

43-18].

Actuator Removal And Installation (Out of Loader)

(Cont’d)
1
Figure 20-43-19
1
P107804
1
from the lift actuator.
P107808 Installation: Tighten the mounting bolts to 10,2 - 11,3

Using a punch and a hammer, remove the actuator Figure 20-43-22

linkage pin (Item 1) [Figure 20-43-19] from the actuator
and the tilt spool.

Figure 20-43-20
1
1
P107805
2 Slide the actuator mount bracket (Item 1) [Figure 20-43-

P-54340 Pull the actuator away from the control valve [Figure 20-
43-22].

face of the actuator.

replace as needed.

4
(Cont’d)
Figure 20-43-23
2
1 3
P107807A
1
NOTE: The two long bolts (Item 1) are used to mount
the lift actuator (Item 2) [Figure 20-43-25] to
the control valve.
P107806 The two short bolts (Item 3) are used to mount
the tilt actuator (Item 4) [Figure 20-43-25].
Using a punch and a hammer, remove the actuator Installation: Tighten the mounting bolts to 10,2 - 11,3
linkage pin (Item 1) [Figure 20-43-23] from the actuator N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-43-25].
and the tilt spool.
Figure 20-43-24
P-54340

face of the actuator.

replace as needed.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D)
Figure 20-43-26
AR
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1
F1 MR C1
H1
J3
J1
NA5825

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)

A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulic Rod End E1 Lift Spool Detent
B1 Lift Cylinder Rod End
E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End
E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Base End
F1 Lift Spool
C1 Load Check
F2 Tilt Spool
C2 Load Check Valve Tilt Function
G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function
G2 Auxiliary Solenoid Stem
C4 Check Valve
H1 BICS™ Solenoid
Lift (Rod End) H2 BICS™ Lock Valve (Tilt)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa (276
H3 BICS™ Lock Valve (Lift)
bar) (4000 psi)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J2 Outlet Fluid Flow (Return to Tank)
(2756 bar) (4000 psi) J3 Lift Arm Bypass Orifice
Tilt (Base End)
J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa (276
bar) (4000 psi) MR Main Relief Valve – Without auxiliary Relief Valve
Tilt (Rod End) 24132 KPa (241 bar) (3500 psi)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) 27579 Main Relief Valve - with Auxiliary Relief Valve
kPa (276 bar) (4000 psi) (Optional) MR 25511 - 26200 KPa (255 - 262 bar) (3700 - 3800
psi)
Auxiliary Relief Valve - If Equipped 23787 -
AR
24476 KPa (238 - 245 bar) (3450 - 3550 psi)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
Figure 20-43-27 IMPORTANT

damage the system.
I-2003-0888
1 Figure 20-43-29
P-90280
Support the mounting bracket (Item 1) [Figure 20-43-27].
Figure 20-43-28 1
2 P107848

check valve.
P100202

[Figure 20-43-28].
Remove the two frame bolts (Item 2) [Figure 20-43-28]

20-43-28] to 300 - 330 ft lb (406 - 447 N•m).

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(LATER MODELS) (CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-43-32

(Cont’d)
Figure 20-43-30
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-43-
32].
30] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-43-32].

Figure 20-43-31 interchangeable.
Figure 20-43-33
1
5
1
2
2
3 4 4
P107716
3
P107624
[Figure 20-43-31].
Inspect the spring (Item 3) and the free movement in the 20-43-33].
load check valve (Item 4) [Figure 20-43-31].
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-43-31].
33] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

(LATER MODELS) (CONT’D) Installation (Lift, Base End)

Rod End)
Figure 20-43-34
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-43-36].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-43-34]. Figure 20-43-37
Figure 20-43-35
1
2
2
1
4
P107952
3
P107624
20-43-35]. Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-43-35] in the needed.
Installation: Install a new O-ring (Item 4) [Figure 20-43- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

(LATER MODELS) (CONT’D) Installation (Tilt, Rod End)

Figure 20-43-38
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-43-40]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-43-38] from the base end of the tilt section. Figure 20-43-41
Figure 20-43-39
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief / anti-cavitation relief

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat


Port Relief Valve Removal And Installation
Figure 20-43-42
P107628

P107628
Figure 20-43-43
1
1
2
P107629


Port Relief Valve Removal And Installation (Cont’d)
Figure 20-43-46
P107628

P107628
Figure 20-43-47
1
1
2
P107629


Figure 20-43-50
P107632

(Item 1) [Figure 20-43-52].
P107631
Figure 20-43-53
1) [Figure 20-43-50].
Figure 20-43-51
1
1
P107633

plug.
P107633

plug.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-43-5.) Remove the end cap block from the control valve.
Figure 20-43-54 Figure 20-43-56
1 2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-43-54] from Remove the O-ring (Item 1) [Figure 20-43-56].
the end cap block.

Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-43-54].
Figure 20-43-57
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-43-55
1
P107753
1
P107852 20-43-57] from the lift spool.


Lift Spool Removal And Installation (Cont'd)
Figure 20-43-58
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-43-60] from the control valve.
P107854
Figure 20-43-61
Remove the four screws (Item 1) [Figure 20-43-58] from


11,6 N•m (95 - 105 in-lb) torque.
Figure 20-43-59
1
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-43-61]

from the actuator end of the valve.
P107855
Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-43-59] from the control valve.

59] and lubricate lightly with oil before installation of the
spool centering block.

Lift Spool Disassembly And Assembly
Figure 20-43-62
1
P107647

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-
43-62]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-43-65
Figure 20-43-63
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-43-65].
centering spring.

Remove the end cap block. (See End Cap Block

Figure 20-43-66 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-43-68].
2 Figure 20-43-69
P107856

Figure 20-43-67
1
P107770
Remove the spool seal (Item 1) [Figure 20-43-69].
P107769

with oil before installation of the spool centering block.

Tilt Spool Disassembly And Assembly

2 1
Figure 20-43-70
3
N-18944B
3), and washer (Item 4) [Figure 20-43-72].
P107646
Put the actuator end of the spool in the vice [Figure 20-
43-70].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-43-71
P107647


in-lb) torque.
Remove the spring tool from the spring assembly.

Figure 20-43-73
2
1
2 P107760

1 (Item 2) [Figure 20-43-75] from the auxiliary spool.
P107758
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.
Figure 20-43-76
Figure 20-43-74
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
Figure 20-43-78
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-43-77
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-43-78] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-43-77]. Remove the solenoids (Item 2) [Figure 20-43-78].
Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -

23.9 in-lb) torque.
Figure 20-43-79
P107798

[Figure 20-43-79] from the solenoid stem.

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-43-79].

Figure 20-43-80 1
P107857
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
solenoid stem.
2
Figure 20-43-81
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.

Figure 20-43-84
1 2 P107937

P107858
Figure 20-43-87
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-43-
84]. 1 3
Figure 20-43-85 2
1
P107767

P107859 valve (Item 3) [Figure 20-43-87].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-43-85] from the back of the control valve.


Figure 20-43-88
1 P107937

P107860
Figure 20-43-90
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-43-88] from the front of the control valve.
1 3
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque. 2
P107767

valve (Item 3) [Figure 20-43-90].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
Figure 20-43-93
Figure 20-43-91
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-43-93].
Figure 20-43-94
Remove the fitting (Item 1) [Figure 20-43-91] from the
valve.
Figure 20-43-92
1 1
P107659

P-51437 main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-43-
92].

casting.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Check Valve Removal And Installation
Figure 20-43-97
Figure 20-43-95
1 1
P107848
P107863 Remove the tubeline (Item 1) [Figure 20-43-97].
Figure 20-43-98
95].
Figure 20-43-96
2 1
P107864
1
P107627 98] from the hydraulic control valve.
Remove the O-rings (Item 1) [Figure 20-43-96] and

back-up ring (Item 2) [Figure 20-43-96] from the auxiliary
relief valve.

Check Valve Removal And Installation (Cont’d)
Figure 20-43-99
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-43-99].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.

20-43-30
T770 Service Manual
LIFT ARM BYPASS CONTROL VALVE
Description
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90° clockwise. Then pull up and hold the lift arm
bypass control knob until the lift arms slowly lower. The
valve releases the hydraulic fluid from the base end of the
lift cylinder(s) which allows the lift arm to slowly come
down to the transport position.
Testing
Figure 20-50-1
1
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob should return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure
support. Replace if damaged. 20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
W-2059-0598
Lower the lift arms.

1
P-85671
Disconnect and cap the hydraulic tubeline and hose (Item

1) [Figure 20-50-3].
Remove the two mounting bolts and nuts (Item 2) [Figure

20-50-3].
Installation: Tighten the mounting bolts to 21 - 23 N•m

(180 - 200 in-lb) torque.
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.
Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Reverse the removal procedure to install the lift arm lb) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.

20-50-4
T770 Service Manual
HYDRAULIC PUMP Start the engine and run at low idle rpm. Press the
Auxiliary hydraulics button. Engage the front auxiliary
Description with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
The hydraulic pump is attached to the end of the the tester, the hoses are connected wrong. With the
hydrostatic pumps and is located on the right side of the hoses connected correctly, increase the engine speed to
loader between the hydraulic control valve and the full rpm*.
engine.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump is a combination of gear pumps that control clockwise on the tester so it reads about 6895
provide hydraulic flow to several hydraulic systems. kPa (68,9 bar) (1000 psi).
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If any the tester counterclockwise to obtain free flow, the flow
of the main components of the pump are damaged, the should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The L/min (U.S. gpm) should drop
Pump Test At Quick Couplers off slightly until the pressure reaches approximately
21374 kPa (213,7 bar) (3100 psi). At approximately
The tools listed will be needed to do the following 21374 kPa (213,7 bar) (3100 psi) the flow should start
procedure: decreasing rapidly until the pressure reaches 23787 -
24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi). At
TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter 23787 - 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi)
MEL10006 - Fitting Kit the flow should be at 0 L/min (0 U.S. gpm). Turn the
restrictor (Item 2) [Figure 20-60-1] counterclockwise to
Figure 20-60-1 free flow. Shut the auxiliary hydraulics off.
1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-4.)

for system relief pressure and full rpm.
2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

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

one operator running the tester.

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

procedure:
MEL1563 or 7217666 - Remote Start Tool Kit 2

TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter
MEL10006 - Fitting Kit
1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

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

P-90177
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT- MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6895 kPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*.
On the remote start tool engage the auxiliary hydraulics,

the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (L/min [U.S. gpm]). The high
pressure flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm])

%= X 100
FREE FLOW (L/min [U.S. gpm])
A low percentage may indicate a failed pump.



HYDRAULIC PUMP (CONT'D) Figure 20-60-4
Direct Pump Test (Charge Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool Kit

1
WARNING
P-85897A
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-4].
W-2017-0286
Figure 20-60-5

1.)

1
2
WARNING
P-90177
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the inlet fitting on the fan (Item
Tester, to prevent any contamination to the 1) [Figure 20-60-4].
Hydrostatic Pumps.
Connect the remote start tool. (See REMOTE START

TOOL KIT- MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
IMPORTANT
I-2024-0284
tester, the hoses are connected wrong. With the hoses
rpm*.

psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100
%=
*Refer to the Hydraulic Schematics for pump flow and

rpm.

HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

to fall and cause injury or death. 1
W-2059-0598
1
1
1
DANGER
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-6] from the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

P-90328 Removal And Installation on Page 20-130-1.)
AVOID DEATH Figure 20-60-7
D-1009-0409
IMPORTANT 1

P106593
tubelines and ports to keep dirt out. Dirt can quickly Remove the bracket mounting bolt / nut (Item 1) [Figure
damage the system. 20-60-7].
I-2003-0888
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28
Lift and block the rear of the loader. (See Procedure on ft-lb) torque.
Page 10-10-1.)


Figure 20-60-8
1 2
2
1
P-90509
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

Remove the two mounting bolts (Item 2) [Figure 20-60-8]

from the hydraulic pump.

Remove the hydraulic pump (Item 3) [Figure 20-60-8]

from the loader.
Figure 20-60-9
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-9] on the

hydraulic pump.
Reverse the removal procedure to install the hydraulic

pump.

HYDRAULIC PUMP (CONT'D) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Hydraulic Pump Startup arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
NOTE: This procedure is necessary to prevent a dry of cylinder stroke.
startup of the hydraulic pump.
With the loader parked on a level surface and lift arms
Fill the system with hydraulic fluid. (See Removing And down, check and fill the hydraulic reservoir as required.
Replacing Hydraulic Fluid on Page 10-120-2.) Check for hydraulic leaks.
Figure 20-60-10
P100685
Figure 20-60-11
1
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-10] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-11].
Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.

3
4
Figure 20-60-12
16
2
11
1
5
6
12
2
13
3
14
4
5
5
2
20-60-9
6
7
8
15
9
5
2
17
10
P-66540
18
T770 Service Manual

HYDRAULIC PUMP (STANDARD) (CONT'D) Disassembly And Assembly
Parts Identification (Cont’d)
The items listed below refer to [Figure 20-60-12].

IMPORTANT
1. Auxiliary Pump End Section
2. Section Seal clean the work area before disassembly and keep all
3. Pre-Load Seal tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
4. Load Seal I-2003-0888
5. Wear Plate Mark the pump sections for correct assembly.
6. Alignment Pins To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
7. Drive Gear (Auxiliary Pump) Page 20-60-9.) for proper placement of components
along with the information below.
8. Idler Gear (Auxiliary Pump)
NOTE: A seal kit is available through Bobcat Service
9. Auxiliary Pump Center Section Parts.
10. Auxiliary Pump End Section Assembly: Tighten the eight pump housing bolts (Item 1)
11. Spline Shaft
NOTE: Position the wear plate (Item 4) [Figure 20-60-
12. Drive Gear (Charge Pump) 12] as shown with the bronze side toward the
gears.
13. Idler Gear (Charge Pump)
NOTE: Inspect all gears, shafts and pump end
14. Charge Pump Center Section sections. If any of these components have
excessive wear or damage, the complete
15. Charge Pump End Section pump must be replaced.
16. Shaft Seal
17. Bolts (4)
18. Bolts (4)

HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6895
The high flow hydraulic pump has an additional pump kPa (68,9 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
from a button on the panel in the cab. psi).
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately
The tools listed will be needed to do the following 21374 kPa (213,7 bar) (3100 psi). At approximately
procedure: 21374 kPa (213,7 bar) (3100 psi) the flow should start
decreasing rapidly until the pressure reaches 23787 -

TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi). At
MEL10006 - Fitting Kit 23787 - 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi)
the flow should be at 0 L/min (0 U.S. gpm). Turn the
Figure 20-61-1 restrictor (Item 2) [Figure 20-61-1] counterclockwise to
free flow. Shut the auxiliary hydraulics off.
1
If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.

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

procedure:

1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

1
WARNING 2

P-90177
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT- MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6204 L/min (54 U.S. gpm) Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

control on the tester to about 6,9 MPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*. Put jackstands under the front axles and rear corners
On the remote start tool engage the auxiliary hydraulics, Failure to use jackstands can allow the machine to
the light will come ON. Pull the trigger on the right handle fall or move and cause injury or death.
or joystick for fluid flow to the quick coupler (fluid W-2017-0286
pressure will go over main relief). Record the highest
pressure (psi) and flow (L/min [U.S. gpm]). The high Lift and block the loader. (See Procedure on Page 10-10-
pressure flow must be at least 80% of free flow. 1.)
%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 Raise the lift arms and install an approved lift arm
FREE FLOW (L/min [U.S. gpm]) support device. (See Installing on Page 10-20-1.)

WARNING

W-2059-0598
NOTE: The fluid from the charge pump must be

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

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-61-4 rpm*.

psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

1 approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=
P-85897A
Disconnect the inlet hose (Item 1) [Figure 20-61-4]. A low percentage may indicate a failed pump.
Figure 20-61-5 *Refer to the Hydraulic Schematics for pump flow and
rpm.
1 2
P-90580
Connect the INLET hose (Item 1) [Figure 20-61-5] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-61-4].
IMPORTANT
I-2024-0284

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-6] onto the

front auxiliary quick couplers.
W-2059-0598
IMPORTANT
I-2024-0284

procedure:
MEL1563 or 7217666 - Remote Start Too Kit

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

1.)

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 60°C (140°F) by turning the restrictor
Direct Pump Test (High Flow Section) (Cont'd) psi).
Figure 20-61-7 NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
psi).
1 [U.S. gpm]) at full rpm. Increase the restriction and the
flow should drop to 0 L/min (0 U.S. gpm) between 24132
kPa (241,3 bar) (3500 psi) and 25511 kPa (255,1 bar)
(3700 psi).
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure. (See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)
2
Record the highest pressure (psi) and flow (L/min [U.S.
gpm]). The high pressure flow must be at least 80% of
P-90183 free flow.

%=
Disconnect the high flow pump OUTLET hose (Item 1) FREE FLOW (L/min [U.S. gpm])
from the high flow check valve INLET fitting (Item 2)
[Figure 20-61-7].
Figure 20-61-8
*Refer to Hydraulic Schematics Legend for system relief
pressure and full rpm.
1 2
P-90580
Connect the INLET hose (Item 1) [Figure 20-61-8] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
P-45443
[Figure 20-61-11] will need to be turned 90° clockwise
and retested with the procedure above. (1/4 turn equals
approximately 1379 kPa (13,8 bar) (200 psi).)
1
NOTE: If the relief screw has been turned in 1/4 turn 2
and the pressure remains the same, go to the
high flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been checked and is OK, go to the P-64022
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-14.) Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove the track from the right side of the loader. (See
Track Removal And Installation on Page 40-20-4.) OR Remove the plug (Item 2) [Figure 20-61-10] located on
(See Track Removal And Installation on Page 40-21-4.) the bottom of the high flow relief valve.

1 1
1
1
1
P-90352 P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-9] NOTE: [Figure 20-61-11] shows adjusting the relief
from the access cover and remove the cover from the screw on a wheeled machine for photo clarity.
loader.
If the pump reaches 25511 kPa (255,1 bar) (3700 psi)
and there is flow stop the engine. The relief screw must
be turned 90° counterclockwise retested with the
procedure above.

High Flow Relief Valve Removal And Installation
WARNING
Failure to use jackstands can allow the machine to 1
W-2017-0286
Remove the track from the right side of the loader. (See P-64022
Track Removal And Installation on Page 40-20-4.) OR
(See Track Removal And Installation on Page 40-21-4.)
Locate the high flow relief valve through rear door along
Figure 20-61-12 the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-13] from

the pump.
Installation: Tighten the relief valve to 41 - 47 N•m (30 -

35 ft-lb) torque.
1 1
Figure 20-61-14
1
1 1 1
P-90352 3
Remove the mounting bolts (Item 1) [Figure 20-61-12] 2

from the access cover and remove the cover from the
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
If the relief valve is bad, it must be replaced as a

complete unit.
Remove the plug (Item 3) and replace the O-ring [Figure

20-61-14].

Solenoid Removal And Installation 2
Figure 20-61-15
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 17] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-16
Figure 20-61-18
1
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-16].

Remove the solenoid (Item 2) [Figure 20-61-16]. replace.
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 - Remove the O-ring and back-up washer (Item 2) [Figure
72 in-lb) 20-61-18] and replace.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
Never work on a machine with the lift arms up unless 1

1
W-2059-0598
DANGER 1
1
P-90184
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

61-19] from the front of the hydraulic pump.
Figure 20-61-20
P-90328
AVOID DEATH
D-1009-0409
1
IMPORTANT P-90185

Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
from the back of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Figure 20-61-21
1
2
3
P-90509A
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

Remove the two mounting bolts (Item 2) [Figure 20-61-

19] from the hydraulic pump.

Remove the hydraulic pump (Item 3) [Figure 20-61-19]

from the loader.
Figure 20-61-22
P-43940 P-43938A

hydraulic pump.
Reverse the removal procedure to install the hydraulic

pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Hydraulic Pump Startup arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
NOTE: This procedure is necessary to prevent a dry of cylinder stroke.
startup of the hydraulic pump.
With the loader parked on a level surface and lift arms
Fill the system with hydraulic fluid. (See Removing And down, check and fill the hydraulic reservoir as required.
Replacing Hydraulic Fluid on Page 10-120-2.) Check for hydraulic leaks.
Figure 20-61-23
P100685
Figure 20-61-24
1
P100352

Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.

Figure 20-61-25
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal
13
17. Center Housing
4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-13.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 7)

NOTE: Position the wear plate (Item 4) [Figure 20-61-
25] as shown with the bronze side toward the
gears on all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage, the complete
pump must be replaced.
NOTE: The relief valve and the solenoid can be

replaced along with the O-rings and back-up
washers.

HYDRAULIC / HYDROSTATIC FILTERS Figure 20-70-1
Description
2
The hydraulic / hydrostatic filters help to remove 2
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including oil returning from the main valve.
1
2
The charge flow filter removes contaminants after the
charge pump. P-90010
Housing Removal And Installation

DANGER Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the fluid from the reservoir. (See Removing And

Disconnect the electrical connector (Item 1) [Figure 20-

70-1] from the hydraulic / hydrostatic filter sender.
Disconnect and plug the three hoses (Item 2) [Figure 20-

70-1] from the hydraulic / hydrostatic filter housing.
P-90328
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTER (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
P-90011
Remove and plug the two hoses (Item 1) [Figure 20-70-

2] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-70-3
1
1 P-90537
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the

operator’s cab under the rear grille on the right side of the
loader.

P-90579
Remove the two bolts, (Item 1) [Figure 20-80-2] nuts,
Raise the operator cab. (See Raising on Page 10-30-2.) and bracket.
Drain the fluid from the reservoir. (See Removing And Remove the hydraulic fluid reservoir from the loader.
Installation: Tighten the mount bolts and nuts to 21,7 -
Remove the Hydraulic / Hydrostatic Filter Housing. (See 24,4 N•m (16 - 18 ft-lb) torque.
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-1
P-90013
Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen

1.)
Figure 20-80-3
P-90506
Remove the hydraulic fluid reservoir breather cap

[Figure 20-80-3] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-
80-3] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER Figure 20-90-2
Description
The oil cooler is used to cool the loaders hydraulic and 2

1
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
The oil cooler is located underneath the rear grille

between the A/C condenser (if so equipped) and the 3
radiator.
P-85936
IMPORTANT Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-2] and
When repairing hydrostatic and hydraulic systems, pull hose out.
parts clean. Always use caps and plugs on hoses, Cap or plug all hoses and fittings.
damage the system.
I-2003-0888
Remove the rear grille from the loader. (See Removing

on Page 50-60-1.)
Figure 20-90-1
1 2
P-85938
Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-1] and
pull hose out.
Cap or plug all hoses and fittings.

OIL COOLER (CONT’D)
Figure 20-90-3
4 4
2
5
3
P-85905
Undo the rubber straps (Item 1) [Figure 20-90-3]
Remove the bolts (Item 2) and remove the condenser

guards (Item 3) [Figure 20-90-3].
Remove the clips and pins (Item 4) [Figure 20-90-3].
Remove the bolt (Item 5) [Figure 20-90-3] from the prop
rod.
NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.

BUCKET POSITION VALVE Cover the fuel tank inlet.
Description Figure 20-100-2

The Bucket Position Valve is an option that allows the
operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function. 3
The bucket position valve is mounted to the inside lower
right rear side of the loader frame.
See Hydraulic Schematic for more circuit information. 2
DANGER
1 P-90197
Disconnect the wire harness connector (Item 1) [Figure

20-100-2] from the bucket position shut-off solenoid.
Disconnect the cap the two tubelines (Item 2) [Figure 20-

100-2].
P-90328
Remove the solenoid nut, coil, and stem (Item 3) from the
AVOID DEATH
bucket positioning valve [Figure 20-100-2].
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
D-1009-0409 torque. Overtightening may cause valve failure.
Drain the hydraulic reservoir. (See Removing And NOTE: The engine is shown removed for photo
Replacing Hydraulic Fluid on Page 10-120-2.) clarity.
Figure 20-100-1 Figure 20-100-3
1
1 2
2 N-18191
P-90187
Inspect the solenoid stem and replace the O-rings (Item
(Item 2) to the middle of the hose, and the place the fuel
1) and the back-up washer (Item 2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT'D) Cover the fuel tank inlet.
Solenoid Testing Figure 20-100-5
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
DANGER
1 P-90197
NOTE: The engine is shown removed for photo

clarity.
P-90328 NOTE: Mark all hoses and tubelines for correct

installation.
AVOID DEATH
• Disconnecting or loosening any hydraulic Disconnect the electric solenoid connector (Item 1)
tubeline, hose, fitting, component or a part failure [Figure 20-100-5].
Figure 20-100-6
D-1009-0409
1
Figure 20-100-4
3 2
4 3
1
P-90188
Disconnect and cap the tilt base inlet hose (Item 1), the
tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.
2
P-90187
(Item 2) to the middle of the hose, and the place the fuel

BUCKET POSITION VALVE (CONT'D) Figure 20-100-9
Figure 20-100-7
P-90190A
2
1
Remove the mounting screws (Item 1) [Figure 20-100-9].
P-90189A
Remove the bucket position valve from the loader.
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]
from the valve block.
Figure 20-100-8
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-12
Figure 20-100-10
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear and replace as needed.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-10]. ft-lb) torque.
Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-13

lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3
Figure 20-100-11
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-13].
Inspect for wear and replace as needed. Install a new O-

P-90195 ring on the plug before installing.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

Remove the flow adjustment valve and O-ring (Item 1) ft-lb) torque.
[Figure 20-100-11].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new O-rings before any parts

are installed into the valve. Check the parts
for wear or damage and replace as needed.

REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts oil from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Correct resistance for the solenoid coil with a
pigtail connector is 4.6 - 5.7 ohm.
1
Figure 20-110-3
2
P100766
The rear auxiliary diverter valve has two types of solenoid

coils, one type with a pigtail connector (Item 1) and one
type with a molded connector (Item 2) [Figure 20-110-1]. P100763

110-3]. Correct resistance for the solenoid coil with a
molded connector is 8.1 - 9.9 ohm.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-5
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-5]
can cause lift arms to drop. Figure 20-110-6
D-1009-0409
1
Put jackstands under the rear corners of the loader.

P100810
Figure 20-110-4
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-6] from the main harness.
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20-

110-4]

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-7 assembly.
Inspect cartridges, check valves, solenoid valves and

2
sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure to dry them.
Install new O-rings and back-up washers.
1 Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.
Figure 20-110-8
P-90581
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7]
1
1
P100760
Figure 20-110-9
P-48752
Several plugs (Item 1) [Figure 20-110-8] and [Figure 20-

110-9] are located on the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up

washers.Tighten to 10 ft-lb (13,6 N•m) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
damage the system.
I-2003-0888 1
P100761
Figure 20-110-10
Figure 20-110-13
1 2
2
P100761
P-48757
Figure 20-110-11
Remove the differential sensing valve (Item 1) [Figure

20-110-12] and [Figure 20-110-13] from diverter valve
and inspect the O-rings and back-up washers (Item 2)
[Figure 20-110-13] for damage.
2
2 2
Assembly: Put oil on O-ring and back-up washers.
1 Tighten to 50 - 55 ft-lb (68 - 75 N•m) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-10]

and [Figure 20-110-11] from diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
110-11] for damage.
Assembly: Put oil on the O-rings and back-up washers.

Tighten to 10 - 12 ft-lb (14 - 16 N•m) torque.

Figure 20-110-14 1
P100762
1
Figure 20-110-17
P-48753
Figure 20-110-15
1
2 P100764
NOTE: Before removing the solenoid coils mark the

P-48754 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-16] and [Figure

Remove the relief valve (Item 1) [Figure 20-110-14] and 20-110-17] from the solenoid valve stem.
[Figure 20-110-15] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20- Assembly: Tighten the nut to 3 ft-lb (4,1 N•m) torque.
110-15] for damage.
Remove the solenoid valve coils (Item 1) [Figure 20-110-
Assembly: Put oil on O-ring and back-up washers. 17].

Figure 20-110-18
1
1
P-48762
Figure 20-110-20
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-18] from the

solenoid valve stems.
Assembly: Tighten the nut to 4 - 6 ft-lb (5 - 8 N•m)

2 2
torque. 1 1
P-48763
Remove the solenoid valve stems (Item 1) [Figure 20-

110-19] and [Figure 20-110-20] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-20] for
damage.
Assembly: Put oil on O-rings and back-up washers.


Figure 20-110-21
P-48765
Remove the plug (Item 1) [Figure 20-110-23].

P-48763A
Assembly: Tighten the plug to 38 ft-lb (51,5 N•m) torque.
Figure 20-110-22 Figure 20-110-24

1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-21] and [Figure 20-110-22] and inspect the O-rings 24] for dirt and debris.
and back-up washers (Item 2) [Figure 20-110-22] for
damage. Assembly: Tighten the orifice to 22 ft-lb (29,8 N•m)
torque.
Assembly: Put oil on O-rings and back-up washers.

Figure 20-110-25
1 1
P100767
Remove the plugs (Item 1) [Figure 20-110-27].

P-48765
Assembly: Tighten the plug to 14 ft-lb (19 N•m) torque.
Remove the plug (Item 1) [Figure 20-110-25]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
Assembly: Tighten the plug to 10 ft-lb (13,6 N•m) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Figure 20-110-26
Inspect diverter valve manifold block cavities for
contamination. Wash valve in clean solvent. Use air
pressure to dry.
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].
Assembly: Tighten the orifice to 3.3 ft-lb (4,5 N•m)

torque.

BOB-TACH (POWER) BLOCK Removal And Installation
Description
The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
The power Bob-Tach block is mounted on the right side of to fall and cause injury or death.
the machine in front of the engine on the back side of the W-2059-0598
hydraulic pump.
DANGER
P-90328
AVOID DEATH

D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-3

1 1
Figure 20-120-1
1
1
P101859
Remove the four mounting bolts (Item 1) [Figure 20-120-

P100806 3].
Installation: Tighten the mounting bolts to 35 - 40 ft-lb

Lift and block the loader. (See Procedure on Page 10-10- (48 - 54 N•m) torque.
1.)
Remove the power Bob-Tach block.
Disconnect the two electrical solenoid coil connectors

(Item 1) [Figure 20-120-1] from the loader electrical
harness.
Figure 20-120-2
2
1
2 2
P101862
Disconnect and cap the outlet hose (Item 1) [Figure 20-

120-2] from block.
Disconnect and cap the hoses (Item 2) [Figure 20-120-2]

from block.

IMPORTANT 2

damage the system.
I-2003-0888
P100769
Figure 20-120-4
Clean the block (Item 1) [Figure 20-120-5] to remove dirt

before disassembly. Block ports are labeled for correct
assembly.

1
Installation: Tighten the plug to 67,8 N•m (50 ft-lb)
torque.
Figure 20-120-6
3
P100820
Do not remove these plugs (Item 1) [Figure 20-120-4].

1
NOTE: Do not remove the two plugs located next to
the outlet port. A new Power Bob-tach valve 2
will be required if tampered with. All other
plugs can be removed.
4
P100770
Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-6] and inspect. Replace damaged parts
as needed.
Inspect the O-ring (Item 4) [Figure 20-120-6] on the plug

and replace as needed.

Figure 20-120-7
P100826
Remove the plug (Item 1) [Figure 20-120-9], inspect the

P100823 O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-120-9]

Remove the plug (Item 1) [Figure 20-120-7], inspect the to 17,6 N•m (13 ft-lb) torque.
O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-120-7]

to 17,6 N•m (13 ft-lb) torque.
Figure 20-120-8
3
1
2
P107069
Remove the spool (Item 1), the spring (Item 2) and the
orifice (Item 3) [Figure 20-120-8]. Inspect the spring,
spool and orifice replace as needed.
Installation: Clean threads on the orifice and apply

Loctite® 603. Tighten the orifice (Item 3) [Figure 20-120-
8].

Figure 20-120-10
P100773
1
Remove the first solenoid coil (Item 1) and the second

P100821 solenoid coil (Item 2) [Figure 20-120-12].
Figure 20-120-13
Remove the orifice screw (Item 1) [Figure 20-120-10].
Installation: Tighten the orifice screw (Item 1) [Figure

20-120-10] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.
Figure 20-120-11
1
1
P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

13].
P100774 Installation: Tighten the solenoid coil stem to 27,14 N•m

(20 ft-lb) torque.
NOTE: Mark the solenoid coil orientation for ease of

installation.
Remove the solenoid coil nut (Item 1) [Figure 20-120-

11].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.

Figure 20-120-14
2 2 2
1 1 1 1 P100829
Inspect the O-ring (Item 1) [Figure 20-120-16] and

P100776 replace as needed.
Figure 20-120-17
Replace the O-rings (Item 1) and the back-up washers
(Item 2) [Figure 20-120-14].
Figure 20-120-15
1
P100840
Remove the plug (Item 1) [Figure 20-120-17], inspect

P100828 the O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-120-

Remove the fitting (Item 1) [Figure 20-120-15]. 17] to 17,6 N•m (13 ft-lb) torque.

Figure 20-120-18
2
1
P100843
1
Remove the shuttle seat (Item 1) and check ball (Item 2)

P100841 [Figure 20-120-20]. Inspect the shuttle seat and check
ball, replace as needed.
Remove the filter assembly (Item 1) [Figure 20-120-18], Figure 20-120-21

inspect and replace as needed.
Figure 20-120-19
1
P100845
P100842 Remove the plug (Item 1) [Figure 20-120-21], inspect

the O-ring and replace as needed.
Remove the plug (Item 1) [Figure 20-120-20], inspect Installation: Tighten the plug (Item 1) [Figure 20-120-
the O-ring and replace as needed. 21] to 30 N•m (22 ft-lb) torque.

19] to 17,6 N•m (13 ft-lb) torque.

Figure 20-120-22
P100837


Remove the plug (Item 1) [Figure 20-120-22], inspect 24] to 17,6 N•m (13 ft-lb) torque.
Figure 20-120-25
Figure 20-120-23
2
2
1
P100838
Remove the spring (Item 1) and the check ball (Item 2)

P100835 [Figure 20-120-25], inspect and replace as needed.
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-23], inspect and replace as needed.

Figure 20-120-26
P100847
Remove pilot piston (Item 1) [Figure 20-120-28].

P100846
Figure 20-120-29

Installation: Tighten the plug (Item 1) [Figure 20-120- 2 2

26] to 30 N•m (22 ft-lb) torque.
1
Figure 20-120-27
1 P100834
Inspect the pilot piston (Item 1), the back-up washers

(Item 2) and the O-ring (Item 3) [Figure 20-120-29] for
damage and replace as needed.
P100853
Using a small diameter tool remove the pilot piston (Item

1) [Figure 20-120-27].

Figure 20-120-30 1
P100850


Remove the plug (Item 1) [Figure 20-120-30], inspect 32] to 30 N•m (22 ft-lb) torque.
Figure 20-120-33
Figure 20-120-31
1
1
2
P100851


Remove the annular orifice shaft (Item 1) and the annular 33] to 17,6 N•m (13 ft-lb) torque.
orifice shaft guide (Item 2) [Figure 20-120-31], inspect

BOB-TACH (POWER) BLOCK (CONT'D)
Figure 20-120-34
P100854

replace.

20-120-12
T770 Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
The front auxiliary hydraulic coupler block is the 1

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
1
The front auxiliary coupler block is located at the front of
the left side lift arm.
Removal And Installation 1
IMPORTANT P-90002

clean the work area before disassembly and keep all Remove the fittings (Item 1) [Figure 20-130-2].
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-130-3
damage the system.
I-2003-0888
1
Figure 20-130-1
2
1 3
P-90003
1
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-3].
P-85281
Installation: Tighten the female and male coupler to 80
N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-6
(CONT’D)
Disassembly And Assembly (Cont’d) 1

Figure 20-130-4
2
1
2
2
2 1
2
1
P-34664

[Figure 20-130-6] from the female coupler.
P-90001
Remove the springs (Item 1) [Figure 20-130-4].

fittings and coupler body.
Figure 20-130-5
1
P-34665
Remove the O-rings (Item 1) and back-up rings

(Item 2) [Figure 20-130-5] from the male coupler.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ANKA11001 - ANKA13449) . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-40-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-14
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-2
Hydrostatic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-23
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-33
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-36

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
TWO-SPEED / BRAKE VALVE (S/N A3P811001 - A3P13174 & A3P911001 - A3P912024)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
TWO-SPEED / BRAKE VALVE (S/N A3P813175 & ABOVE AND S/N A3P912025 & ABOVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost do to internal leakage in the components
of the hydrostatic system.

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5, 9
The hydrostatic system is overheating. 6,7,8
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.
5. Track tension is to tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct rpm.
9. The hydrostatic pump is to properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR Removing And Replacing Oil
Description For the correct service interval. (See SERVICE

The hydrostatic drive motors are driven by the hydrostatic
pump. Machines equipped with SJC are monitored by a Park the loader so that the plug in the hydrostatic drive
sensor mounted onto the motor housing. The sensor is motor is at the bottom.
used for detection of motion and for rate of speed for the
SJC option. Standard machines use the same motor but Remove the plug and let the oil drain from the hydrostatic
have a plate and O-ring that covers the sensor hole. drive motor.
The hydrostatic drive motors contain a spring applied Figure 30-20-1

pressure release braking system to stop the loader. In
addition there is a separate oil chamber in the motor that
is filled with high performance synthetic oil for maximum
durability, this oil has a recommended service interval.
(See SERVICE SCHEDULE on Page 10-70-1.)
There are two hydrostatic drive motors and they are

located on the track carriage. 1
P-90680B
Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-20-1] is at the top. Add high performance
synthetic oil (P/N 7024981). (See Capacities on Page
SPEC-10-5.)
Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.
Repeat for the other hydrostatic drive motor.
Recycle or dispose of the used oil in an environmentally

safe manner.

HYDROSTATIC DRIVE MOTOR (CONT'D) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
Figure 30-20-2
IMPORTANT 1

clean the work area before disassembly and keep all 1 1
damage the system.
I-2003-0888
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
P-85927
DANGER Remove the mounting bolts (Item 1) [Figure 30-20-2]

from the access cover and remove the cover from the
loader.
Remove the sprocket. (See Sprocket Removal And

Installation (Single Speed) on Page 40-20-12.) OR (See
Sprocket Removal And Installation on Page 40-21-13.)
(SJC equipped machines only) Disconnect and remove
the speed sensor (SJC). (See Removal And Installation
P-90328 on Page 60-80-2.)
AVOID DEATH NOTE: Speed sensor removal is recommended to

• Disconnecting or loosening any hydraulic prevent damage while removing the
tubeline, hose, fitting, component or a part failure hydrostatic motor from the track carriage.
D-1009-0409
WARNING
W-2059-0598


HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-20-4
Figure 30-20-3
2 3
2
4 1
1
P100901
3
Installation: Install both flanges and tighten the bolts to
half of the required torque in the sequence shown in
P-85992
[Figure 30-20-4]. Retighten all bolts to required torque in
the same sequence. from the motor.
Remove the case drain hydraulic hose (Item 1) [Figure
30-20-3] from the motor. Figure 30-20-5
Remove the hydraulic brake hose (Item 2) [Figure 30-20-

3] from the motor.
1 1
Remove the eight flange bolts (Item 3) from the main
drive hoses. Remove the flanges and drive hoses (Item

4) [Figure 30-20-3].
Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.
Installation: Tighten the flange bolts to 48 - 54 N•m (35 -

40 ft-lb) torque.
P-85991
With an arm hoist support the hydrostatic motor.
Remove the ten hydraulic motor mounting bolts (Item 1)

[Figure 30-20-5].
Installation: Tighten the motor mounting bolts to 257,6

N•m (190 ft-lb) torque.
Remove the hydrostatic motor from the loader.

HYDROSTATIC DRIVE MOTOR (CONT'D)
10
9
7 8
5 6
4
2 3
25
24
1 23
22
10 21
12
20
11
17 15
16
18
16
13 15
14
19 52
50 51
48 49
37 46
35 33 47
27 33
29 31 40
30 38 36
26 32 34 53 54
28
39
43 44
41 42 60 62
59 61
45
58
57
56
55 63
P-90205

REF. DESCRIPTION REF. DESCRIPTION

1. PLUG 33. SPRING
2. SHAFT 34. SPOOL
3. SEAL 35. WASHER
4. BEARING 36. O-RING
5. HOUSING / FRONT 37. PLUG
6. SEAL 38. BOLT
7. BEARING 39. PIN
8. WASHER 40. O-RING
9. RINGS 41. O-RING
10. O-RING 42. PLUG
11. NUT 43. O-RING
12. STUD 44. PLUG
13. RPM TARGET DISK 45. HOUSING / REAR
14. ROLL PIN 46. HOUSING / BRAKE
15. SNAP RING 47. SHAFT
16. RETAINER 48. SHIM
17. ROLLER 49. SHIM
18. PISTON 50. DISC / OUTER
19. BLOCK 51. DISC / INNER
20. CAM 52. SEAL
21. DISTRIBUTOR 53. WASHER

22. SPRING 54. BOLT
23. SEAL W / O-RING 55. BUSHING
24. SEAL W / O-RING 56. PISTON
25. SEAL W / O-RING 57. SEAL
26. PLUG 58. WASHER
27. O-RING 59. GASKET
28. SPRING 60. COVER
29. SHIM 61. O-RING
30. POPPET 62. PLUG
31. PLUG 63. BOLT
32. O-RING

Figure 30-20-6
1
1
1
N-18295
Remove the twenty four mounting bolts (Item 1) and the

P-48683 brake cover plate (Item 2) [Figure 30-20-8].
NOTE: Remove every other bolt, then uniformly

NOTE: Motors that do not have the SJC sensor (Item remove the last twelve bolts to maintain equal
1) [Figure 30-20-6] will be covered by a plate preload on the brake cover plate.
and O-ring. The plate will need to be ordered
separately when ordering a new motor from Assembly: Replace the gasket and end cap.
Bobcat Parts.
Assembly: Tighten the bolts to 35 - 39 N•m (26 - 29 ft-lb)
Figure 30-20-7 torque.
Figure 30-20-9
N-18294
N-18296
NOTE: Mark the motor, brake and motor housings for
proper alignment during assembly [Figure 30-
20-7]. Remove the disk spring (Item 1) [Figure 30-20-9] from
the brake housing.
Drain the oil from the motor casing.
NOTE: Mark the top side of the disk spring for proper
Check for the vendor motor serial number (Item 1) installation.
[Figure 30-20-7], these serial numbers may be needed
when ordering replacement parts. Assembly: Apply multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.

Figure 30-20-10
2 1
N-18299
1
Inspect the piston surface (Item 1) and the bushing

N-18297 surface (Item 2) [Figure 30-20-12] in the brake shaft.
NOTE: The bushing (Item 2) [Figure 30-20-12] can be

Remove the piston from the brake housing [Figure 30- replaced in the brake shaft. When the bushing
20-10]. is replaced, install the bushing flush with the
top of the brake shaft.
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-20-10] will aid
in piston removal.
Figure 30-20-11
N-18298
Inspect the brake piston (Item 1) [Figure 30-20-11] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-20-11].
Assembly: Apply oil to the seal (Item 2) [Figure 30-20-

11] for added protection when installing the brake piston.

Figure 30-20-13
2 1
3
N-18347
1
Assembly: Clamp the disc pack in a vise and check the
1
N-18300 disc pack height [Figure 30-20-14].
Assembly: The correct disc pack specifications is 37,7 +

Remove the eight mounting bolts (Item 1) [Figure 30-20- 0,05 mm (1.48 + 0.002 in).
13] and washers from the brake housing.
Assembly: Extra outer disc's (Item 2) are used to reduce
Remove the brake housing (Item 2) [Figure 30-20-13] the number of required shims (Item 3) [Figure 30-20-14]
from the rear housing. to make up the required thickness for the brake pack.
Remove the snap ring and inner piston seal (Item 3) Figure 30-20-15
[Figure 30-20-13].
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake

housing on the rear housing.
Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-20-13].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness. N-18347
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)

torque. Assembly: Install the needed amount of shims [Figure
30-20-15]. Outer discs can also be used as shims.

HYDROSTATIC DRIVE MOTOR (CONT'D) NOTE: The 20 kN (4500 lbf) is NOT the amount of
pressure required by the press. It is the
Disassembly And Assembly (Cont'd) amount of downward force applied by the
press.
Figure 30-20-16
Figure 30-20-18
3
2 1
N-18348
N-18301
Assembly: Assemble the brake discs into a pack making

sure the inner discs (Item 1), alternate with the outer disc Disassembly: Remove the brake disks (Item 1) [Figure
(Item 2) and an outer disc is placed at each end of the 30-20-18] and shims from the brake shaft.
disc pack with the shims (Item 3) [Figure 30-20-16] and
base of the pack. Figure 30-20-19
Figure 30-20-17
1 2
N-18302
3
P100800
Remove the brake shaft (Item 1) [Figure 30-20-19] from
the rear housing.
Assembly: Assemble the brake piston into the brake
housing without the inner brake position seal (Item 3) NOTE: Be sure shaft seats fully into the cylinder
[Figure 30-20-13] and brake piston outer seal (Item 2) block.
[Figure 30-20-11]. Apply 20 kN (4500 lbf) to set the
brake pack. Using a depth gauge (Item 1), measure from Assembly: Install new O-ring (Item 2) [Figure 30-20-19]
the gasket mating surface (Item 2) to the inner machined on the rear housing.
groove (Item 3) on the brake piston [Figure 30-20-17].
The dimensional measurement must be 8,7 ± 0,1 mm

(0.343 ± 0.003 in) if not adjust brake pack discs to the
required measurement.

Disassembly And Assembly (Cont'd) 1
Figure 30-20-20
1
2
1 1
P-48686
1 1
Remove and replace with a new O-ring (Item 1) [Figure
P-48684 30-20-22].
Remove the distributor (Item 2) [Figure 30-20-22] from

Remove the eight mounting bolts (Item 1) [Figure 30-20- the rear housing.
20] from the rear housing.
Assembly: Install the distributor (Item 2) [Figure 30-20-
Assembly: Use Loctite® #243 on the threads and install 22] by using the alignment pin.
the eight mounting bolts (Item 1) [Figure 30-20-20].
Figure 30-20-23
Assembly: Tighten the bolts to 282 - 300 N•m (208 - 221
ft-lb) torque.
Figure 30-20-21
1
1
N-18318
Remove the two seals and back-up O-rings (Item 1)

P-48685 [Figure 30-20-23] under the seals, from the rear
housing.
Remove the rear housing assembly (Item 1) [Figure 30- Assembly: Apply a slight amount of oil to the O-rings
20-21] from the rotating group / front housing assembly. and seals (Item 1) [Figure 30-20-23].
Remove and inspect the stop pin (Item 2) [Figure 30-20-

23].

Figure 30-20-24
1 1
2 N-18308
Remove the plug (Item 1) [Figure 30-20-26] from the

P-48713 rear housing assembly.
Remove the twelve springs from the distributor (Item 1) Remove the spring (Item 1), spool (Item 2), and washer
[Figure 30-20-24]. (Item 3) and rear spring (Item 4) [Figure 30-20-28].
Remove and replace the two seals and back-up O-rings Figure 30-20-27
(Item 2) [Figure 30-20-24] under the seals, from the
distributor.
Inspect the distributor surfaces for scratches.

Assembly: Apply a small amount of grease to the

springs to hold them in place during installation.
Figure 30-20-25
1 1
N-18309
2
Remove the plugs (Item 1) [Figure 30-20-27] from the

rear housing assembly to inspect alignment of springs,
washer and spool when reassembling.
1
N-18323
Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor marked L
(Item 2) [Figure 30-20-25].
When the distributor is aligned correctly, the distributor

can be depressed slightly by hand and will return to its
original position.

Figure 30-20-28
1
4
3
N-18311
1
Replace the O-ring (Item 1) on the plug [Figure 30-20-

N-18315 30].
Figure 30-20-31
Inspect all parts and replace as needed [Figure 30-20-
28].
Figure 30-20-29 2
1
N-18312
Remove the internal plug (Item 1) [Figure 30-20-31].

N-18310
Replace the O-ring (Item 2) [Figure 30-20-31].
Remove the plug (Item 1) [Figure 30-20-29]. Assembly: Apply Loctite®) activator 7649 to the plug
threads. Allow ten seconds for the activator to dry. Apply
Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-30] and tighten to 85 N•m (63 ft-lb) torque.

Figure 30-20-32
1 2
P-48687
Remove the cam ring (Item 1) [Figure 30-20-34] from the

N-18313 front housing assembly.
Inspect the cam ring inside surface for wear and

Remove the plug (Item 1) [Figure 30-20-32]. scratches.
Assembly: Apply Loctite® activator 7649 to the plug Assembly: Align the marks (Item 2) [Figure 30-20-34]
threads. Allow ten seconds for the activator to dry. Apply on the cam rings to the front housing.
Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-32] and tighten to 85 N•m (63 ft-lb) torque. Figure 30-20-35
Figure 30-20-33
2
1
4
1
3
2
P-48688
N-18314
Remove and replace the O-ring (Item 1) [Figure 30-20-
35] from the front housing assembly.
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-20-33]. Assembly: Slightly smear the O-ring (Item 1) [Figure
30-20-35] with grease to hold in place.
Inspect all parts and replace as needed.
Remove the rotating group (Item 2) [Figure 30-20-35]
Install a new O-ring (Item 4) [Figure 30-20-33] on the from the front housing assembly.
plug before installation.

Figure 30-20-36
1
P-48689
1 Remove the snap ring (Item 1) [Figure 30-20-38] from

P-48690 the top side of the rotating group.
Figure 30-20-39
Remove the snap ring (Item 1) [Figure 30-20-36] from
the bottom side of the rotating group.
Figure 30-20-37
P-48694
1 The retainer ring (Item 1) [Figure 30-20-39] cannot be

P-48691 removed from the top side of the rotating group, because
the rpm target disk is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-20-37] from

HYDROSTATIC DRIVE MOTOR (CONT'D) If the rpm target disk needs to be changed, remove the
heads of the five roll pins (Item 2) [Figure 30-20-41] and
Disassembly And Assembly (Cont'd) remove the disk. Replace the target disk and use new roll
pins. Using a small hammer, tap the new roll pins through
Figure 30-20-40 the new target disk into the cylinder block.
Figure 30-20-42
1
2
P-48695
P0076
Lift the retaining ring (Item 1) [Figure 30-20-40].
Use low air pressure and remove the roller / piston Disassembly: Remove the oil fill plug (Item 1) [Figure
assembly (Item 2) [Figure 30-20-40] from the cylinder 30-20-42] from the housing to drain the oil from the
block. bearing and face seal area.
NOTE: Soak the roller / piston assembles (Item 2) Assembly: Install drain plug using Loctite® 243, tighten
[Figure 30-20-40] in oil and put all roller / flush with the face of the hub.
piston assembles back in the original bore.
Figure 30-20-43
NOTE: The roller / piston assembly (Item 2) [Figure
30-20-40] is not a serviceable part.
Figure 30-20-41
1 2
N-18343
Disassembly: With a hammer and punch remove the

P-48693 split ring and the preload washer located under the split
Inspect the rpm target disk (Item 1) [Figure 30-20-41] for

wear and replace as needed.


2
Figure 30-20-44 1
1
2
P0020
Disassembly: Install the bearing puller (Item 1) [Figure

N-18345 30-20-45] under the front housing and support the puller
and housing with blocks.
Assembly: Install the front housing (Item 1) and bearing Disassembly: Press the shaft (Item 2) [Figure 30-20-45]
over the shaft. Install the special tool (MEL1562) (Item 2) from the housing.
[Figure 30-20-44] over the bearing and press the
bearing onto the shaft. Apply 40034 N (9000 lbf) to set Figure 30-20-46
the bearing. Rotate the housing to check for free travel.
NOTE: The 40034 N (9000 lbf), is NOT the amount of

amount of downward force applied by the
press.
Assembly: Install the split ring (Item 3) [Figure 30-20-

44] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.
Assembly: Add the necessary washer to get closest to

the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

remove the tool.
P0682
Disassembly: Use a bearing puller to remove the

bearing from the shaft [Figure 30-20-46].
NOTE: The bearing will be destroyed during the

removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.


2
Figure 30-20-47 1
P0123
Remove and replace the face seal (Item 1) [Figure 30-

P13083 20-48] on the front housing.
NOTE: When installing face seals, apply a layer of

Assembly: Remove and replace the face seal (Item 1) good quality lithium grease to the mating
[Figure 30-20-47] from the shaft. surfaces of the face seal.
Assembly: Install a new bearing (Item 2) [Figure 30-20- Remove and replace the bearing cup (Item 2) [Figure
47] onto the shaft. 30-20-48] on the front housing.
NOTE: The bearing cup in the housing may be loose

after installation. The bearing cup will tighten

in its bore after the motor is completely
assembled.
Figure 30-20-49
P0122
Remove and inspect the bearing (Item 1) [Figure 30-20-

49] located in the front housing.
Replace the bearing if worn or damaged.

Figure 30-20-50
1
3
P0126
Remove the shaft seal (Item 1) [Figure 30-20-50].
Replace the outer O-ring and inner shaft seal (Item 2)

[Figure 30-20-50].
Remove the bearing cup (Item 3) [Figure 30-20-50] if it

needs replacement.
Figure 30-20-51
3/4
Full
Range
1/2
P-24562
Fill housing with synthetic Mobilgear SHC XMP 150 to

[Figure 30-20-51] 1/2 to 3/4 full.

plug.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Removing And Replacing Oil
ANKA11001 - ANKA13449)
For the correct service interval (See SERVICE
Description SCHEDULE on Page 10-70-1.)
The hydrostatic drive motors are driven by the hydrostatic Park the loader so that the plug in the hydrostatic drive
pump. Machines equipped with SJC are monitored by a motor is at the bottom.
sensor mounted onto the motor housing. The sensor is
used for detection of motion and for rate of speed for the Remove the plug and let the oil drain from the hydrostatic
SJC option. drive motor.
The hydrostatic drive motors contain a spring applied Figure 30-21-1

pressure release braking system. In addition there is a
separate oil chamber in the motor that is filled with high
performance synthetic oil for maximum durability, this oil
has a recommended service interval. (See SERVICE
There are two hydrostatic drive motors and they are 1

located on the track carriage.
P100737A
Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-21-1] is at the top. Add high performance
synthetic oil (P/N 7003026). (See Capacities on Page
SPEC-10-5.)

plug.
Repeat for the other hydrostatic drive motor.
Recycle or dispose of the used oil in an environmentally

safe manner.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Remove the track. (See Track Removal And Installation
ANKA11001 - ANKA13449) (CONT’D) on Page 40-20-4.)
Removal And Installation Figure 30-21-2
IMPORTANT 1

clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888

10-10-1.) P100811
Remove the mounting bolts (Item 1) [Figure 30-21-2]

DANGER from the access cover and remove the cover from the
loader.
Remove the sprocket. (See Sprocket Removal And

Installation (Two-Speed) on Page 40-20-12.)
Disconnect and remove the speed sensor. (See Removal
And Installation on Page 60-80-2.)
NOTE: Speed sensor removal is recommended to

P-90328 prevent damage while removing the
hydrostatic motor from the track carriage.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Figure 30-21-5
ANKA11001 - ANKA13449) (CONT’D)

1 1
Figure 30-21-3
1 P-85991
With an arm hoist support the hydrostatic motor.

3
Remove the ten hydraulic motor mounting bolts (Item 1)
P-85992 [Figure 30-21-5].
Remove the case drain hydraulic hose (Item 1) [Figure Installation: Tighten the motor mounting bolts to 257,6
30-21-3] from the motor. N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-21- Remove the hydrostatic motor from the loader.
3] from the motor.
Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-21-3].
Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.
Figure 30-21-4
2 3
4 1
P100901
Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-21-4]. Retighten all bolts to 34 N•m (25 ft-lb)
torque in the same sequence.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ANKA11001 - ANKA13449) (CONT’D)
10
9
8
65 7
6
5
4
3
12
2 23
11 22
65
21
10
1 20
14
40
39
17
18
38
13 36 37
15 41
16
36
19 42
16 29 42
15 35 30
31
43
34 64
24 32 44 36
25 33
26 31
28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ANKA11001 - ANKA13449) (CONT’D)
REF. DESCRIPTION REF. DESCRIPTION

1. PLUG 34. BOLT
2. SHAFT 35. BOLT
3. SEAL 36. PIN
4. BEARING 37. WASHER
5. HOUSING / FRONT 38. BOLT
6. SEAL 39. DISC / OUTER
7. BEARING 40. DISC / INNER
8. WASHER 41. BUSHING
9. SPLIT RINGS 42. SHIM
10. O-RING 43. HOUSING / BRAKE
11. NUT 44. SHAFT
12. STUD 45. O-RING
13. RPM TARGET DISC 46. BOLT
14. ROLL PIN 47. COVER PLATE
15. SNAP RING 48. GASKET
16. RETAINER 49. PIN
17. ROLLER 50. SEAL
18. PISTON 51. CLIP
19. BLOCK 52. SPRING
20. CAM 53. SPOOL
21. DISTRIBUTOR 54. PLUG

22. SPRING 55. HOUSING / REAR
23. SEAL W / O-RING 56. SEAL
24. PLUG 57. O-RING
25. O-RING 58. SNAP RING
26. SPRING 59. PISTON
27. SHIM 60. SEAL
28. POPPET 61. DISC SPRING
29. PLUG 62. GASKET
30. O-RING 63. COVER PLATE
31. SPRING 64. BOLT
32. WASHER 65. PLUG
33. SPOOL

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Assembly: Replace the gasket and torque bolts to 35 -
ANKA11001 - ANKA13449) (CONT’D) 39 N•m (26 - 29 ft-lb).
Disassembly And Assembly Figure 30-21-8
Figure 30-21-6
N-18296
P100869
Remove the disc spring (Item 1) [Figure 30-21-8] from
the brake housing.
NOTE: Mark the motor, brake and motor housings for
proper alignment during assembly [Figure 30- NOTE: Mark the top side of the disc spring for proper
21-6]. installation.
Drain the oil from the motor casing. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Inspect for the vendor motor serial number (Item 1)
[Figure 30-21-6], these serial numbers may be needed
when ordering replacement parts.
Figure 30-21-7
P100799
Remove the mounting bolts (Item 1) and the brake cover

plate [Figure 30-21-7].
NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

Figure 30-21-9
1
2
P100868
1 Inspect the piston surface (Item 1) and the bushing

surface (Item 2) [Figure 30-21-11] in the brake shaft.
P100804
NOTE: The bushing (Item 2) [Figure 30-21-11] can be
replaced in the brake shaft. When the bushing
Remove the piston from the brake housing [Figure 30- is replaced, install the bushing flush with the
21-9]. top of the brake shaft.
NOTE: The use of air pressure through the brake line

connection (Item 1) [Figure 30-21-9] will aid in
piston removal.
Figure 30-21-10
2
P100801
Inspect the brake piston (Item 1) [Figure 30-21-10] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-21-10].
Assembly: Apply oil to the seal (Item 2) [Figure 30-21-

10] for added protection when installing the brake piston.

Figure 30-21-12
N-18347
3
2
Assembly: Clamp the disc pack in a vise and inspect the
disc pack height [Figure 30-21-13].
1 P100866
Assembly: The correct disc pack reference
specifications is 37,7 mm (1.48 in).
Remove the five mounting bolts (Item 1) [Figure 30-21-
12] and washers from the brake housing. Assembly: Extra outer disc's are used to reduce the
number of required shims [Figure 30-21-13] to make up
Remove the brake housing (Item 2) [Figure 30-21-12] the required thickness for the brake pack.
from the rear housing.
NOTE: Brake pack height is for reference only.
Remove the snap ring and inner piston seal (Item 3)
[Figure 30-21-12]. Figure 30-21-14
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake

housing on the rear housing.
Assembly: Install new washers on the brake housing 1

mount bolts (Item 1) [Figure 30-21-12].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
P100867
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)
torque.
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-21-14]. Outer discs can also be used as
shims.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N press.
Figure 30-21-17
Figure 30-21-15
1
2
3
P100858
1
P100805
Disassembly: Remove the brake discs (Item 1) [Figure
30-21-17] and shims from the brake shaft.
Assembly: Assemble the brake discs into a pack making
sure the inner discs (Item 1), alternate with the outer disc Figure 30-21-18
(Item 2) and an outer disc is placed at each end of the
disc pack with the shims (Item 3) [Figure 30-21-15] and
the base of the pack.
Figure 30-21-16 1
P100859
Remove the brake shaft (Item 1) [Figure 30-21-18] from

3 the rear housing.
P100800
NOTE: Be sure shaft seats fully into the cylinder
Assembly: Assemble the brake piston into the brake block.
housing without the inner brake piston seal (Item 3)
[Figure 30-21-12] and brake piston outer seal (Item 2) Assembly: Install new O-ring (Item 2) [Figure 30-21-18]
[Figure 30-21-10]. Apply 20 kN (4500 lbf) to set the on the rear housing.
brake pack. Using a depth gauge (Item 1), measure from
the gasket mating surface (Item 2) to the inner machined
groove (Item 3) on the brake piston [Figure 30-21-16].
The dimensional measurement must be 8,7 ± 0,1mm
(0.343 ± 0.003), if not adjust brake pack discs to the
required measurement.
NOTE: The 20 kN (4500 lbf) is NOT the amount of

Figure 30-21-19
P100872
Remove the plug (Item 1) [Figure 30-21-20] from the

rear housing.
P100870
Figure 30-21-22
Remove the two-speed spool assembly (Item 1) [Figure

30-21-19] from the rear housing.
Figure 30-21-20
1 2
P100871
2
4
3 Remove the spool (Item 1) [Figure 30-21-20].
N-22501 Assembly: Install new O-ring (Item 2) [Figure 30-21-18]

on the plug and torque to 50 N•m (37 ft-lb)
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-20].
NOTE: If the spool (Item 1) [Figure 30-21-20] is

damaged the entire rear housing assembly
has to be replaced.


1
Figure 30-21-23 1 1
1
2 4 3
1 1
1
2 2
P100861
Remove the ten mounting bolts (Item 1) [Figure 30-21-

24] from the rear housing.
N-22504
Remove the two (8 mm) cam ring mount bolts (Item 2)
[Figure 30-21-24].
Remove the spring (Item 1), washer (Item 2) and rear
spring (Item 3) from the spool (Item 4) [Figure 30-21-23]. Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Assembly: Clean the threads on the bolts and front
housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-24] to 210 - 220 N•m

(154 - 162 ft-lb) torque. Clean the threads on the two (8
mm) bolts (Item 2) [Figure 30-21-24] and the cam ring.
Apply Loctite® #243 and tighten the bolts to 70 - 77 N•m
(52 - 57 ft-lb).

Figure 30-21-25
1
P100856
Remove the springs from the distributor (Item 1) [Figure

30-21-27].
P100860
Inspect the distributor surfaces for scratches.
Remove and replace with a new O-ring (Item 1) [Figure Assembly: Apply a small amount of grease to the
30-21-25]. springs to hold them in place during installation.
Remove the distributor (Item 2) [Figure 30-21-25] from Figure 30-21-28

the rear housing.
Assembly: Install the distributor (Item 2) [Figure 30-21-
25] by using the alignment pin.
Figure 30-21-26
2 1
P100855
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) [Figure 30-21-27] from the distributor.
2
N-18318
Remove the seal and back-up O-ring (Item 1) [Figure 30-

21-26] under the seal, from the rear housing.
Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-21-26].
Remove and inspect the stop pin (Item 2) [Figure 30-21-

26].

Figure 30-21-29
P100873
1

plug. Torque to 60 N•m (44 ft-lb)
P100812
Figure 30-21-32
Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor (Item 2)
[Figure 30-21-29].
When the distributor is aligned correctly, the distributor

1
can be depressed slightly by hand and will return to its
original position.
Figure 30-21-30
1
P100875
P100874
Remove the drain plug (Item 1) [Figure 30-21-30].


1
Figure 30-21-33
4
1
3
2
P100924
Remove and replace the O-ring (Item 1) [Figure 30-21-

35] from the front housing assembly.
N-18314
Assembly: Slightly smear the O-ring (Item 1) [Figure
30-21-35] with grease to hold in place.
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-21-33]. Remove the rotating group (Item 2) [Figure 30-21-35]
from the front housing assembly.
Figure 30-21-36
Install a new O-ring (Item 4) [Figure 30-21-33] on the
plug. Torque to 25 N•m (18 ft-lb)
Figure 30-21-34
2
1
1
P-48690

P100925 the bottom side of the rotating group.
Remove the cam ring (Item 1) [Figure 30-21-34] from the

front housing assembly.
Inspect the cam ring inside surface for wear and

scratches.
Assembly: Align the marks (Item 2) [Figure 30-21-34]

on the cam rings to the front housing.

Figure 30-21-37
P100927
The retainer ring (Item 1) [Figure 30-21-39] cannot be

1
removed from the top side of the rotating group, because
P-48691 the rpm target disc is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-21-37] from Figure 30-21-40
Figure 30-21-38
2
1
P100928
P100926 Lift the retaining ring (Item 1) [Figure 30-21-40].
Use low air pressure and remove the roller / piston

Remove the snap ring (Item 1) [Figure 30-21-38] from assembly (Item 2) [Figure 30-21-40] from the cylinder
the top side of the rotating group. block.
NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-21-40] in oil and put all roller /
piston assembles back in the original bore.
NOTE: The roller / piston assembly (Item 2) [Figure

30-21-40] is not a serviceable part.


2
Figure 30-21-41
1
P100932
Assembly: Install the front housing (Item 1) and bearing

over the shaft. Install the special tool (MEL1562) (Item 2)
P100929 [Figure 30-21-43] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
bearing. Rotate the housing to inspect for free travel.
Disassembly: Remove the oil fill plug (Item 1) [Figure
30-21-41] from the housing to drain the oil from the NOTE: The 40 kN (9000 lbf) is NOT the amount of
bearing and face seal area. pressure required by the press. It is the
Clean the threads of the plug and drain hole. Apply press.
Assembly: Install the split ring (Item 3) [Figure 30-21-
plug.
43] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.
Figure 30-21-42
Assembly: Add the necessary preload washer to get
closest to the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

remove the tool.
1
P100931
Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split

Figure 30-21-44
2
1
2
P13083
Assembly: Remove and replace the face seal (Item 1)

[Figure 30-21-46] from the shaft.
P100934
Assembly: Install a new bearing (Item 2) [Figure 30-21-
46] onto the shaft.
Disassembly: Install the bearing puller (Item 1) [Figure
30-21-44] under the front housing and support the puller Figure 30-21-47
and housing with blocks.
Disassembly: Press the shaft (Item 2) [Figure 30-21-44] 1

from the housing.
Figure 30-21-45
P100941
Remove and inspect the bearing (Item 1) [Figure 30-21-

47] located in the front housing.
P0682 Replace the bearing and bearing cup if worn or

damaged.
Disassembly: Use a bearing puller to remove the

bearing from the shaft [Figure 30-21-45].
NOTE: The bearing will become unserviceable during

the removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.

Figure 30-21-48 2 1
2
1
P100940
Remove the shaft seal (Item 1) [Figure 30-21-49].
P100939 Remove the bearing cup (Item 2) [Figure 30-21-49] if it

needs replacement.
Remove and replace the face seal (Item 1) [Figure 30- Figure 30-21-50
21-48] on the front housing.
NOTE: When installing face seals, apply a layer of

good quality lithium grease to the mating
surfaces of the face seal. 1
Remove and replace the bearing cup (Item 2) [Figure
30-21-48] on the front housing.
NOTE: The bearing cup in the housing may be loose

after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.
P100930
Rotate the hydrostatic drive motor so that the drain plug

(Item 1) [Figure 30-21-50] is vertical with the center of
the hydrostatic drive motor. Fill housing with 180 mL (6.1
U.S. fl oz) high performance synthetic oil (P/N 7003026).

plug.

CHARGE PRESSURE Testing
Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
2 4
hydraulic control valve. 1 3
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6895 kPa (68,9 bar) (1000 psi) (Item 3), adapter
fitting (P/N 93F-5) (Item 4) [Figure 30-30-1] and
MEL1563 or 7217666 Remote Start Tool Kit.
WARNING

W-2059-0598
Raise the loader lift arms and install an approved lift arm

10-10-1.)

CHARGE PRESSURE (CONT’D) Figure 30-30-4
Testing (Cont’d)
Figure 30-30-2
1
1
2
3 3
2
P-90301
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].

P-43197
Install the hose (Item 2) [Figure 30-30-4], that was
disconnected from the motor, to the T fitting.
Connect the gauge (Item 1), to the adapter fitting (P/N
93F5) (Item 2) [Figure 30-30-2]. Install the hose (Item 3) [Figure 30-30-4], that is
attached to the pressure gauge, to the T fitting.
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to
the adapter fitting. Tighten all connections. Tighten the hydraulic fittings.
Figure 30-30-3 Connect the remote start tool. (See REMOTE START
7217666 on Page 10-61-1.)
Start the loader and warm the hydraulic fluid to 140

degrees Farenheit.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 140 degree
Farenheit is 2999 - 3413 kPa (30,0 - 34,1 bar) (435 - 495
1
psi) with the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 2482 -
P-90302 2827 kPa (24,8 - 28,3 bar) (360 - 410 psi) at
60°C (140°F) fluid @ High idle.
Disconnect the hydraulic hose (Item 1) [Figure 30-30-3].

CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-30-5
P-90302
Disconnect the wire (Item 1) [Figure 30-30-5] from the

sender.
Remove the sender (Item 2) [Figure 30-30-5] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

1,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Inspect the O-ring on the sender before

installation.

CHARGE PRESSURE (CONT'D) Figure 30-30-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-30-6 Remove the plug, spring and poppet [Figure 30-30-7].
Inspect the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-30-8
P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item 1)
[Figure 30-30-8] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55 kPa

(0,6 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2999 - 3413 kPa (30,0 - 34,1 bar) (435 - 495 psi) with the
pump in neutral.

CHARGE PRESSURE (CONT'D) Figure 30-30-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
damage the system.
P-64435
I-2003-0888
Figure 30-30-9 Inspect the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-30-10] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim (Item 1) [Figure 30-30-10] = 300

kPa (3,0 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2482 - 2827 kPa

(24,8 - 28,3 bar) (360 - 410 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.

30-30-6
T770 Service Manual
HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT'D) Figure 30-40-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

50-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-40-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-40-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-40-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-40-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two mounting bolts and nuts (Item 1) [Figure
ft-lb) torque 30-40-3].
Installation: Tighten the mounting bolts and nuts to 88 -

95 N•m (65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (CONT'D)
Figure 30-40-4
P-90224

at the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 125 - 135 N•m (90

- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-40-3.)
Hydrostatic Pump Startup
Follow the hydraulic pump startup procedure. (See

Hydraulic Pump Startup on Page 20-60-8.)

HYDROSTATIC PUMP (CONT’D) Inspect the O-ring (Item 2) [Figure 30-40-6] for damage
Replenishing / High Pressure Relief Valve Removal
And Installation If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
Figure 30-40-5
The pressure setting for a new high pressure relief valve
is 36197 kPa (362,0 bar) (5250 psi).
P-43857
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-40-5] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
Figure 30-40-6
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-40-5] and [Figure 30-40-6] from the pump.
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)

torque.
Inspect for damage and replace as needed.

Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block
19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10
18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
10
23. Piston Retainer
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

HYDROSTATIC PUMP (CONT'D) Figure 30-40-9
Disassembly
Figure 30-40-7
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-40-9].

P-43858
Remove the large O-ring (Item 2) [Figure 30-40-9].
Remove the four mounting bolts (Item 1) [Figure 30-40- Remove the two small O-rings (Item 3) [Figure 30-40-9].
7].
Figure 30-40-10
Figure 30-40-8
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-40-10] from

Separate the two hydrostatic pumps [Figure 30-40-8]. the pump housing end cap.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-13
Disassembly (Cont’d)
2
1
Figure 30-40-11
N-17194
2
Inspect the valve plate locating pin (Item 1) [Figure 30-
N-19551 40-13] for wear and replace if needed.
Inspect the needle bearing (Item 2) [Figure 30-40-13] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
40-11].
Figure 30-40-14
Remove the gasket (Item 2) [Figure 30-40-11].
Figure 30-40-12
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-40-14]

from the pump.
Remove the valve plate (Item 1) [Figure 30-40-12].
Inspect the valve plate for wear. (Both Sides.)

3 3
Figure 30-40-15
1 1
3 2
3
2
N-17200
Inspect the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-40-17] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-40-17] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-40-15] from the cylinder block.
Inspect the cylinder block for wear and replace as
Inspect all the pistons (Item 2) [Figure 30-40-15] for needed.
wear and replace the rotating group as needed.
Inspect pins (Item 3) [Figure 30-40-17] to see if they are
Figure 30-40-16 all the same length.
Figure 30-40-18
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-40-
16] from the cylinder block.
Remove the thrust plate (Item 1) [Figure 30-40-18] from
the pump housing.

Figure 30-40-19
1
1
2
N-17240
3
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
Remove the driveshaft key (Item 1) the snap ring (Item 2) Figure 30-40-22
and the support washer (Item 3) [Figure 30-40-19] from
the drive shaft end of the pump.
Figure 30-40-20
1
N-17241

N-17239 the driveshaft and remove the bearing.
Inspect the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-40-20] from the pump housing.

Figure 30-40-23
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-40-25] from the pump housing.
Figure 30-40-26
Inspect the pump shaft (Item 1) [Figure 30-40-23] for
wear and replace if needed.
Figure 30-40-24
1
N-17245
1 1
Inspect the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-40-26] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-40-24]

from the lower trunnion cover. Remove the cover.

Figure 30-40-27
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-40-29] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-40-30
Inspect the dust seal on the pintle shaft.
Remove the four mount bolts (Item 1) from the pump

housing and remove the linkage bracket (Item 2) [Figure
30-40-27].
Figure 30-40-28
1
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-30] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-40-

28].

1
Figure 30-40-31
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-40-33] and

N-17249 remove the swash plate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-31] and replace as needed.
Figure 30-40-32
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-40-32] from
the swash plate shaft.

Assembly
Figure 30-40-34
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-36] on

N-17253 the swash plate shaft.
Figure 30-40-37
Install the lower bearing (Item 1) [Figure 30-40-34] on
the swash plate.
Figure 30-40-35
N-17248
Install the bearing race (Item 2) [Figure 30-40-36] and O-

N-17252 ring (Item 3) [Figure 30-40-36] as shown in [Figure 30-
40-37].
Install the swash plate and bearing into the pump

housing [Figure 30-40-35].

Assembly (Cont’d)
Figure 30-40-38
1 N-17245
Figure 30-40-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-38]

and cover.
Figure 30-40-39
1
N-17244
Install the bearing race (Item 1) [Figure 30-40-40] and O-

ring (Item 2) [Figure 30-40-40] at the lower trunnion as
shown in [Figure 30-40-41].
N-17246
Install the linkage bracket (Item 1) [Figure 30-40-39] and

the four mounting bolts and tighten to 24 - 30 N•m (18 -
22 ft-lb) torque.
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-40-42
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-40-

N-17243 44] on the pump shaft.
Figure 30-40-45
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-42].
Install the four mounting bolts and tighten to 24 - 30 N•m

Figure 30-40-43
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-45].
Install the snap ring (Item 1) [Figure 30-40-45].

N-17242
Install the snap ring (Item 1) [Figure 30-40-43] on the

pump shaft.

Assembly (Cont’d)
Figure 30-40-46
1
1
1
1 2 3
N-17198
Assemble the piston assemblies into the slipper guide.

N-17200 Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
40-48].
Install the four slipper pins (Item 1) [Figure 30-40-46]
into the cylinder block. Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
Apply a small amount of grease to the washer (Item 2)
and install into the ball guide retainer (Item 3) [Figure 30- Figure 30-40-49
40-46].
Figure 30-40-47
N-17197
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-40-49].
Install the ball guide retainer and washer (Item 1) [Figure

30-40-47] onto the slipper holddown pins.

Assembly (Cont’d)
Figure 30-40-50
1
1
2
N-17193
Coat the backside of the valve plate with petroleum jelly

N-17194 to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-52].
Replace the needle bearing (Item 1) and valve plate The notch (Item 1) [Figure 30-40-52] on the valve plate
locating pin (Item 2) [Figure 30-40-50] in the charge must engage the locating pin.
pump.
Figure 30-40-53
Figure 30-40-51
2
1
N-19551
N-17196
Coat a new end cap gasket (Item 1) [Figure 30-40-53]

The bearing cage (Item 1) [Figure 30-40-51] will with petroleum jelly and install onto the end cap.
protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

40-51] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.

Assembly (Cont’d)
Figure 30-40-54
1 1
N-19570
Install the two pumps together [Figure 30-40-56].

N-19550
Figure 30-40-57
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-40-54] to 47 - 61
N•m (35 - 45 ft-lb) torque. 1
Figure 30-40-55
1
1
3 P-43858
2 Tighten the four bolts (Item 1) [Figure 30-40-57] to 47 -

1 61 N•m (35 - 45 ft-lb) torque.
N-19571
Install the two small O-rings (Item 1) [Figure 30-40-55].
Install the large new O-ring (Item 2) [Figure 30-40-55].
Install the pump coupler (Item 3) [Figure 30-40-55].

30-40-20
T770 Service Manual
HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The hydrostatic pump is a fully proportional dual piston forward or reverse drive motor rotation is obtained.
pump in one pump casing. The endcaps are removable
to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are supplied with charge
pressure from an external charge pump. 12 volt electrical Ports are labeled on the hydrostatic pump casting.
solenoids shift a spool in the hydraulic controller that
directs flow to a servo piston.
Figure 30-41-1
P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the wire harness (Item 1) [Figure 30-41-3]
10-10-1.) from both sides of the hydrostatic pump.
WARNING IMPORTANT
Put jackstands under the front axles and rear corners When repairing hydrostatic and hydraulic systems,
of the frame before running the engine for service. clean the work area before disassembly and keep all
Failure to use jackstands can allow the machine to parts clean. Always use caps and plugs on hoses,
W-2017-0286 damage the system.
I-2003-0888
Figure 30-41-4
Figure 30-41-2
1
1
1
P-90208
P-90207
Remove the four bolts (Item 1) [Figure 30-41-4] from the

Locate the two hydraulic controllers (Item 1) [Figure 30- hydraulic controller.
41-2] on the hydrostatic pumps.
Installation: Tighten the bolts to 10,4 N•m (7.7 ft-lb).

HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Removal And Installation

(Cont'd)
Figure 30-41-5
3
2
1
4
P-90210
Remove the cover (Item 1) gaskets (Item 2) and control

(Item 3) [Figure 30-41-5] from the pump.
Figure 30-41-6
2 2
P-90209
Install the controller with the feedback lever (Item 4)

[Figure 30-41-5] in the center of the servo piston groove
(Item 1) [Figure 30-41-6].
NOTE: Do NOT remove the three screens (Item 2)

[Figure 30-41-6] they will be damaged during
removal and must be replaced.
NOTE: When a hydraulic controller is replaced, the

hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Page 30-41-36.)


Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

50-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-41-8] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-41-7 Remove the pump pulley from the pump drive shaft.
Figure 30-41-9
1
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-41-7] on the
hydrostatic pump drive shaft.
Remove the two bolts and nuts (Item 1) [Figure 30-41-9].
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque Installation: Tighten the bolts and nuts to 88 - 95 N•m

Figure 30-41-10
P-90224
Remove the two bolts (Item 1) [Figure 30-41-10] at the

hydraulic pump mounting bracket.
Installation: Tighten the bolts to 125 - 135 N•m (90 - 100

ft-lb).
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Start Up on Page 30-41-6.)

Hydrostatic Pump Start Up
Before putting a hydrostatic pump back into operation,

the hydrostatic pump must be filled with hydrostatic fluid.
This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry will cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Fill the hydrostatic pump by removing a plug at the top of

the hydrostatic pump. A clean funnel should be used to
avoid washing contaminants into the hydrostatic pump.
Fill the hydrostatic pump case as much as possible
before start up.
Figure 30-41-11
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-41-11].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Installation: Tighten plugs to 25 N•m (18 ft-lb) torque.
NOTE: The hydrostatic pump is removed from the

loader for photo clarity.

3 1
1. O-ring 4 1
2. Bolt
3. End Housing 6
4. Right Rotating Assembly 5
5. Timing Pin 7
6. Bearing
7. Spacer/Coupler
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer 9
1 8 2
1
10
11
2
12
16 2
2 14
16 17
15 13
17
13
18 20
14
22 19
12. Steel Cover

13. Hydraulic Controller
14. High Pressure Relief
5 15. Case Housing
6 16. Plug
2 17. Dowel Pin
18. Charge Pressure Relief
19. Left Servo
21 20. Right Servo
8 1 21. Left Rotating Assembly
1 22. End Housing
9 1
11
10
2
12 2
P-90240

High Pressure Relief And Bypass Valve
Figure 30-41-12
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-41-14]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-14] for

There are four system high pressure relief valves (Item 1) breakage.
[Figure 30-41-12] in the back of the hydrostatic pump.
Inspect the seats inside the case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-12].
Do not disassemble the relief valve assembly. If
Installation: Tighten cap to 150 - 170 N•m (111 - 125 ft- replacement is required, replace as an assembly.
lb) torque.
Factory setting on the relief valve is 36197 kPa (362 bar)
Figure 30-41-13 (5250 psi).
4
3
2 1
P-64436
Inspect the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-13] and replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-13]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-41-13] for

damage.

Charge Relief Valve

1 4 5
Figure 30-41-15 6
2 3
1 P-64435
Inspect the O-ring (Item 1) [Figure 30-41-16].

P-64431
Inspect the poppet (Item 2) and the spring seat (Item 3)
[Figure 30-41-16] for damage or foreign material. Must
The charge relief valve (Item 1) [Figure 30-41-15] is move freely in the relief valve bore.
located on the back of the hydrostatic pump.
Inspect the sealing ring (Item 4) [Figure 30-41-16] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Installation: Tighten the charge relief valve to 70 N•m
(52 ft-lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-41-16].
NOTE: 1,0 mm shim = 300 kPa (3 bar) (43.5 psi) in

pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.

Disassembly

the loader. (See Engine Removal And Installation on 1
Page 70-10-7.)
Remove the hydrostatic pump. (See Removal And

Figure 30-41-17 1
2
P-90228
Remove the bolts (Item 1) for the swash plate angle

1 sensor (Item 2) [Figure 30-41-19].
1
Figure 30-41-20
P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-41-
17]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.)
Figure 30-41-18
3 3
2 2 P-90218
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-41-18].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-41-18] from both sides.

Figure 30-41-21
P-64464
1
Remove the end housing / rotating group assembly
P-64445 [Figure 30-41-23] from both ends of the pump.
Figure 30-41-24
Remove the bolts (Item 1) from the right end housing
(Item 2) [Figure 30-41-21] 1
Figure 30-41-22
1
P-64465
1
Remove O-ring (Item 1) [Figure 30-41-24].
P-64447
Remove the four bolts (Item 1) from the left end housing
(Item 2) [Figure 30-41-22].

Figure 30-41-25
RIGHT SIDE
B25012
Disassemble the right side rotating group [Figure 30-41-

P-64454 27].
Figure 30-41-28
Remove valve plate (Item 1) [Figure 30-41-25] from the
right side pump.
NOTE: The valve plates are NOT interchangeable

between the right and left sides.
Figure 30-41-26
LEFT SIDE
B25011
Disassemble the left side rotating group [Figure 30-41-

28].
P-64501
Remove valve plate (Item 1) [Figure 30-41-26] from the

left side pump.
NOTE: The valve plates are NOT interchangeable

between the right and left sides.
NOTE: Pay attention to the notches [Figure 30-41-25]

and [Figure 30-41-26] in the valve plate for
assembly reasons. There are different valve
plates for the left and right side. The valve
plates are NOT interchangeable.

1
Figure 30-41-29
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64475 31].
Figure 30-41-32
Remove the pistons (Item 1) [Figure 30-41-29] from the
rotating block.
1
Figure 30-41-30
1
P-64472
Do Not remove the pins (Item 1) [Figure 30-41-32] from

P-64476 the cylinder block.
Remove the pistons (Item 1) [Figure 30-41-30] from the

piston retainer.

1 1
Figure 30-41-33
P-64483
2
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64479 35].
Remove the positioning pin (Item 2) [Figure 30-41-35].

Remove the swash plate (Item 1) from the endcap
housing (Item 2) [Figure 30-41-33]. Figure 30-41-36
Remove the link (Item 3) [Figure 30-41-33],
Figure 30-41-34
1
P-64485

P-64482
Remove the shell bearing (Item 1) [Figure 30-41-34].

Figure 30-41-37
LEFT SIDE
1
P-76742
Remove the pump seal (Item 1) [Figure 30-41-39] by

P-64486 inserting a screw into the seal and prying out.
Figure 30-41-40
Figure 30-41-38
RIGHT SIDE 1
1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-41-37] and a rubber mallet.
[Figure 30-41-38] from the end housing.
Remove the snap ring (Item 1) and remove the bearing
(Item 2) [Figure 30-41-40].

Figure 30-41-41
P-90231
Rotate the servo piston cover (Item 1) [Figure 30-41-43].

P-64490
Figure 30-41-44
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-41].
Figure 30-41-42
1 1
P-90237
Slide the servo piston assembly out of the bore. [Figure

30-41-44].
P-90232
Remove servo piston bolts (Item 1) [Figure 30-41-42].

Figure 30-41-45 1
2
1 2
P-64496
Remove the servo cover (Item 1) [Figure 30-41-47] from

P-64493 the servo piston.

Remove the bushings (Item 1), seals and O-rings (Item 2) cover.
[Figure 30-41-45] from the pump housing.
Figure 30-41-48
Figure 30-41-46
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-41-48] from the

Remove the lock nut (Item 1) [Figure 30-41-46] from the servo piston.
servo piston.

Figure 30-41-49
1
2
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-41-49] from the servo piston.
Remove the O-ring (Item 2) [Figure 30-41-49]
Figure 30-41-50
2
1
P-64502
Remove the bearings (Item 1) [Figure 30-41-50].
Remove the coupler (Item 2) [Figure 30-41-50].

Inspection
Figure 30-41-51
P-64477
Inspect the mating surface of the piston retainer for

P-86718 scoring or scratches (Item 1) [Figure 30-41-53].
Figure 30-41-54
Inspect the valve plates (Item 1) [Figure 30-41-51] for
scratches or scoring. Replace a valve plate if the 1
scratches are deep enough to catch with a fingernail. 1
Figure 30-41-52
P-64472
1
Inspect the pins (Item 1) [Figure 30-41-54]. The pins

must be all the same length.
P-64476
Inspect the pistons for scoring and scratches. The holes

(Item 1) [Figure 30-41-52] in the slippers must not be
plugged.

Inspection (Cont’d)
Figure 30-41-55
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-41-57].
Figure 30-41-58
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-41-55].
2
Figure 30-41-56
2
1
3
P-64482
Inspect individual roller bearings (Item 1) and machined

P-64478 surfaces (Item 2) [Figure 30-41-58] on swash plate.
Inspect the back surface of the rotating block (Item 1)

[Figure 30-41-56] where the valve plate seals. There
must be no scratches or scoring.
Inspect that the spring (Item 2) and snap ring (Item 3)

[Figure 30-41-56] are not bent or damaged.

Figure 30-41-59 1
1
P-64498
Inspect the servo piston stop adjustment (Item 1) [Figure

P-86723 30-41-61] for broken parts.
Figure 30-41-62
Inspect bearing surfaces (Item 1) [Figure 30-41-59] for
scratches or scoring.
Figure 30-41-60 1
3
3 1
P-64436
Inspect the conical spring (Item 1) [Figure 30-41-62] for

P-64488 damage.
Inspect the bearing (Item 1) [Figure 30-41-60].
Inspect wear surfaces (Item 2) for scratches. Inspect the

splines (Item 3) for excessive wear.

Figure 30-41-63
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-41-63]

for scratches.
Inspect the spring (Item 2) [Figure 30-41-63] for

breakage.
Inspect the seats inside the case housing.
Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.

Assembly
Figure 30-41-64
P-64497
2
Install the snap ring (Item 1) [Figure 30-41-66].

P-64502
Figure 30-41-67
Install the coupler (Item 1) [Figure 30-41-64].
Install the bearings (Item 2) [Figure 30-41-64].
Figure 30-41-65
1
1
2
P-64496
Install the O-ring (Item 1) [Figure 30-41-67] on the servo

cover.
P-64498
Install the piston stop adjustment mechanism (Item 1) in

to the servo piston (Item 2) [Figure 30-41-65].

Assembly (Cont’d)
Figure 30-41-68
P-90237
2 Install the servo piston assembly [Figure 30-41-70].

P-64495
Figure 30-41-71
Install the servo cover (Item 1) on the servo piston to the

dimension recorded earlier. Install the lock nut (Item 2)
[Figure 30-41-68].
Figure 30-41-69
1
1
2
1
2 P-64466
Align the servo piston with the guide slot (Item 1) [Figure
30-41-71] parallel to the driveshaft center line.
P-64493
Install the bushings (Item 1), seals and O-rings (Item 2)

[Figure 30-41-69] in the pump housing.

Assembly (Cont’d)
Figure 30-41-72
1 1
P-90232
Install the bolts (Item 1) [Figure 30-41-72].
Tighten the bolts to 10,4 N•m (7.7 ft-lb) torque.


Assembly (Cont’d) LEFT SIDE

Figure 30-41-73 1
2
RIGHT SIDE
1 P-64503
2
Align the timing pin (Item 1) [Figure 30-41-73] and
P-64455 [Figure 30-41-74] in the case housing with the notch
(Item 1) [Figure 30-41-75] and [Figure 30-41-76] that
does not go through the valve plate.
Figure 30-41-74
Align the shoulder of the roller bearing (Item 2) [Figure
LEFT SIDE 30-41-73] and [Figure 30-41-74] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-75] and [Figure
30-41-76].
NOTE: Valve plate must sit FLUSH with the case
housing when properly installed.
Figure 30-41-77
1
2
P-64502
2
1
Figure 30-41-75
RIGHT SIDE
1
2
P-64488
Install the bearing (Item 1) and snap ring (Item 2) [Figure

30-41-77] on the shaft.
Install the shaft in both end housings.
P-64456

Assembly (Cont’d)
Figure 30-41-78
LEFT SIDE
P-64486
Install the snap ring (Item 1) [Figure 30-41-78] on both

sides of the pump.
Figure 30-41-79
RIGHT SIDE 2
P-76743
Install the seal (Item 1) and snap ring (Item 2) [Figure

30-41-79] on the right side pump.

Assembly (Cont’d)
1 1
Figure 30-41-80
1
2
P-64481
Install the locating wires (Item 1) through the bearings

P-64485 and into the hole (Item 2) [Figure 30-41-82] in the side of
the swash plate.
Install the O-ring (Item 1) [Figure 30-41-80] on the Figure 30-41-83

positioning pin.
Figure 30-41-81
1
1
2
2 2
1
P-64480
P-64483 Install the swash plate assembly over the shaft and in to
the end cap housing. The locating wires (Item 1) must
engage the holes (Item 2) [Figure 30-41-83] of the end
Install the positioning pin (Item 1). Install the bearing cap housing.
races with the tall edge (Item 2) [Figure 30-41-81] of the
race towards the outside of the housing.

Assembly (Cont’d)
Figure 30-41-84
1 1
P-64476
Install the pistons (Item 1) [Figure 30-41-86] in the piston

P-64479 retainer.
Figure 30-41-87
The swash plate (Item 1) must move smoothly on the
bearings. Install the feedback link (Item 2) [Figure 30-41-
84] on the swash plate.
1
Figure 30-41-85
1
P-64475
Install the piston / retainer (Item 1) [Figure 30-41-87]

assembly in the cylinder block.
P-64471
Install the ball guide (Item 1) [Figure 30-41-85] on the

cylinder.

Assembly (Cont’d)
Figure 30-41-88
1
1
P-64466
Install the end housing assembly into the pump housing.

P-64469 The feedback link (Item 2) [Figure 30-41-89] must
engage the notch in the servo piston (Item 1) [Figure 30-
41-90].
Install the cylinder block / piston assembly (Item 1)
[Figure 30-41-88] on the shaft. Figure 30-41-91
Figure 30-41-89
1 2
1
2
P-64463
P-64465
Align the dowel pin (Item 1) with the hole in the case
(Item 2) [Figure 30-41-91] as the end cap is installed.

Assembly (Cont’d)
1
Figure 30-41-92
1 1
1 1 P-90218

P-64445
Figure 30-41-95
Figure 30-41-93
1 1
2
1 1
P-64476
P-64447
Install the swash plate angle sensor (Item 1) into the slot
of the positioning pin (Item 2) [Figure 30-41-95].
Install the bolts (Item 1) [Figure 30-41-92] and [Figure
30-41-93]. Tighten the bolts to 130 N•m (96 ft-lb) torque.

Assembly (Cont’d)
Figure 30-41-96
P-64475
Install the bolts (Item 1) [Figure 30-41-96]. Tighten the

bolts to 3,1 N•m (27.4 in-lb) torque.
Figure 30-41-97
2 2
1 1
2 2
P-64469
Install the covers (Item 1) and bolts (Item 2) [Figure 30-

41-97]. Tighten the bolts to 51 N•m (38 ft-lb) torque.
Install the hydraulic controllers. (See Hydraulic Controller


Mechanical Neutral Adjustment

WARNING
procedure:
The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
immediately.
relative to the hydraulic controller. This procedure should W-2145-0290
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted. Figure 30-41-98
1
10-10-1.) 1
WARNING
W-2017-0286
P-64973
Raise the lift arms, and install an approved lift arm
Connect a hydraulic hose (Item 1) [Figure 30-41-98]
Raise the operator cab. (See Raising on Page 10-30-2.) between port X1 and port X2 on each side of the
hydrostatic pump, to equalize the pressures on both ends
Connect the remote start tool. (See REMOTE START of the servo pistons.
7217666 on Page 10-61-1.)
Disconnect the swash plate angle sensors in the 1

electrical harness. This prevents unwanted swash plate 1
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
If equipped disconnect the speed sensors located on the

top of the motor carriers. This prevents uncommanded
wheel movement error codes from occurring during
adjustments.
P-90242

MB ports on the front side of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-100
P-90226
Loosen the pump neutral adjustment locknut (Item 1)

P-64438 [Figure 30-41-102].
Start the loader using the remote start tool and run at
Remove the plugs (Item 1) [Figure 30-41-100] from the idle.
MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.
Figure 30-41-101 WARNING

Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1 1
Figure 30-41-103
1 1
P-90243
Remove the drive hoses from the A and B ports (Item 1)

[Figure 30-41-101]. Plug the ports with metal caps. The
1
caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the P-90238
pump mechanical neutral setting.
Turn the adjustment screw (Item 1) [Figure 30-41-103]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-104
P-90238
1
While holding the adjustment screw (Item 1) in position,

P-90238 tighten the lock nut (Item 2) [Figure 30-41-106] to 30
Turn the adjustment screw (Item 1) [Figure 30-41-104] Shut the loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the hydraulic hose from the X1 and X2 ports on
adjustment screw. the pump. Install the plugs and tighten to 25 N•m (18 ft-
lb) torque.
Figure 30-41-105
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 N•m (18

ft-lb) torque.
NOTE: The Hydraulic Controller Neutral Adjustment

must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41-
36.)
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment aligns the

pump swash plate and the control spool so that a zero 1
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted, removed or after the pump mechanical neutral
setting is adjusted. The pump mechanical neutral setting
must be correct before performing the hydraulic controller
neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic 1

controller. Procedure is the same for the right P-90239
side hydraulic controller, with the exception
of the following procedures. Disconnect the
electrical connectors for the right side Disconnect the wire harness (Item 1) [Figure 30-41-107]
hydraulic controller and connect pressure from the controller being adjusted.
gauges in the X1 and X2 ports on the right
side of the pump. Figure 30-41-108

10-10-1.)
1
WARNING
2
W-2017-0286
P-90226
Raise the lift arms, and install an approved lift arm
Remove the X1 plug (Item 1) and X2 plug (Item 2)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 30-41-108] from the side of the hydrostatic pump
being adjusted.
7217666 on Page 10-61-1.)

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-109
P-90236

P-64975 clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Install 3447 kPa (34 bar) (500 psi) pressure gauges in the
X1 and X2 ports [Figure 30-41-109]. Figure 30-41-112
Figure 30-41-110
1
1
P-90236
P-90236
counterclockwise, until the other gauge registers an
Loosen the screw (Item 1) [Figure 30-41-110]. increase in system pressure. Mark the position of the
adjustment screw.
Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-113
P-90236

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
Figure 30-41-114
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

tighten the locking screw (Item 2) [Figure 30-41-114] to
6,1 N•m (4.5 ft-lb) torque.
Shut the loader OFF.
Remove the pressure gauges from the X1 and X2 ports

on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the wire harness to the controller.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

DRIVE BELT Stop Adjustment
Belt Adjustment See your SERVICE SCHEDULE for the correct interval to
check the idler stop adjustment. (See SERVICE
The drive belt does not need adjustment. The belt has a SCHEDULE on Page 10-70-1.)
spring loaded idler which constantly maintains the correct
belt tension. Stop the engine and open the rear door.
Figure 30-50-1
P-90470
Loosen the spring loaded idler adjustment bolt (Item 1)

and insert a breaker bar (Item 2) [Figure 30-50-1] into
the slot provided in the stop arm as shown.
Figure 30-50-2
P-90471
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-50-2] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-2] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Figure 30-50-5
Belt Replacement
Stop the engine and open the rear door. (See REAR 1
DOOR (TAILGATE) on Page 50-70-1.)
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
2
Figure 30-50-3
P-90470
1
Loosen the spring loaded idler adjustment bolt (Item 1).
Insert a breaker bar (Item 2) [Figure 30-50-5] into the
slot provided in the stop arm as shown and push breaker
bar down to release tension on drive belt.
Tighten the adjustment bolt (Item 1) [Figure 30-50-5] to

hold the spring loaded idler off the drive belt.
P-90724A
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley. Inspect the pulleys for wear.
Remove the drive belt shield bolt (Item 1) [Figure 30-50-
3]. Install new drive belt.
Figure 30-50-4 Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-50-5] and allow the idler to contact the drive
belt.
Figure 30-50-6
1
2 1
P-90467
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
P-90471
toward the back of the loader to unseat the shield from
the top and bottom drive belt shield mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-50-4]. Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-50-6] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-5] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Belt Replacement (Cont’d) Remove the engine air cleaner. (See Housing Removal
Figure 30-50-7
Remove the belt. (See Belt Replacement on Page 30-50-
Top Mounting Bolt 2.)
Figure 30-50-9
1
P-90468A
Bottom Mounting Bolt 2
P-85520
Loosen the spring loaded idler adjustment bolt (Item 1).

P-90469A Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30-
50-9] into the slot provided in the stop arm as shown and
push breaker bar down to release tension on drive belt.

Position the drive belt shield over the drive belt shield
mounting bolts and slide the drive belt shield toward the
Tighten adjustment bolt (Item 1) [Figure 30-50-9] to hold
front of the loader to fully seat the shield onto the top and
the spring loaded idler off the drive belt.
bottom mounting bolts (Items 1 and 2) [Figure 30-50-7].
Figure 30-50-10
Figure 30-50-8
1
1 2
P-85741
P-90724A

Install the drive belt shield bolt (Item 1) [Figure 30-50-8].
10].
Install the battery. (See Removal And Installation on
Remove the tensioner pulley (Item 2) [Figure 30-50-10].
Page 60-20-1.)
Installation: Apply Loctite® 243 to the mounting bolts
(Item 1) [Figure 30-50-10].

DRIVE BELT (CONT'D) Figure 30-50-13
Tensioner Pulley Disassembly And Assembly
Figure 30-50-11
1
1
1
P-90303
3 Disassembly the tensioner pulley as shown [Figure 30-

P-90306 50-13].
Inspect the parts for wear and replace as needed.

Loosen the two bolts (Item 1) [Figure 30-50-11] but do
not remove. NOTE: The wheel and arm assembly (Item 1) [Figure
30-50-13] are not serviceable and must be
Release the spring tension by allowing the adjustment replaced as a complete assembly.
plate (Item 2) to slide past the tensioner pulley stop (Item
3) [Figure 30-50-11].
Remove the two bolts (Item 1) and the adjustment plate
(Item 2) [Figure 30-50-11].
Figure 30-50-12
P-90304
Remove the pivot sleeve (Item 1) [Figure 30-50-12].

TWO-SPEED / BRAKE VALVE (S/N A3P811001 -
A3P13174 & A3P911001 - A3P912024)
Description
Figure 30-60-1
P-90507
The two-speed / brake valve (Item 1) [Figure 30-60-1] is

located on top of the chaincase in front of the hydrostatic
pump. The high range is selected by a switch located on
the right handle for manual loaders and on the left
joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts

and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE (S/N A3P811001 - Figure 30-60-2
A3P13174 & A3P911001 - A3P912024) (CONT'D)
Valve Block Removal And Installation 1
DANGER
2
2
P-90437
P-90328
Remove the steering shock (Item 1) [Figure 30-60-3].
AVOID DEATH
Mark all hydraulic hoses for proper installation.
Disconnect the five hydraulic hoses (Item 2) [Figure 30-
60-3] from the brake / two-speed valve block.
Figure 30-60-3
D-1009-0409
WARNING
1
W-2059-0598
P-90425
WARNING Disconnect the three hydraulic hoses (Item 1) [Figure

30-60-3] from the two-speed / brake valve.
W-2017-0286

1.)

TWO-SPEED / BRAKE VALVE (S/N A3P811001 -
A3P13174 & A3P911001 - A3P912024) (CONT'D)
Valve Block Removal And Installation (Cont’d)
Figure 30-60-4
P-90444

30-60-4] from the two-speed solenoid.

30-60-4] from the brake solenoid and make-up valve.
Figure 30-60-5
P-90446


A3P13174 & A3P911001 - A3P912024) (CONT'D)
Valve Block Disassembly And Assembly

1
Figure 30-60-6
1
2
1 N-22580
Inspect the back-up washers (Item 1) and O-rings (Item

2) [Figure 30-60-8] for wear and replace as needed.
P-90548
Figure 30-60-9
Mark all hydraulic hoses and fittings for proper 1

installation.
Remove the hydraulic fittings (Item 1) [Figure 30-60-6]

4
Figure 30-60-7
2
3
1
2
P-90550
Remove the two bolts (Item 1) from the brake valve

solenoid (Item 2) [Figure 30-60-9].
Remove the electrical solenoid nut (Item 3) from the

make-up solenoid (Item 4) [Figure 30-60-9].
P-90549
Assembly: Tighten the nut to 6,78 - 9,49 N•m (60 - 84 in-
lb) torque.
Remove the check valves (Items 1 and 2) [Figure 30-60-
7] from the two-speed valve.
NOTE: The check valves (Items 1 and 2) [Figure 30-

60-7] are interchangeable.

A3P13174 & A3P911001 - A3P912024) (CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-60-10
P-90552
Remove the make-up solenoid (Item 1) [Figure 30-60-

12] from the valve block.
P-90435
Figure 30-60-13
Use a test meter and test the solenoid coils (Item 1)

[Figure 30-60-10] for resistance.
The resistance value for the solenoid coil can be found on

the electrical schematic.
Figure 30-60-11
1
N-22584
Assembly: Always install new O-rings and back-up

washers [Figure 30-60-13]. Tighten the solenoid valve to
P-90551


Assembly: Always install new O-rings [Figure 30-60-

10].

A3P13174 & A3P911001 - A3P912024) (CONT'D)
Figure 30-60-14
1
P-90547
1
Use a test meter and test the solenoid (Item 1) [Figure
30-60-16] for resistance.
P-90553
brake / two-speed / brake valve. Assembly: Always install new O-rings [Figure 30-60-
10].
Inspect the O-ring [Figure 30-60-14] on the plugs and
replace as needed.
Figure 30-60-15
1
P-90554
Remove the two-speed solenoid bolts (Item 1) [Figure

30-60-15].

TWO-SPEED / BRAKE VALVE (S/N A3P813175 &
ABOVE AND S/N A3P912025 & ABOVE)
Description
Figure 30-61-1
P107947
The two-speed / brake valve (Item 1) [Figure 30-61-1] is

located on top of the chaincase in front of the hydrostatic
pump. The high range is selected by a switch located on
the hand control.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each

motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

ABOVE AND S/N A3P912025 & ABOVE) (CONT'D)
Valve Block Removal And Installation

IMPORTANT
DANGER clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)
Raise the operator cab. (See OPERATOR CAB on Page

P-90328 10-30-1.)
AVOID DEATH
Mark all hydraulic hoses for proper installation.
Figure 30-61-2
unless supported by an approved lift arm 1
support. Replace if damaged. 1
D-1009-0409
WARNING
to fall and cause injury or death. P107947
W-2059-0598
Disconnect and plug the two tubelines (Item 1) [Figure

30-61-2] from the two-speed brake valve.
WARNING
W-2017-0286

TWO-SPEED / BRAKE VALVE (S/N A3P813175 & Figure 30-61-5
Valve Block Removal And Installation (Cont’d)
Figure 30-61-3 2
1
1
P107946
Disconnect the wire harness (Item 1) [Figure 30-61-5].
P107948 Remove the two mounting bolts (Item 2) [Figure 30-61-5]

Disconnect and plug the two hydraulic hoses (Item 1) Remove the two-speed / brake block from the loader.
[Figure 30-61-3] from the two-speed brake valve.
Figure 30-61-4
P107949
Disconnect and plug the two hydraulic hoses (Item 1)

[Figure 30-61-4].

TWO-SPEED / BRAKE VALVE (S/N A3P813175 & Figure 30-61-8
Valve Block Disassembly And Assembly
Figure 30-61-6
1
1
P107100

P107098
Mark all hydraulic hoses and fittings for proper
installation. Figure 30-61-9
Remove the hydraulic fittings (Item 1) [Figure 30-61-6]

Figure 30-61-7 1
1
4
P107101
2
3
P107099
Remove the two bolts (Item 1) from the brake valve
solenoid (Item 2) [Figure 30-61-7].
Remove the electrical solenoid nut (Item 3) from the

make-up solenoid (Item 4) [Figure 30-61-7].
Assembly: Tighten the bolts (Item 1) [Figure 30-61-7] to

Assembly: Tighten the nut (Item 3) [Figure 30-61-7] to 6

N•m (53 in-lb) torque.

Figure 30-61-10
P107104
Remove the make-up solenoid (Item 1) [Figure 30-61-

10] from the valve block.
Assembly: Tighten the solenoid valve to 27 N•m (20 ft-

lb) torque.
Figure 30-61-11
1
1
2 2 2
P107103
Replace the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-61-11].

30-61-6
T770 Service Manual
DRAIN MANIFOLD Figure 30-70-2
Description
The drain manifold is an external assembly in the drain

2
circuit that returns the hydraulic oil to the reservoir.
Drain Manifold Removal And Installation

1
IMPORTANT 2
2
P100002
damage the system. Disconnect the wiring harness from the oil temperature
I-2003-0888 switch (Item 1) [Figure 30-70-2].
Raise the operator cab. (See Raising on Page 10-301.) Remove the three hoses (Item 2) [Figure 30-70-2].
Drain the hydraulic reservoir. (See Removing And Mark and cap all hoses and tubelines.
Figure 30-70-3
Figure 30-70-1
1
1
P100003
P100001
Remove the two hoses (Item 1) [Figure 30-70-3].

Remove the tubeline (Item 1) [Figure 30-70-1] from the
drain manifold. Remove the two bolts and nuts (Item 2) [Figure 30-70-3].
Mark and cap all hoses and tubelines. Mark and cap all hoses and tubelines.

30-70-2
T770 Service Manual
DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Sprocket Removal And Installation (Two-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) . . . . . . . . . . . 40-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2

Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-12
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-13
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-14
TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

40-02
T770 Service Manual
BRAKE
Description
WARNING
Figure 40-10-1
W-2059-0598

1
Figure 40-10-2
P-85426
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the left panel.
Block Removal And Installation

DANGER
1 P-85428

10-2] located on the side of the transmission.
P-90328
AVOID DEATH
D-1009-0409

BRAKE (CONT'D) Block Disassembly And Assembly
Block Removal And Installation (Cont'd) Figure 40-10-5
Figure 40-10-3
1
2
P-85431
P-85427
Loosen the electrical brake solenoid nut (Item 1) and the
three fittings (Item 2) [Figure 40-10-5].
Disconnect and cap the tube line (Item 1) [Figure 40-10-
3] from the rear of the brake valve. Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48
- 60 in-lb) torque.
Figure 40-10-4
Figure 40-10-6
2 2
1
1 1
1
1 3
P-85430
P-85429
Mark the hydraulic hoses for proper installation.

Remove the solenoid nut (Item 1) and solenoid coil (Item
Remove and cap the four hydraulic hoses (Item 1) 2) [Figure 40-10-6].
[Figure 40-10-4].
Remove the solenoid valve (Item 3) [Figure 40-10-6]
Remove the two mount bolts (Item 2) [Figure 40-10-4]. from the block.
Remove the brake block from the loader.

BRAKE (CONT'D)
Block Disassembly And Assembly (Cont’d)
Figure 40-10-7
1
2 1
2 1
2 3
P-85432
Replace the O-rings (Item 1) and back-up rings (Item 2)

[Figure 40-10-7] on the solenoid valve.
Inspect the screens (Item 3) [Figure 40-10-7] and clean

with solvent.
Assembly: Tighten the solenoid valve to 21,7 - 27,1 N•m


40-10-4
T770 Service Manual
BRAKE (TWO-SPEED)
Description
Figure 40-11-1
P-85413
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-11-1]
located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure oil to
the brakes. The charge pressure oil pushes the spring
away from the brake discs allowing the drive motor to
move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure oil to hold the spring away from the brake discs.
When the hold signal is interrupted the solenoid will close

the circuit and the charge oil will be shut off an the spring
will apply the brakes. This will happen if the engine rpm
drops below a set rpm, the seat bar sensor fails or if there
is a break in the wires for the brake block solenoid.
For more information on the brake. (See TWO-SPEED /

BRAKE VALVE (S/N A3P811001 - A3P13174 &
A3P911001 - A3P912024) on Page 30-60-1.)

.
40-11-2
T770 Service Manual
TRACK UNDERCARRIAGE COMPONENTS (SOLID-
MOUNTED)
Description
Figure 40-20-1
MS2786S
The track carriage components consist of front and rear

idlers, rollers, the track, track tensioner, the drive sprocket
and the track housing [Figure 40-20-1].

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Figure 40-20-3
MOUNTED) (CONT'D)
Checking Tension
Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
prematurely.
1
NOTE: The wear of track rollers vary with the working
conditions and different types of soil
conditions.
Park the loader on a level surface.
Figure 40-20-2
P-85869A
Figure 40-20-4
Track
13 - 16 mm Roller
(1/2 - 5/8 in)
P-85243C
Track
Raise one side of the loader and put jackstands at the B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-20-2].
Lower the loader to the jackstands. Be sure the DO NOT put your fingers into the pinch points between
jackstands do not touch the tracks. the track and the roller. Use a 13 - 16 mm (1/2 - 5/8 in)
bolt, dowel or block to check the gap [Figure 40-20-3]
Measure the track sag at the middle track roller (Item 1) and [Figure 40-20-4].
[Figure 40-20-2]. The correct gap is 13 - 16 mm (1/2 - 5/
8 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

MOUNTED) (CONT'D)
Adjusting Tension
Figure 40-20-5
2 1
1
2 P-76047
Pressure must be released from the grease cylinder to

1 decrease track tension.
P-76325
Install the bleed tool (MEL1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-20-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-20-5]. Figure 40-20-7
NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-20-5] is used to remove grease. 1
Increase Track Tension
Add grease to the grease fitting (Item 1) [Figure 40-20-5]

until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].
NOTE: Do not remove grease fitting unless pressure
P-76837
is released using the bleed fitting. (See
[Figure 40-20-6] on Page 40-20-3)
NOTE: If replacement is necessary, always replace Tighten the access cover bolt (Item 1) [Figure 40-20-7]
grease fitting (Item 1) [Figure 40-20-5] with to secure the tool.
genuine Bobcat Parts. The fitting is a special
fitting designed for high pressure. Turn the tool 90° counterclockwise and let the grease
flow into a container. Release pressure [Figure 40-20-7]
Decrease Track Tension until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].
WARNING Tighten the bleed fitting. Pivot the access cover closed
and tighten the access cover bolts.
HIGH PRESSURE GREASE CAN Raise the loader. Remove the jackstands.
CAUSE SERIOUS INJURY
• Do not loosen grease fitting. Repeat the procedure for the other track.
• Do not loosen bleed fitting more than 1 - 1/2
turns. Dispose of grease in an environmentally safe manner.
W-2781-0109

TRACK UNDERCARRIAGE COMPONENTS (SOLID-
MOUNTED) (CONT'D)
Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,
DANGER grease, etc. must be disposed of in an

environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 1/4 turn. This will allow the grease
P-90328 to flow out faster when lifting the track in the next step.
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-20-8]
• Disconnecting or loosening any hydraulic before continuing.
D-1009-0409
1.)
1
WARNING P-85416

the lift arms are secured by an approved lift arm With a chain hoist, lift on the track moving the front idler
support device. Failure to use an approved lift arm assembly toward the rear of the track assembly until all
support device can allow the lift arms or attachment track tension has been released [Figure 40-20-8].
W-2059-0598 Tighten the bleed fitting using the MEL1560 tool (Item 1)
[Figure 40-20-8].
Decrease the track tension. (See Adjusting Tension on
Page 40-20-3.)
NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76 mm (3 in).

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Put the track on the front idler wheel.
MOUNTED) (CONT'D)
Adjust the track to the proper tension. (See Adjusting
Track Removal And Installation (Cont’d) Tension on Page 40-20-3.)
Figure 40-20-9 NOTE: The grease tube must be completely retracted

against the coil spring assembly before
adding grease, to prevent air from being
trapped in the grease tube.
NOTE: Check the alignment of the grease tube (Item

1) [Figure 40-20-19] before adjusting the track.
P-85370
With pry bars, pry the track up and over the front idler
[Figure 40-20-9].
Completely remove the track from the front track

assembly.
Figure 40-20-10
P-85417
With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-20-10].
To install the rubber track:
Completely retract the front idler and track tensioner.
Put the track over the rear drive sprocket lugs.
Put the track over the rear idler.
Slide the track under the rollers.

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation
1 1
1.)
Remove the track. (See Track Removal And Installation

on Page 40-20-4.)
Figure 40-20-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

[Figure 40-20-13] may be inserted to keep the front idler
wheel in place until the track is installed.
1 NOTE: The bolts must be removed before completing

track installation. It will not be possible to
remove the bolts after track tension has been
set.
P-76843
Slide the front idler wheel out of the track housing
[Figure 40-20-11].
NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-20-11] is toward the top of the
track housing for installation.
Figure 40-20-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-20-

12] on the front idler wheel frame engage the holes in the
track tensioner (Item 1) [Figure 40-20-14].

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation (Cont’d)
Figure 40-20-14
P-76325
Installation: Track tensioner must be seated properly

1 against the end of the track housing [Figure 40-20-16].
P-85418
Slide the track tensioner (Item 1) [Figure 40-20-14] out

of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-20-14] before sliding it into the track
housing.
Figure 40-20-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-20-15].

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation (Cont'd) CORRECT
Figure 40-20-17
WRONG
2 2
1
1
P-85014A
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
P-85371 against the coil spring assembly (Item 2) [Figure 40-20-
19].
Figure 40-20-18
WRONG
1
P-85014
Installation: [Figure 40-20-17] and [Figure 40-20-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-20-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

MOUNTED) (CONT'D)
Track Tensioner Disassembly And Assembly
WARNING 4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
(Item 3), and wear ring (Item 4) [Figure 40-20-21] from
AVOID INJURY OR DEATH the grease tube.
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to new O-ring, back-up ring, seal,
• Do not disassemble the coil spring assembly. and wear ring before installation.
W-2617-1004
Installation: Apply grease to area between seal and O-

Figure 40-20-20 ring before installing.
NOTE: The grease tube must be completely retracted

onto the chrome shaft before replacing the

2 grease fitting and adding grease, to prevent
air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-20-20].

MOUNTED) (CONT'D)
Track Tensioner Disassembly And Assembly (Cont’d) 8
WARNING
1 2 3 4 5 6 7
P-85019
Inspect and replace any damaged parts.

P-62574
AVOID INJURY OR DEATH 1. Coil Spring Assembly

• Spring loaded components under pressure can 2. O-ring
cause serious injury or death. 3. Chrome Shaft
• Do not disassemble the coil spring assembly. 4. Seal
W-2617-1004 5. Back-up Ring
6. O-ring
Figure 40-20-22 7. Wear Ring
8. Grease Tube
1
NOTE: The O-ring (Item 2) is used to secure the
chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-20-23] during the
installation of the track tensioner into the
track housing.
P-85372
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 4536 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

20-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Roller Removal And Installation
MOUNTED) (CONT'D)
Remove the track from the loader. (See Track Removal
Idler (Rear) Removal And Installation And Installation on Page 40-20-4.)
Remove the track. (See Track Removal And Installation Figure 40-20-25
on Page 40-20-4.)
Figure 40-20-24
1
1
1
1
2
2 P-85421
P-76847 Remove the bolts (Item 1) [Figure 40-20-25] from the

roller shaft. (Both ends of the roller shaft.)
Remove the two mount bolts and washers (Item 1) Installation: Tighten the bolts or nuts to 410 - 450 N•m
[Figure 40-20-24]. (300 - 330 ft-lb) torque.
Remove the rear idler from the loader.

Remove the roller from the track assembly.
Installation: Align the square sides of the idler shaft with

the notches in the track housing (Item 2) [Figure 40-20-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 407 - 447


TRACK UNDERCARRIAGE COMPONENTS (ROLLER Sprocket Removal And Installation (Two-Speed)
SUSPENSION) (CONT'D)
Figure 40-20-27
Sprocket Removal And Installation (Single Speed)
Figure 40-20-26 1
2
2
1
2
2
2
P100737A
2
P-85407 Remove the eight nuts (Item 1) [Figure 40-20-27] and

remove the drive sprocket from the motor.
Remove the six nuts (Item 1) [Figure 40-20-26] and NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in
remove the drive sprocket from the motor. the sprocket holes (Item 2) [Figure 40-20-27]
to aid in the removal of the sprocket.
NOTE: Install three (1/2” - 13UNC x 3 in) long bolts in
the sprocket holes (Item 2) [Figure 40-20-26] Installation: Tighten the nuts to 492 - 544 N•m (363 -
to aid in the removal of the sprocket. 401 ft-lb) torque.
Installation: Tighten the nuts to 280 - 300 N•m (207 -
222 ft-lb) torque.

MOUNTED) (CONT'D)
Track Housing Removal And Installation
NOTE: Jackstands used when removing the track

must not interfere with track housing removal. 1

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-2.)
Support the track housing.

P-76864
Figure 40-20-28
At the rear of the loader remove the two mount bolts

1 (Item 1) [Figure 40-20-29].
Installation: Tighten the mount bolts to 410 - 450 N•m

Figure 40-20-30
1
P-85409

from the bottom track housing mount plate. (At the front
and rear of the loader.)

P-85408
At the front of the loader remove the two mount bolts

(Item 1) [Figure 40-20-30].
Remove the track housing from the loader.


40-20-14
T770 Service Manual
TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION)
Description
Figure 40-21-1
P-85368
The track carriage components consist of front and rear

idlers, rollers, leaf springs, the track, track tensioner, the
drive sprocket and the track housing [Figure 40-21-1].

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-21-3
Checking Tension
Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
prematurely.
NOTE: The wear of track rollers vary with the working

conditions and different types of soil
conditions.
Park the loader on a level surface.
Figure 40-21-2
P-85379A
Figure 40-21-4
Track
13 mm Roller
(1/2 in)
1
P100726A
Track
Raise one side of the loader and put jackstands at the B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-21-2].
Lower the loader to the jackstands. Be sure the DO NOT put your fingers into the pinch points between
jackstands do not touch the tracks. the track and the roller. Use a 13 mm (1/2 in) bolt, dowel
or block to check the gap [Figure 40-21-3] and [Figure
Measure the track sag at either middle track roller (Item 40-21-4].
1) [Figure 40-21-2]. The correct gap is 13 mm (1/2 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

Adjusting Tension
Figure 40-21-5
2 1
1
2 P-76047
Pressure must be released from the grease cylinder to

1 decrease track tension.
P-76325
Install the bleed tool (MEL1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-21-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-21-5]. Figure 40-21-7
NOTE: Fittings may be oriented differently than
shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-21-5] is used to remove grease.

1
Increase Track Tension
Add grease to the grease fitting (Item 1) [Figure 40-21-5]

[Figure 40-21-4].
NOTE: Do not remove grease fitting unless pressure

is released using the bleed fitting. (See P-76837
[Figure 40-21-6] on Page 40-21-3)
NOTE: If replacement is necessary, always replace Tighten the access cover bolt (Item 1) [Figure 40-21-7]
grease fitting (Item 1) [Figure 40-21-5] with to secure the tool.
genuine Bobcat Parts. The fitting is a special
fitting designed for high pressure. Turn the tool 90° counterclockwise and let the grease
Decrease Track Tension flow into a container. Release pressure [Figure 40-21-7]
[Figure 40-21-4].
WARNING Tighten the bleed fitting. Pivot the access cover closed
and tighten the access cover bolts.
HIGH PRESSURE GREASE CAN Raise the loader. Remove the jackstands.
CAUSE SERIOUS INJURY
• Do not loosen grease fitting. Repeat the procedure for the other track.
• Do not loosen bleed fitting more than 1 - 1/2
turns. Dispose of grease in an environmentally safe manner.
W-2781-0109

Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,
DANGER grease, etc. must be disposed of in an

environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 1/4 turn. This will allow the grease
P-90328 to flow out faster when lifting the track in the next step.
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-21-7]
• Disconnecting or loosening any hydraulic before continuing.
D-1009-0409
1.)
Raise the lift arms and install an approved lift arm 1

WARNING P-85380

the lift arms are secured by an approved lift arm With a chain hoist, lift on the track moving the front idler
support device. Failure to use an approved lift arm assembly toward the rear of the track housing assembly
support device can allow the lift arms or attachment until all track tension has been released [Figure 40-21-
to fall and cause injury or death. 8].
W-2059-0598
Tighten the bleed fitting using the MEL1560 tool (Item 1)
Decrease the track tension. (See Adjusting Tension on [Figure 40-21-8].
Page 40-21-3.)
NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76 mm (3 in).

Track Removal And Installation (Cont’d)
Figure 40-21-9
P-85369
With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-21-10].
P-85370
Installation: Completely retract the front idler / track
tensioner.
With pry bars, pry the track up and over the front idler
[Figure 40-21-9]. Put the track on the front idler wheel.
Completely remove the track from the front track Put the track over the rear drive sprocket lugs.
assembly.
Slide the track under the rollers.
Put the track over the rear idler.
NOTE: Check the alignment of the grease tube (Item

1) [Figure 40-21-19] before adjusting the track.
Adjust the track to the proper tension. (See Adjusting

Tension on Page 40-21-3.)

Idler (Front) Removal And Installation
1 1
Remove the track. (See Track Removal And Installation
on Page 40-21-4.)
Figure 40-21-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

1 [Figure 40-21-13] may be inserted to keep the front idler
wheel in place until the track is installed.
NOTE: The bolts must be removed before completing

P-76843 track installation. It will not be possible to
remove the bolts after track tension has been
set.
Slide the front idler wheel out of the track housing
[Figure 40-21-11].
NOTE: The notch on the front idler wheel frame (Item
1) [Figure 40-21-11] is toward the top of the
track housing for installation.
Figure 40-21-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-21-

12] on the front idler wheel frame engage the holes in the
track tensioner.

Idler (Front) Removal And Installation (Cont’d)
Figure 40-21-14
P-76325
Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-21-16].
P-76844
Slide the track tensioner (Item 1) [Figure 40-21-14] out

of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-21-14] before sliding it into the track
housing.
Figure 40-21-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-21-15].

Idler (Front) Removal And Installation (Cont'd) CORRECT
Figure 40-21-17
WRONG
2 2
1
1
P-85014A
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
P-85371 against the coil spring assembly (Item 2) [Figure 40-21-
19].
Figure 40-21-18
WRONG
1
P-85014
Installation: [Figure 40-21-17] and [Figure 40-21-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-21-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

Track Tensioner Disassembly And Assembly
WARNING 4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
(Item 3), and wear ring (Item 4) [Figure 40-21-21] from
AVOID INJURY OR DEATH the grease tube.
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to new O-ring, back-up ring, seal,
• Do not disassemble the coil spring assembly. and wear ring before installation.
W-2617-1004
Installation: Apply grease to area between seal and O-

Figure 40-21-20 ring before installing.
NOTE: The grease tube must be completely retracted

onto the chrome shaft before replacing the

2 grease fitting and adding grease, to prevent
air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-21-20].

Track Tensioner Disassembly And Assembly (Cont’d) 8
WARNING
1 2 3 4 5 6 7
P-85019

P-62574
AVOID INJURY OR DEATH 1. Coil Spring Assembly

• Spring loaded components under pressure can 2. O-ring
cause serious injury or death. 3. Chrome Shaft
• Do not disassemble the coil spring assembly. 4. Seal
W-2617-1004 5. Back-up Ring
6. O-ring
Figure 40-21-22 7. Wear Ring
8. Grease Tube
1
NOTE: The O-ring (Item 2) is used to secure the
chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-21-23] during the
installation of the track tensioner into the
track housing.
P-85372
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 4536 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

21-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Roller Removal And Installation
Idler (Rear) Removal And Installation And Installation on Page 40-21-4.)
Remove the track. (See Track Removal And Installation Figure 40-21-25
on Page 40-21-4.)
Figure 40-21-24
1
1
2
2 P-85374
P-76847 Remove the bolt and washer (Item 1) [Figure 40-21-25]

from the roller shaft. (Both ends of the roller shaft.)
Remove the two mount bolts and washers (Item 1) Remove the roller from the track assembly.
[Figure 40-21-24].
Installation: Support the roller from underneath with a
Remove the rear idler from the loader.
hydraulic floor jack and tighten the bolts to 711,5 N•m

(525 ft-lb) torque.
Installation: Align the square sides of the idler shaft with
the notches in the track housing (Item 2) [Figure 40-21-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 711,5 N•m

(525 ft-lb) torque.

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Installation: Tighten the leaf spring bolts (Item 2)
SUSPENSION) (CONT'D) [Figure 40-21-26] and (Item 1) [Figure 40-21-27] to 237
Leaf Spring Removal And Installation
Figure 40-21-28
Figure 40-21-26
1
3
P-76930
Remove the leaf spring assembly [Figure 40-21-28] from

P-85375 the track housing.
NOTE: The leaf spring assembly [Figure 40-21-28] is

Remove the roller bolt and washer (Item 1) [Figure 40- only sold as a complete left-hand or right
21-26] from the roller shaft. (Both ends of the roller hand assembly from Bobcat Parts.
shaft.)
Figure 40-21-29
Remove the roller from the track housing.
Installation: Support the roller from underneath with a

hydraulic floor jack and tighten the bolts to 711,5 N•m
(525 ft-lb) torque.
Remove the leaf spring bolts (Item 2) [Figure 40-21-26]

from the leaf spring mounts. (Both sides of the track
housing.) 1
Figure 40-21-27
P-76027
The upper and lower leaf spring mounts are wider on one
1 side to prevent the leafs from rubbing on the track
housing during operation.
Installation: The leaf springs are installed correctly

when there is a slight gap (Item 1) [Figure 40-21-29]
P-85377 between the leafs and the track housing. (Cutaway view
shown for clarity.) The gap is easily seen at the roller end
of the leaf spring (Item 3) [Figure 40-21-26].
Access the front, inside leaf spring assembly bolts (Item
1) [Figure 40-21-27] from underneath the loader through
an access hole in the track housing.

Sprocket Removal And Installation
Figure 40-21-30
1
2
P-85407
Remove the six nuts (Item 1) [Figure 40-21-30] and

remove the drive sprocket from the motor.
NOTE: Install three (1/2” - 13UNC x 3 in) long bolts in

the sprocket holes (Item 2) [Figure 40-21-30]
to aid in the removal of the sprocket.
Installation: Tighten the nuts to 280 - 300 N•m (207 -

222 ft-lb) torque.

Track Housing Removal And Installation
NOTE: Jackstands used when removing the track

must not interfere with track housing removal. 1

Remove the hydrostatic motor from the track housing.

Support the track housing.

P-76864
Figure 40-21-31
At the rear of the loader remove the two mount bolts

(Item 1) [Figure 40-21-32].
1
Figure 40-21-33
P-85422

from the bottom track housing mount plate. (At the front
and rear of the loader.)

P-85408
At the front of the loader remove the two mount bolts

(Item 1) [Figure 40-21-33].
Remove the track housing from the loader.


TRACK MAINTENANCE Driving over sharp objects should be avoided. If this
is impossible, do not make turns while driving over
Track Damage Identification sharp objects.
The following pages show photos and illustrations of Cutting Of Steel Cords
track damage and the probable cause of the damage. It
is intended to be used for identifying the reason for track Figure 40-30-2
damage and how to avoid future track damage.
Track and Sprocket Rotation:
Figure 40-30-1
Move Sprockets to opposite sides of the loader
P-3864
Remove track
Reinstall 180° Figure 40-30-3
P-85440
NOTE: All applications and conditions will cause

wear on the track inbeds and sprocket teeth.
Rotating the tracks and sprockets will extend Steel Cords
their life. The track can be removed and PI-13034
reinstalled 180 degrees. The sprocket can be
removed and installed on the opposite side of
the loader [Figure 40-30-1]. Damage:
Prevention: Embedded steel cords are cut off [Figure 40-30-2]

and [Figure 40-30-3].
The following preventions should be taken to minimize
the risk of this damage:
Recommended track tension should be periodically

checked. (See DRIVE SYSTEM TOC on Page 40-
01.)
Avoiding quick turns on bumpy and rocky fields.
Drive carefully to avoid having stones and other

articles clog the rubber tracks.

TRACK MAINTENANCE (CONT'D) Causes of the damage:
Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 40-30-4
Rubber tracks are driven with an extraordinary heavy
load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
P-3865 Figure 40-30-6
Damage:
Embedded metals will gradually wear away by friction Minimum Wear

[Figure 40-30-4].
Figure 40-30-5
Excessive Wear
PI-13037A
Track Rotation:
Certain applications or conditions can cause wear on the

track inbeds and sprocket teeth. Rotating the tracks 180
degrees will help extend track life [Figure 40-30-6]. (See
PI-13037 Track Damage Identification on Page 40-30-1.)
Remove the track and rotate it 180 degrees on the same

Replacement: side of the loader. (See DRIVE SYSTEM TOC on Page
40-01.)
When track embedded metals are worn
approximately 50% or more, replace the track.
Example of excessive wear is shown in [Figure 40-
30-4] and [Figure 40-30-5].

TRACK MAINTENANCE (CONT'D) Figure 40-30-8
Track Damage Identification (Cont'd)
Separation Of Embedded Metals
Figure 40-30-7
Idler
Rubber
track
PI-13039
Causes of the damage:
Embedded metals are adhered between the steel cords

P-4379 and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:
Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded embedded metals, the embedded metals will
metals cause their separation from the rubber track's eventually peel off [Figure 40-30-8].
body [Figure 40-30-7].
Figure 40-30-9
Replacement:
Even a partial separation of embedded metals

requires replacement of the track.
Guide
PI-13040
When a rubber track is detracked, it becomes stuck

between the guide or the undercarriage frame,
causing the separation of embedded metals [Figure
40-30-9].

Figure 40-30-10
Minimum
wear
Excessive
wear
PI-13041A
Sprocket Rotation:
PI-13041
Certain applications or conditions can cause wear on the
sprockets. Rotating the sprockets to the opposite side of
Excessively worn sprockets, example shown [Figure the loader will help extend sprocket life [Figure 40-30-
40-30-10] will pull embedded metals out of the track. 11]. (See Track Damage Identification on Page 40-30-1.)
Prevention: Remove the sprocket. (See DRIVE SYSTEM TOC on

Page 40-01.)
Similar to the prevention against the cutting of the steel
cords:
Recommended track tension should be periodically
checked. (See DRIVE SYSTEM TOC on Page 40-
01.)
Quick turns on bumpy and rocky fields should be

avoided.

Track Damage Identification (Cont'd) Embedded metal
Separation Of Embedded Metals Due To Corrosion
Figure 40-30-12
Good
Separation of
bonded rubber
cover
PI-13043
Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the
Damage: rubber body [Figure 40-30-13].
Due to corrosion of embedded metals, the adhesion Excessively salty fields, like the sea shore
to the rubber body deteriorates, resulting in complete
separation [Figure 40-30-12]. Strong acidic or alkali soil conditions
Replacement: Compost spread grounds
Even a partial separation of embedded metals On tracks that are out of adjustment, the track rollers,
requires a rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
Prevention:
If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.
When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.

Cuts On The Lug Side Rubber Cuts
Figure 40-30-14
PI-13045
When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 40-30-14]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-30-15].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately Machine operators are requested to drive with great
repaired with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-30-16 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.
Figure 40-30-17 Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.

Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-30-16] and [Figure 40-30-
17].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.

Track Damage Identification (Cont'd) Lug abrasion is more or less inevitable. Even if lug
abrasion is proceeding, the rubber track can be used.
Lug Abrasion However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
Figure 40-30-18 abraded tracks with new ones when the lug height
becomes less than 5 MM.
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads
Driving up and down hilly paths with slippage
Making frequent turns on paths covered with rocks

P-4381 and wood
Figure 40-30-19
Lug abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-30-18] and [Figure
40-30-19].
Replacement:
No replacement is required.

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-30-20 embedded metal rubber
PI-13051
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
Damage: [Figure 40-30-21].
Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-30-20]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested

Replacement: to avoid driving over stumps and ridges.
Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.

Abrasion Of The Track Roller Side

Track roller
Figure 40-30-22
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
Damage: the side of the rubber track to cause the abrasion [Figure
40-30-23].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-30-22]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

Cuts On The Edges Of Track Roller Side
Figure 40-30-24
PI-13056
This damage is caused by objects on the field or by

P-4384 interference with the machine frame.
In case of damage by objects on the operating ground:

Figure 40-30-25
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage

Edge Edge easily occurs [Figure 40-30-26].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-30-24] and
[Figure 40-30-25].
Replacement:
In such case, the rubber track does not have to be

replaced.

TRACK MAINTENANCE (CONT'D)
Cuts On The Edges Of Track Roller Side (Cont’d)
Figure 40-30-27
Cut
Tear
PI-13057
In case of damage by interference with the machine

frame
If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-30-27].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.

MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1


RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

SEAT BAR Figure 50-10-2
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
The seat bar is located in the operator cab.

1
Figure 50-10-1
P-85652
Remove the seat bar mounting nuts (Item 1) [Figure 50-

1 10-2] (both sides).
Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-

lb) torque.
2 Lower the operator cab. (See Lowering on Page 10-30-

3.)
P-85653 P-85654 Figure 50-10-3

Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
1
Lower the seat bar.
P-90021
Remove the seat bar (Item 1) [Figure 50-10-3] from the

operator cab.
Reverse the above procedure to install the seat bar into

the operator cab.

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023
4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)
Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®

#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

50-10-4
T770 Service Manual
OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or 1
death.
W-2113-0288

P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].
Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
Figure 50-20-1 1
3
1
P-85652
Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Removal And Installation
Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.).
Figure 50-20-5
3 2
1
1
2 1
P-85661
P100756
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4]. Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: Apply a small amount of thread-locker on
the threads of the gas spring rod before installing the Figure 50-20-6
clevis (Item 1) [Figure 50-20-4].
1
WARNING
AVOID INJURY 2
Cylinders for raising and lowering operator cab have
1
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
P100879
Disconnect the expansion / heater unit O-ring connectors

(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve with
plugs to prevent coolant loss from the
system.

OPERATOR CAB (CONT’D) Figure 50-20-8
Figure 50-20-7
1
P-85663
1
Disconnect the cab harness connector screw (Item 1)

P103082 [Figure 50-20-8].
Installation: Tighten the connector screw to 3,39 - 3,96

Disconnect the two A/C hoses (Item 1) [Figure 50-20-7]. N•m (30 - 35 in-lb) torque.
Cap and plug the hoses and expansion valve fittings with
proper A/C caps and plugs.
Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)

torque.
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Remove the engine speed control cable from the cab.

(See Cable Removal And Installation on Page 70-20-2.)
Remove the operator cab gas spring(s). (See Gas Spring

NOTE: Use the hoist connected to the operator cab

grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

OPERATOR CAB (CONT’D)
Figure 50-20-9
P-85658
Remove the two cab mount bolts and nuts (Item 1)

[Figure 50-20-9] from both sides of the cab.
Installation: Tighten the cab mount bolts and nuts to

24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
Figure 50-20-10
P-85662
Using a strap and a hoist remove the cab from the loader
[Figure 50-20-10]

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-30-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure
Remove the four seat mounting nuts (Item 1) [Figure 50- 50-30-2].
30-1] and washers from the operator seat mounting
studs. Figure 50-30-3

3.)
Remove the seat. 2
NOTE: With the seat removed, the cab may raise.
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-30-3].
Remove the slide rail (Item 2) [Figure 50-30-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-30-6
Figure 50-30-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-30-6].
Remove the nut (Item 1) [Figure 50-30-4] from the seat
belt mount.
Figure 50-30-5
1
P-85772
Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-30-9
Figure 50-30-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
30-7]. the seat back to the upright position.
Figure 50-30-8 Remove the back cushion from the seat

1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-30-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-30-10
Figure 50-30-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) Remove the mounting nut (Item 1) [Figure 50-30-11].
Remove the seat shock clips (Item 1) [Figure 50-30-10]. Remove the end release buckle (Item 2) [Figure 50-30-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-30-10]. Figure 50-30-12
2
P-85784
Remove the mounting nut (Item 1) [Figure 50-30-12].
Remove the seat belt retractor (Item 2) [Figure 50-30-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-30-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-30-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-30-15].
13].
Figure 50-30-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].

50-30-6
T770 Service Manual
BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
The Bob-Tach is located on the front of the loader

connected to the loader lift arms.
Figure 50-40-1 P-85649
1
P-85554
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5
Figure 50-40-3
1 P-31405
Replace O-ring (Item 1) [Figure 50-40-5] on the grease

P-31402 plug.
Figure 50-40-6
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
1
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Removal And Installation (Cont’d) Figure 50-40-9
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 Figure 50-40-10
ft-lb) torque.
Figure 50-40-8
2
P-85665
1
P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-40-8]

and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd) 4
Figure 50-40-11
1 3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.
Remove the bolt and replace the damaged parts as

Use a punch and hammer to remove the roll pin (Item 1) needed.
[Figure 50-40-11] from the Bob-Tach wedge and spring
clevis. Assembly: Clean threads and apply Loctite® 242 to the
bolt (Item 1) [Figure 50-40-13], torque to 88,0 - 95,0 N•m
Remove the spring clevis assembly (Item 2) [Figure 50- (65 - 70 ft-lb).
40-11].
Figure 50-40-12
P-85667
Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach.
Always replace bent or broken wedges.

BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-14
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)
Use a seal pick to remove seal (Item 1) [Figure 50-40-

14] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-14]

with a driver tool and hammer.
Figure 50-40-15
3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-40-15].

50-40-6
T770 Service Manual
BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

40 ft-lb) torque.
Figure 50-41-3
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649

BOB-TACH (POWER) (CONT’D) Figure 50-41-8
Figure 50-41-6
P-31406
1
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Replace the O-ring (Item 1) [Figure 50-41-6] on the [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
grease plug. ft-lb) torque.

1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.

BOB-TACH (POWER) (CONT'D) Figure 50-41-12
Lever And Wedge Disassembly And Assembly
Figure 50-41-10
1 1 2
P-85665
Remove the washer and spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-12].
Figure 50-41-13
Remove the washers and bolts (Item 1) [Figure 50-41-
10] from the cylinder (both ends).

lb) torque.
Remove the cylinder from the lever pivots.
1
Figure 50-41-11
P-85666
1 Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-41-13] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

11].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.

BOB-TACH (POWER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14
2 1
P-85669
P-85667 Remove the Power Bob-Tach. (See Removal And

Remove the wedge (Item 1) [Figure 50-41-14] out the Use a seal pick to remove seal (Item 1) [Figure 50-41-
bottom of the Bob-Tach. 16] from the Bob-Tach.
Always replace bent or broken wedges. Remove and replace bushing (Item 2) [Figure 50-41-16]
with a driver tool and hammer.
Figure 50-41-15
Figure 50-41-17
4 3
1
2
3 2
1
P-85668
NA5472
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-15] are damaged, put the Installation: The seal (Item 1) needs to be seated in the
assembly in a vise. Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-41-17].
Remove the bolt and replace the damaged parts as
needed.
Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-41-15], torque to 88, - 95,0 N•m
(65 - 70 ft-lb).

50-41-6
T770 Service Manual
LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4
P-90592A
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].
Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT'D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1
P-90611

P-85692 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being
removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.

50-50-6
T770 Service Manual
REAR GRILLE Installing
Removing Figure 50-60-3
Figure 50-60-1
P100807
P100808
Align the tabs of the two side covers into the slots in the
loader frame and lower [Figure 50-60-3].
Flip the lockable handle (Item 1) [Figure 50-60-1] up and
turn the handle 90° counterclockwise. Lift and pull the Figure 50-60-4
rear grille backward to remove from the loader.
Figure 50-60-2
P-85604
P100809A Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
Lift and remove the two side covers (Item 1) [Figure 50- Turn the lockable handle 90° clockwise and fold the
60-2]. handle down [Figure 50-60-1].

50-60-2
T770 Service Manual
REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
3
2
P-85695
1
Remove the top and bottom door hinge mounting bolts

P-85697 and nuts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness. [Figure 50-70-3].
Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the mounting bolts and nuts to 34 -
the door. (See Rear Removal And Installation on Page 38 N•m (25 - 28 ft-lb) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2 flat on the floor.
1 1
P-90585
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation

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-85698A
Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].
Remove the striker assembly from the loader.
Striker Disassembly And Assembly P-85698A
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
5 50-70-6].
Align the striker assembly in the center of the mounting

3 4 holes.
2 1
NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P106584
Tighten both striker mount bolts (Item 1) [Figure 50-70-
6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Remove the bolt (Item 2) spacer (Item 3) and roller (Item
4) from the bracket (Item 5) [Figure 50-70-5].
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation (Early Models)
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.
Remove the bolt and nut (Item 2) [Figure 50-70-7] from

the latch.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-12
Latch Removal And Installation (Later Models)
Figure 50-70-10
1
2
1
P109094
Remove the door handle (Item 1) [Figure 50-70-12] from

P109092 the rear door.

Remove the bolt (Item 1) and nut (Item 2) [Figure 50-70-
10] from the latch.
Installation: Tighten the bolt (Item 1) and nut (Item 2) to

34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-70-11
2
1
P109093
Remove the spacer (Item 1) [Figure 50-70-11] from the

latch.

latch.

FUEL TANK Figure 50-80-2
WARNING 1

explosion or fire.
W-2103-0508
P-85713
1.)
Remove the drain plug (Item 1) [Figure 50-80-2].
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on Drain the fuel into a container.
Page 70-10-7.)
Figure 50-80-3
Figure 50-80-1
1
1
1
P-85707
P-85714
Disconnect the fuel vent hose (Item 1) and remove the

Remove the three mount bolts (Item 1) [Figure 50-80-1] two bolts (Item 2) [Figure 50-80-3].
from the access cover at the rear of the loader frame.
Remove the access cover.

FUEL TANK (CONT'D) Figure 50-80-6
Figure 50-80-4
4
1 1
2 3
2
P-85709
1
Remove the two mounting bolts (Item 1) and the bracket
P-85708 (Item 2) [Figure 50-80-6].
Figure 50-80-7
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].
NOTE: Mark the fuel lines for correct installation.

50-80-4] from the fuel level sender.
1
Remove the two mounting bolts (Item 3) and remove the
bracket (Item 4) [Figure 50-80-4].
Figure 50-80-5 1
1 P-85711
At the right side of the loader, remove the two main frame
1
mount bolts and nuts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount bolts to 542 -

583 N•m (400 - 430 ft-lb) torque.
P-85710
Remove the bolts (Item 1) [Figure 50-80-5] from the

battery hold down plate.
Remove the hold down plate from the loader.

FUEL TANK (CONT'D) Fuel Level Sender Removal And Installation
Removal And Installation (Cont'd) Lift and block the loader. (See Procedure on page 10-10-
1.)
Figure 50-80-8
Page 70-10-7).
Figure 50-80-9
1
1
P-85712
At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-8].
P-85708
Installation: Tighten the main frame mount bolts to 542 -
583 N•m (400 - 430 ft-lb) torque.
Lift the fuel tank and remove it from the loader frame. 50-80-9] from the fuel level sender.
NOTE: When installing the fuel tank, avoid striking Remove the fuel level sender.
the tank with heavy objects to prevent
damage. Figure 50-80-10
P-85716
Inspect the fuel level sender and replace if worn or

damaged.

FUEL TANK (CONT'D)
Fuel Fill Screen Removal And Installation
Figure 50-80-11
P-85707
Remove the two bolts (Item 1), disconnect the fuel fill and
vent hoses (Item 2) [Figure 50-80-11].
Figure 50-80-12
1
P-85715
Remove the fuel fill screen (Item 1) [Figure 50-80-12].
Inspect and replace as needed.

CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
WARNING P100782
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-90-2

DANGER
1
P100783
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P100786 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the bolt and nut (Item 1) [Figure 50-90-3] to 90-6].
disconnect the lift pedal linkage from the crossbar.
Figure 50-90-6
Figure 50-90-4
2
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) The pedals should be positioned at a comfortable angle
so full movement of the pedal can be reached easily
Linkage Removal And Installation (Cont’d) while properly sitting in the loader seat.
1
2
1
P100782 P100783
Remove the bolt (Item 1) [Figure 50-90-7] and nut from Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
the pedal linkage. from the pedal mounting bracket.
Remove the linkage (Item 2) [Figure 50-90-7]. Figure 50-90-10
Figure 50-90-8
1
1
2
P100782
P-85675A
Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage. Inspect the bushing in the pedal for wear and replace as
needed.
Remove the linkage (Item 2) [Figure 50-90-8].
Tilt the pedal back and forth until an acceptable “neutral”
Pedal (Adjusting) angle is achieved on the pedal.
After installing the pedal, adjust the pedal angle so that Tighten the two nuts (Item 2) and pivot bolt (Item 1)
there is clearance under the rear of the pedal. The valve [Figure 50-90-10] on the pedal assembly to standard
spool must travel full stroke without the pedal hitting the torque.
floor panel.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11
1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.
to fall and cause injury or death. Figure 50-91-2
W-2059-0598

support device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.
Figure 50-91-4 P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]

from the pedal mounting bracket.
Figure 50-91-6
1
1
P-90981 2
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot.
P-85675
Repeat for other side.
Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7
1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].

50-91-4
T770 Service Manual
CONTROL PANEL
Description
Figure 50-100-1
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-100-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-100-3

• Keep out of this area when lift arms are raised 2
D-1009-0409
WARNING
the lift arms are secured by an approved lift arm P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598 the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Figure 50-100-4
Figure 50-100-6
2
1
1 1
2
2 2
P-90612
1 1
P-85864
Scribe a mark across the top of the steering linkage bars

(Item 1) [Figure 50-100-4] which are connected to the Remove the nuts (Item 1) and the steering stabilizers
steering shaft on the control panel. (Item 2) [Figure 50-100-6].
Remove the four steering linkage mounting bolts, nuts

and rubber isolators (Item 2) [Figure 50-100-4].
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-100-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Disassembly And Assembly (Cont’d)
Figure 50-100-7 2
2 2
1
3 1 3 3 P-85867
3
Remove the four bolts (Item 1) [Figure 50-100-9] from

P-85865 the control panel.
Remove the control handle assembly (Item 2) [Figure

Figure 50-100-8 50-100-9].
Figure 50-100-10
3
2
1
1
P-85861
P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50-
100-8]. Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8]. Remove the control handle (Item 4) [Figure 50-100-10].

CONTROL PANEL (CONT'D) Linkage Removal And Installation

W-2059-0598
1 2 1
WARNING
P-85872
Remove the two bolts (Item 1) from the bellcrank (Item 2) fall or move and cause injury or death.
[Figure 50-100-11]. W-2017-0286
Remove the bellcrank from the bracket [Figure 50-100- Lift and block the loader. (See Procedure on Page 10-10-
11]. 1.)
Figure 50-100-12 Raise the lift arms and install an approved lift arm

2
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-11] for wear and
replace as need.
Repeat the procedure for the other control handle

assembly.

Linkage Removal And Installation (Cont’d)

1
Figure 50-100-13
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-100-14].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-13] which are connected to the Installation: Tighten the centering spring bolt and a
steering shaft on the control panel. NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-100-15
and rubber isolators (Item 2) [Figure 50-100-13].
1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-10.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-15] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-100-16
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect for wear on the centering blocks (Item 1) [Figure
P-48630 50-100-17].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-100-17]. Remove the centering
of the following parts: blocks.
ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -

54,2 N•m (35 - 40 ft-lb) torque.
1 Bolt
2 Bushings NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer NOTE: If the centering blocks are worn, they can be
5 Spring removed and rotated 180 degrees and
6 Lock Nut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-100-18
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-20].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-20].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-21
18] from the pintle.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Figure 50-100-19 2
1 3
1
2 P-48659
4
3 NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-100-21].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-100-21]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the bolt and nut (Item 1) [Figure 50-100-19].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the linkage neutral
steering control lever (Item 4) for damage and replace as adjusting procedure must be performed. (See
needed [Figure 50-100-19]. Linkage Neutral (Adjusting) on Page 50-100-
10.)
NOTE: The washers (Item 2) [Figure 50-100-19] are
hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (CONT'D) NOTE: Anti-sieze should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-22 Figure 50-100-24
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) to catch the
for damage [Figure 50-100-22]. torsion bushing [Figure 50-100-24].
Inspect the torsion bushing (Item 4) [Figure 50-100-22] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-24] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-23 arm should be the same.
4
2
P-54626
Remove the base pintle (Item 1) [Figure 50-100-23] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) from the base pintle
[Figure 50-100-23].
Inspect parts for wear and damage, replace as needed

[Figure 50-100-23].

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
MEL1563 or 7217666 Remote Start Tool Kit 1
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT- MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)

1.) P-85845
Figure 50-100-25
Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing.
3
Figure 50-100-27
1
2
1
2
P-48450A
Tool that may assist in the neutral adjustment [Figure 50-

100-25]. P-54613
To make this tool use a locking grip C-Clamp and grind

one edge flat (Item 1) and grind the other edge (Item 2) Loosen the nut (Item 1) only until the tension is released
[Figure 50-100-25] to a small rounded edge. from the torsion bushing (Item 2) [Figure 50-100-27].
A steering centering block (Item 3) [Figure 50-100-25] is NOTE: The bolt must be loose enough to allow the
also needed. The centering block can be placed as torsion bushing (Item 2) [Figure 50-100-27] to
shown and welded to the C-clamp if desired. turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-28
W-2017-0286
1
loader. (See REMOTE START TOOL KIT- MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.

2
Move the traction lock override switch so the traction
P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-100-28] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine startup to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-29
Tighten bolts (Item 3) [Figure 50-100-29] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-100-28] and
[Figure 50-100-29].
1
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-25] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
29] around both centering blocks.
Lock the C-Clamp in place.

CONTROL PANEL (CONT'D) NOTE: This procedure is shown for neutral
adjustment on the left side of the loader. The
Linkage Neutral (Adjusting) (Cont’d) procedure is the same for the right side
neutral adjustment.
Start the neutral adjustment procedure with the left
pump first and complete the neutral adjustment for Turn the adjustment screw (Item 1) [Figure 50-100-31]
the left pump before adjusting the right pump. counterclockwise until forward creep is seen.
Figure 50-100-30 Turn the adjustment screw (Item 1) [Figure 50-100-31] to

a point between forward and reverse where there is zero
creep.
Stroke the left steering lever to forward and allow the

2 1 lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.
P-48632
Loosen the left pump pintle adjustment lock bolts

(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-30].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
NOTE: If the bolts are too loose or too tight, the

neutral adjustment may be affected.
Figure 50-100-31
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-32
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-32] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre-applied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-14.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, check the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-34
1
WARNING
2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-34].
Pre-load tension in the torsion bushings must be The bolts must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-34] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-35
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-37].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-35] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-36 Figure 50-100-38
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-100-36]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-38].
Verify the cam mounting nuts (Item 4) [Figure 50-100-36]

are tightened to 48 - 54 N•m (35 - 40 ft-lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-39
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-100-41].

P-85844
Figure 50-100-42
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
39] on each steering linkage bar. 2
Figure 50-100-40
1
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-42].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-100-
40]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Inspect the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-43 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,05 m (10

ft) of “drift” in 30,48 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in.
Tighten the two bolts and nuts (Item 1) [Figure 50-100- If the drift is excessive to the right, turn the left
43] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-44 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-46
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-100-46]

from the end of the shocks connected to the steering
linkages.
Remove the mounting nuts (Item 2) [Figure 50-100-46]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-101-1]

DANGER that secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-
101-2].
Remove the lift arm bypass knob and rubber washer

WARNING (Item 2) [Figure 50-101-2].
Remove the control panel (Item 3) [Figure 50-101-2].

W-2059-0598

50-101-2
T770 Service Manual
CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-110-1
2
3
P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-110-2
P-85883A
Remove the rubber boot (Item 1) [Figure 50-110-2].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-111-1 1
P-85882
P-21879
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector.[Figure 50-111-3].
Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.
Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)

torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 neutral and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2
P-21882 [Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-13] from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
P16534 111-14] from the handle assembly.
Installation: Tighten the allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-111-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A
Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC)
Description
The control panel has two electronic handles that control

the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.
Joystick Testing
See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to check function.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-1.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890
Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 47,5 - 54,2 N•m


ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item
2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer (Item [Figure 50-120-2] from the front access panel.
2), and remove the left access panel (Item 3) [Figure 50-
120-1]. Remove the front access panel from the loader.
Remove the front access panel from the loader.

50-120-2
T770 Service Manual
ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
2 1
2
P-90587
P100731
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1]. Figure 50-121-4
Figure 50-121-2
2
3 2
2
1
1
1
2
P-90588
P100732
NOTE: Mark the location of the foot pedal before
removal for correct assembly.
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Loosen the bolt and remove the engine speed control
pedal (Item 1), and remove the mounting screws (Item 2)
[Figure 50-121-4].
Remove the right inside access panel (Item 3) [Figure

50-121-4].

50-121-2
T770 Service Manual
WINDOW (REAR) Disassembly And Assembly
WARNING
1
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-2019-0907
P-85705
Figure 50-130-1
Remove the screw (Item 1) from the latch [Figure 50-

130-2].
Installation: Tighten the screw (Item 1) [Figure 50-130-

2] to 21 - 23 N•m (180 - 200 in-lb) torque.
1 1
Figure 50-130-3
8
7
1
P-85706
6
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] in until they disengage
from the window frame. 2
3
4
Push the rear window out the rear of the operator cab. 5
P-85704A
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. Inspect and replace any damaged parts.
Clean the area before installing the rear window The items listed below refer to [Figure 50-130-3].
assembly.
1. Latch
Reverse the procedure to install the rear window.
2. Spacer
3. Bushing
4. O-ring (factory installed on later models)
5. Washer
6. Screw
7. Rear Window
8. Seal

50-130-2
T770 Service Manual
WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].
Figure 50-131-4
Figure 50-131-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].
Tighten the nuts (Item 1) [Figure 50-131-5] to 9 - 10 N•m

NOTE: Allow two hours of cure time before exposing
to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

1 1
Figure 50-132-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.
Figure 50-132-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.

50-132-2
T770 Service Manual
CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

installed kit. 1
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
2
P-85781A
2 1
Open the cab door.

Disconnect electrical connector (Item 2) and washer fluid

Figure 50-140-2
2
3
2 1
1
P-85837
P-85588A P-85589A
Remove the four bolts and nuts (Item 2) [Figure 50-140-

Rotate and pull the clip (Item 1) out of the gas spring 4] from the cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. Remove the hinges (Item 1) [Figure 50-140-4] from the
cab.
Installation: Install the hinges (Item 1) on the cab and

use the bolts and nuts (Item 2) [Figure 50-140-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].
2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-
140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-140-

4.)
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
1
1
P-85413
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P-85831
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837
Adjustable armrests (Item 1) [Figure 50-150-1].


ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.
P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the nut (Item 3) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the Joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8
1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

Disassembly And Assembly (Cont’d) LATER MODELS
Figure 50-150-9
EARLY MODELS
3
2
1
3
2
P100825
1
Figure 50-150-12
P-90842
LATER MODELS
Figure 50-150-10
EARLY MODELS
4
7
6 3
5
2
1
3
6
5 2 P100824
4 1
Remove the nut (Item 1), washer (Item 2), and the plastic
P-90843 washer (Item 3) [Figure 50-150-11] and [Figure 50-150-
12].
Remove the nut (Item 1), washer (Item 2), and the plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10].
Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

ARMREST (CONT’D)
Figure 50-150-13
ALL MODELS
1 1
P-90844
Remove the two nuts (Item 1) and the slide rail (Item 2)
[Figure 50-150-13] from the armrest mount.
Repeat for the other side.


50-150-6
T770 Service Manual
LEFT SIDE LOWER PANEL Figure 50-160-3
Raise the operator’s cab.
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1

30-4.)
Lower the operator’s cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].
Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-160-9 1
1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.
Figure 50-160-13
1
P-90864

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operator’s cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4
Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new when it has been removed.
side of the cab far enough to access the wire
harness. Figure 50-170-8
Figure 50-170-6
2 1
1
P-90877
2
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove
the radio from the right side lower panel.
Disconnect the wire harnesses (Item 1) and the antenna
(Item 2) [Figure 50-170-6] (if equipped with radio). Installation: Insert a screwdriver into the slot (Item 2)
[Figure 50-170-8] to lock the tab into place.
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.
Remove the input from the right side lower panel.
Figure 50-170-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.

50-170-4
T770 Service Manual
HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if

P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation on Page 60-60-2.)
2) [Figure 50-180-1] (if equipped).
Figure 50-180-4
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
1
1
Figure 50-180-2
1
1
2
1 P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
Installation: Route the cab light wire harness in the

P-90894 grove on the topside of the headliner (if equipped with
HVAC).
Remove the air duct (Item 1) [Figure 50-180-2] (if NOTE: Replace the retainers if needed.
equipped).

50-180-2
T770 Service Manual
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-12
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-13
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-13
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3

60-06
T770 Service Manual
CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C423 BUCKET POSITION 2 13 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C425 BRAKE SOLENOID 3 7 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C434-1 LEFT WORKLIGHT 1 2 11
C106 ENGINE SPEED SENSOR 2 6 C434-2 LEFT WORKLIGHT 2 2 11 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C435-1 RIGHT WORKLIGHT 1 2 11 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C435-2 RIGHT WORKLIGHT 2 2 11 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C437 TWO SPEED MAKEUP 2 13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C110 ALTERNATOR 2 6 C441 TWO SPEED 2 13
C112 HYD OIL FILTER SWITCH 2 7 C446 HYDRAULIC FAN 2 7 SW1 BRAKE SWITCH 6 8
C126 HORN 2 13 C449 LEFT JOYSTICK (CAB HARN) 4 5 SW2 BEACON SWITCH 6 13
C129 CAB ACCESSORY 3 9 C450 RIGHT JOYSTICK (CAB HARN) 4 5 SW3 HAZARD SWITCH 6 13
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW6 BUCKET POSITION SWITCH 6 13
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW9 TRAVEL CONTROL SWITCH 6 8
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW10 BLOWER SWITCH 5 12
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW11 AC SWITCH 3 12
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8 T1 BATT GROUND 1 4
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8 T2 BUZZER GROUND 1 8
C404 BU ALARM-MFR HARN 2 3,10 C602 LEFT REAR TAIL LIGHT 2 11 T3 FLASHER 2 13
C405 AIR FILTER SWITCH 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 T6 BATT GROUND 1 4
C406 FUEL SENDER 2 6 C606 POWER BOBTACH OPEN 2 13 T8 BATT GROUND 1 4
C408 CAB - MFR HARN CONNECTOR 48 3-5,8,9,11-13 C607 POWER BOBTACH CLOSE 2 13 T13 BUZZER POWER 1 8
C409 RIGHT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T14 PRE HEATER 1 6
C410 LEFT HANDLE 10 10 C611 BLOWER MOTOR 4 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C630 THERMOSTAT 3 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C635 HEATER VALVE 6 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C415 HIGH FLOW SOLENOID 2 13 C667 DOOR 6 9 T18 LEFT REAR WORK LIGHT (-) 1 11
C418 FRONT ROD (MALE) 2 7 C670 EXTERIOR BEACON 6 13 T19 BACKUP ALARM 1 10
C419 FRONT BASE (FEMALE) 2 7 C676 RADIO 6 13 T20 BACKUP ALARM (GND) 1 10
C420 HYD LOCK 2 7
C421 TILT SPOOL LOCK 3 10
C422 TILT SPOOL LCOK 3 10
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
BATTERY GROUND
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
WIRING SCHEMATIC
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
(STANDARD MACHINE)
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
Sheet 1 of 13
(PRINTED NOVEMBER 2010)
Printed In U.S.A. 7197683
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 A-29
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

EXMF 7199263
MAINFRAME
LF 7196823
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TAILGATE DOM 7175271
TRK BRAKE ADP 7165061
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 2 of 13
1240/RED/WHT WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SHEET 8 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1400/RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB-MFR HARN SHEET 9
C667 DOOR HARNESS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1450/RED/WHT 17 1450/RED/WHT 1420/RED/WHT BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
SHEET 8
C500 RH KEY SWITCH CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
FC1 FUSE CENTER 1440/RED/WHT MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
2 SHEET 8
FUSE 1 25 A 1110/RED/WHT J1B HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C479 LH PANEL
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
+12V 1025/RED
FUSE 2 25 A
1160/RED/WHT 1150/RED/WHT 3
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
100.0 Amps FUSE 3 OPEN COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATT_CABLE
LEGEND
SCHEMATIC INDEX
FUSE 4 OPEN PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
1010/RED
SHEET 6 CAN BUS PAGE 5
STARTER FC2 FUSE CENTER ENGINE PAGE 6
CONNECTOR
FUSE 1 25 A HYDRAULICS PAGE 7
1190/RED 1165/RED/WHT CAB DISPLAY PAGE 8
SHEET 5
C426 REMOTE RUN, ACD CAB PAGE 9
FUSE 2 25 A MANUAL CONTROLS PAGE 10
1040/RED 1490/RED/WHT 1410/RED/WHT WIRE BREAK
SHEET 13
(TWO WIRE BREAKS LIGHTS PAGE 11
C408 CAB-MFR CONN (OPTIONS)
FUSE 3 OPEN JOIN ONE WIRE) HVAC PAGE 12
1460/RED/WHT
SHEET 13 SHEET # OPTIONS PAGE 13
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
1290/RED 1370/RED/WHT
SHEET 9 SJC PAGE 15
C408 CAB-MFR CONN (ACCESSORIES)
FRC1 FUSE RELAY CENTER
1050/RED
FUSE 5 30 A
1350/RED/WHT
SHEET 6
SHEET 6 1060/RED FRC1 FUEL SHUTOFF RELAY
FUSE 6 30 A
FRC1 PRE HEATER RELAY 1310/RED 1360/RED/WHT
SHEET 7
1030/RED FRC1 TRACTION LOCK RELAY
SHEET 6
FUSE 9 15 A 1320/RED/WHT
FRC1 STARTER RELAY
SHEET 11
FRC1 REAR LIGH RELAY
1340/RED SHEET 11
FRC1 FRONT LIGHT RELAY
C404
FUSE 11 25 A BU ALARM-MFR HARN 1620/RNG/WHT
1300/RED 1140/RED/WHT 1720/RNG/WHT B SHEET 8
SHEET 12 (SEE ADDITIONAL C479 LH PANEL
FUSE1 25 A FRC1 HVAC RELAY OPTIONS SHEET)
1750/RNG/WHT 1940/RNG/WHT
SHEET 8
A T13 LH PANEL BUZZER
1760/RNG/WHT FUSE 2 25 A 1850/RNG/WHT 1780/RNG/WHT C489
SHEET 9 MFR ACCESSORY 1930/RNG/WHT
C408 CAB-MFR CONN (FR WIPER) SHEET 8
FUSE 3 15 A C499 RH PANEL PTOL
1550/RNG/WHT C408
SHEET 13 1775/RNG/WHT
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
FUSE4 5 A 1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
43
SHEET 8
1530/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
C410 LEFT HANDLE
1570/RNG/WHT 1520/RNG/WHT 1950/RNG/WHT
SHEET 10 SHEET 8
C409 RIGHT HANDLE J2B C500 RH PANEL KEY SWITCH
FUSE 7 25 A 1560/RNG/WHT 22
1795/RNG/WHT 1730/RNG/WHT AUX CTRLR
SHEET 9
C426 REMOTE RUN, ACD SW4 H/ISO SWITCH
FUSE 8 25 A
FRC1 1580/RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050/RED 30
87
J1A
GWY CTRLR 1790/RNG/WHT
C110 ALT EXCITATION
SHEET 12
WIRING SCHEMATIC
2055/BLK 85 86 3380/LBL 4 C408 FRC1 HVAC RELAY
SHEET 6
SHEET 12
2030/BLK
CAB-MFR HARN (STANDARD MACHINE)
1920/RNG/WHT 6 1920/RNG/WHT 1840/RNG/WHT
1830/RNG/WHT
SHEET 5
C449 LH JOYSTICK T770 (S/N A3P811001 AND ABOVE)
SHEET 5
C450 RH JOYSTICK (S/N A3P911001 AND ABOVE)
Sheet 3 of 13
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
ACS PAGE 14
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SJC PAGE 15
2080/BLK
SHEET 5
C449 LH JOYSTICK
2070/BLK
SHEET 5
C450 RH JOYSTICK
2920/BLK C408
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940/BLK 2950/BLK 32 2950/BLK
SHEET 8
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8 2765/BLK
C503 RH DELUXE PANEL SHEET 11
16 2540/BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745/BLK BATT GND
2550/BLK 2090/BLK SHEET 12
2930/BLK AUX CTRLR
SHEET 8 C408 CAB-MFR CONN (HVAC)
SW1 BRAKE SWITCH 2790/BLK
2830/BLK 2900/BLK 42 2900/BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SW6 BKT POSITION SWITCH
2780/BLK
SHEET 8 2700/BLK SHEET 13
SW9 TRAVEL CONTROL SWITCH C408 CAB-MFR CONN (OPTIONS)
2785/BLK 2730/BLK
SHEET 13 SHEET 9
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
SHEET 11 2105/BLK
2620/BLK
SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630/BLK C489
SHEET 11 TAILGATE HARN B 2720/BLK
T18 LH REAR LIGHT MFR ACCESSORY
2650/BLK 2600/BLK B 2600/BLK
SHEET 10
T20 BU ALARM 2400/BLK 2390/BLK
SHEET 6
2640/BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200/BLK
C602 LH REAR LIGHT SHEET 7
2610/BLK C425 BRAKE
SHEET 11 2770/BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455/BLK
2170/BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710/BLK 2300/BLK
2160/BRN SHEET 5
SHEET 6 C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320/BRN
SHEET 7
C112 HYD OIL FILTER SWITCH
2370/BRN J1B
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR
SHEET 7
2220/BRN
C108 HYD TEMP SENDER
2230/BRN 17
WIRING SCHEMATIC
SHEET 7 2190/BRN
C105 HYD CHG PRESSURE SENDER
(STANDARD MACHINE)
SHEET 6
2180/BRN T770 (S/N A3P811001 AND ABOVE)
C355 FUEL HARN (FUEL SENDER)
SHEET 6
2140/BRN (S/N A3P911001 AND ABOVE)
C107 ENG OIL PRESS SENDER
2150/BRN
Sheet 4 of 13
SHEET 6
C405 AIR FILTER SWITCH (PRINTED NOVEMBER 2010)
Printed In U.S.A.
7197683
Page 647 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off LEGEND
CAN BUS
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 (TWO WIRE BREAKS * DLX CAB HARN 7196753 ONLY
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7165991)
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200/PUR 9270/PUR 9230/PUR 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4

CAN LO C479
9 9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 7 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426 9260/PUR 4
Remote Run Tool, ACD C503
9160/PUR/WHT 2 RIGHT DELUXE PANEL
14 9500/PUR/WHT A
CAN HI
20 9600/PUR B
CAN LO
21 3090/LBL D REMOTE RUN KEY 1830/RNG/WHT 1
C SHEET 3
SHEET 3
1730/RNG/WHT E SWITCHED POWER SHEET 4
2070/BLK
9560/PUR/WHT
2
3
* C450
RIGHT JOYSTICK
1165/RED/WHT F (SJC/AWS ONLY)
SHEET 3 UNSWITCHED POWER 9660/PUR 4
2710/BLK G GROUND 9220/PUR 8
SHEET 4 J2B
9120/PUR/WHT 9
AUX CTRLR
1840/RNG/WHT 1
SHEET 3
SHEET 4
2080/BLK
9540/PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640/PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 5 of 13
LEGEND
ENGINE
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
FRC1
STARTER RELAY C109
30 S/R ADAPTER STARTER
1030/RED A
SHEET 3 87 8200/TAN TAN S M
B SHEET 3
3560/LBL B TAN R
85 86 8210/TAN 1015/RED
SHEET 12 2005/BLK
C110
B S 1020/RED
ALTERNATOR G
L 1800/RNG/WHT
SHEET 3
EXCITATION
2015/BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100/TAN B
1350/RED/WHT 30 8120/TAN PULL 0.33 OHM
SHEET 3 87 3410/LBL
2400/BLK 2800/BLK C GND
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 8800/TAN A HOLD
24.5 OHM
FRC1 T14
GLOW PLUG PRE HEATER
RELAY 8500/TAN
1060/RED 30
SHEET 3 87
2016/BLK 85 86
2055/BLK
SHEET 3
6 8510/TAN
14 3420/LBL
3 8110/TAN
30 3410/LBL
7 8210/TAN
22 3560/LBL
C107
5140/YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140/LBL C SIG ENGINE OIL PRESSURE
2140/BRN A GND SENDER (0.5-4.5V)
SHEET 4
C405
2150/BRN B GND
SHEET 4 AIR FILTER
16 3150/LBL A SIG
SWITCH (NC)
C106
15 3160/LBL A
B
SIG
ENGINE SPEED SENSOR
WIRING SCHEMATIC
SHEET 4 2160/BRN GND
(163 OHM)
C104
(STANDARD MACHINE)
ENGINE COOLANT
18
SHEET 4 2170/BRN
3170/LBL
B
A
GND
SIG
SENSOR (500-3000 OHM)
(8 VOLT)
4 8800/TAN
J1B C355
GWY CTRLR FUEL HARN
C406
Sheet 6 of 13
12 3180/LBL C 3180/LBL OR 3100, LBL A SIG
2180/BRN D 2180/BRN OR 3110, LBL B GND
FUEL SENDER (PRINTED NOVEMBER 2010)
SHEET 4 (30 - 270 OHM)

LEGEND
PARTIAL CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
HYDRAULICS
GROUND PAGE 4
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS PAGE 11 (TWO WIRE BREAKS
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 13 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100/LGN 4200/LGN A 4200/LGN A SOLENOID
RELAY TRACK 2 SPEED
2200/BLK C 2200/BLK B 9.8 OHM ADAPTER (SEE
1360/RED/WHT 30 SHEET 4
SHEET 3 3430/LBL 12 V ADDITIONAL
87
2025/BLK WHEEL 2 SPD ADAPTER HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035/BLK 4110/LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
C WHEEL SINGLE SPEED
8
TRACTION LOCK
13
C108
2220/BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 4
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND HYDRAULIC
SHEET 4
3190/LBL C SIG CHARGE
5190/YEL A +8V PWR PRESSURE
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A 18 2330/BRN 2 GND FRONT ROD
AUX CTRLR
4330/LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
WIRING SCHEMATIC
1 2340/BRN
C419
2 GND
(STANDARD MACHINE)
FRONT BASE
4340/LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM T770 (S/N A3P811001 AND ABOVE)
19 13
J2B
Sheet 7 of 13
AUX CTRLR
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CAN BUS PAGE 5
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 6 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
CAB DISPLAY PAGE 8
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
* DLX CAB HARN 7196753 ONLY
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14
SJC PAGE 15
T13
BUZZER (+)
C499
LEFT PANEL
Press To Operate Loader
7040/WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930/RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940/BLK 3
7040/WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920/BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960/RNG/WHT 1440/RED/WHT 1 20 3030/LBL 1 3030/LBL OR 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
*
SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5 SWITCHED POWER
J1A
19 2380/BRN 37 2380/BRN OR 9370, PUR 4
PTOL LED
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT
SHEET 13 GWY CTRLR
C500
5 6 3500/LBL 8
SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
4
2700/BLK 2 3 3650/LBL 7 24 8130/TAN 4 8130/TAN OR 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
3600/LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040/LBL 40 4
3040/LBL OR 9350, PUR RUN/ENTER SWITCH
3610/LBL OR 9310, PUR 4 5 GWY CTRLR
SHEET 3 1775/RNG/WHT 6
1950/RNG/WHT 5
SHEET 4 2930/BLK C480 SHEET 3 SWITCHED POWER
LEFT PANEL (GRAY) 1420/RED/WHT 1
SHEET 3 UNSWITCHED POWER
3620/LBL 12 2960/BLK 3
SHEET 9 DOOR SIGNAL SHEET 4 GROUND
11
10
9 C503
3610/LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590/RNG/WHT 5
7 SHEET 3 SWITCHED POWER
6 1240/RED/WHT 1
5 2250/BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 8 of 13

PARTIAL CONNECTOR
CAB
GROUND PAGE 4
HYDRAULICS PAGE 7
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC
OPTIONS
PAGE 12
PAGE 13
JOIN ONE WIRE)
SHEET #
(NOT IN STD CAB HARN 7165991)
ACS PAGE 14
SJC PAGE 15
*
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 3 3
2060/BLK 5 6
SHEET 9
4
C408
CAB-MFR HARN
2
3
4235/LGN
4275/LGN
*C212
POWER
SOCKET
5 4550/LGN 2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
2790/BLK 24 2790/BLK 2790/BLK 2010/BLK

* C209
B GND
SHEET 4
1370/RED/WHT 23 1370/RED/WHT 1390/RED/WHT A +12V PWR DOME
SHEET 3
3640/LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210/RED/WHT A +12V BATT PWR
1580/RNG/WHT 16 1580/RNG/WHT 1865/RNG/WHT B +12V SW PWR
SHEET 3
2820/BLK C GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT SHEET 13
2210/BLK SHEET 13
2885/BLK SHEET 13
2060/BLK
SHEET 4
2730/BLK 33 2730/BLK
SHEET 9
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620/LBL 3630/LBL 4
SHEET 8 DOOR SIGNAL
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
6
1850/RNG/WHT 27 1850/RNG/WHT 1850/RNG/WHT 1

SHEET 3 WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
2370/BRN 45 2370/BRN OR 3910, LBL A GND SENSOR 7310/WHT 3
WASHER SIGNAL
11 3370/LBL 46 3370/LBL OR 3920, LBL B SIG * C252

L SIG
+5V
24 5100/YEL 5370/YEL 44 5370/YEL OR 3900, LBL C +5V PWR 2845/BLK X GND
WASHER
MOTOR WIRING SCHEMATIC
SHEET 6 5140/YEL
(STANDARD MACHINE)
Sheet 9 of 13
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
ACS PAGE 14
SJC PAGE 15
C409
RIGHT HANDLE
J2A
K
AUX CTRLR G
1520/RNG/WHT A
SHEET 3
30 4940/LGN H
C404 31 4930/LGN J SKI CTRL
C103
BU ALARM-MFR HARN 4920/LGN E
TAILGATE HARN DETENT FLOW
T19 TERMINAL (+) 13 4910/LGN F
(SEE ADDITIONAL A 7100/WHT C 7100/WHT TWO SPD
OPTIONS SHEET)
4310/LGN C
BACK UP
4320/LGN D PWM
2650/BLK ALARM
SHEET 4 4300/LGN B (8 VOLT)
T20 TERMINAL (-)
21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670/BRN 3 GND D
GWY CTRLR 4670/LGN 1 SIG TILT SPOOL LOCK 28 4840/LGN C
2 7.8 OHM 12V 22 4830/LGN B SKI CTRL
12 4820/LGN G
C422 11 4810/LGN F SIDE SHIFT
2 2680/BRN 3 GND 1530/RNG/WHT A
LIFT SPOOL LOCK SHEET 3
4680/LGN 1 SIG J
7.8 OHM 12V
2 H
E
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 10 of 13
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 SHEET #
ACS PAGE 14
SJC PAGE 15 C434-1
2735/BLK B GND LEFT FRONT
6100/PNK A SIG WORK LIGHT
C408
37.00 Watts
CAB-MFR HARN
C434-2
2765/BLK 28 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000/PNK 25 6000/PNK 6120/PNK A SIG RIGHT FRONT
2760/BLK B GND WORK LIGHT
37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
2610/BLK 2 GND
1330/RED/WHT 30 SHEET 4 RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 SIG
2640/BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 4 RIGHT REAR
6210/PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
RELAY
1320/RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200/PNK H 6200/PNK SIG LEFT REAR
2630/BLK GND WORK LIGHT
2045/BLK 85 86 SHEET 4
2035/BLK T18 TERMINAL (-)
SHEET 7
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 11 of 13
LEGEND
PARTIAL CONNECTOR
HVAC
HYDRAULICS PAGE 7
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11
WIRE BREAK
(TWO WIRE BREAKS * DLX CAB HARN 7196753 ONLY
HVAC PAGE 12 JOIN ONE WIRE)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
ACS PAGE 14
SJC PAGE 15
2440/BLK * C610
2 GND
#
DLX FUEL HARN 7184255 ONLY
HVAC DUCT
7440/WHT 1 SIG FAN (NOT IN STD FUEL HARN 7149219)
C483
2560/BLK * C BLK
7420/WHT A DBL POTENTIOMETER
7425/WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130/BLK C GND HEATER
7430/WHT A +12V PWR VALVE
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3 6
SHEET 6
2005/BLK
1790/RNG/WHT 3 7530/WHT * C611
1 14.00 Amps High
SHEET 3 7410/WHT 7520/WHT 2 7.50 Amps Med BLOWER
SW11 7510/WHT 3 5.00 Amps Low MOTOR
21 3450/LBL
SHEET 4
2745/BLK 22 2745/BLK *
AC SWITCH 2580/BLK 4
J1A 7015/WHT 1 C 7400/WHT

GWY CTRLR 2100/BLK
3
11 7021/WHT 7020/WHT 34
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570/BLK 2

SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C355
FUEL HARN #
A 7024/WHT 7025/WHT
C486
1 SIG
WIRING SCHEMATIC
2 MAGNET CLUTCH
GND
SHEET 13
2290/BLK 2280/BLK
(COMPRESSOR)
(STANDARD MACHINE)
D4
Sheet 12 of 13
OVERVIEW PAGE 1,2
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 (TWO WIRE BREAKS * DLX CAB HARN 7196753 ONLY
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
C355 #
# C607
FUEL HARN
C408
POWER 10 CAB-MFR HARN
BOB-TACH
SIG
GND
1
2
4470/LGN OR 7010, WHT
2470/OR 2770, BLK 2770/OR 2751, BLK
E
B
4470/LGN
2770/BLK
4470/LGN
4480/LGN
(NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 4
SHEET 12 2290/BLK
#
*POWER
SW5 2 1
3
C606 BOBTACH
POWER 5 4
SIG 2 2480/OR 2775, BLK SWITCH 6
BOB-TACH 1 4480/LGN OR 7000, WHT
GND F 4480/LGN 9
OPEN
1380/RED/WHT
1410/RED/WHT 26 1410/RED/WHT 1200/RED/WHT
SHEET 3
X T3
C411
B 6010/PNK 15
1430/RED/WHT
6010/PNK L
* FLASHER CONN
C 3500/LBL
SHEET 8 D1
LEFT HANDLE A 6515/PNK 6500/PNK 36 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
(BLINKER / FLASHER) E 6540/PNK
5 PIN D2 SWITCH
D 6415/PNK 6400/PNK 29 6400/PNK 6430/PNK
3400/LBL 2725/BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
INSULATED)
2850/BLK
E 6410/PNK 6
EURO TAIL LIGHTS
(SEE ADDITIONAL D 6510/PNK * C670
E
OPTIONS SHEET) 2780/BLK D
30 2780/BLK 2420/BLK BEACON/FLASHER
SHEET 4
6440/PNK F EXTERIOR HARNESS
6540/PNK B (SEE ADDITIONAL
1550/RNG/WHT 13 1550/RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820/WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450/LGN D3 4455/LGN 35 4455/LGN 1
4
2 *BUCKET
SW6 SPEAKER
-
2 7830/WHT 4
2830/BLK 5 POSITION C278 RADIO CONN
SOLENOID GND B 2450/BLK 2455/BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6 2 7810/WHT 6
RIGHT -
C126 SPEAKER 1 7800/WHT 5
SHEET 4 2785/BLK + 1885/RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885/BLK 2
LEFT HANDLE B 7210/WHT 38 7210/WHT A SIG SHEET 9 GND
HORN
(HORN) A 1460/RED/WHT
2 PIN
SHEET 3 C277
* 1
2
3
C415 1510/RNG/WHT 4 PWR
J2A HIGH FLOW SHEET 9 AIR RIDE
26 2460/BRN B GND 2210/BLK 5 GND
AUX CTRLR SOLENOID SHEET 9 SEAT
4460/LGN A SIG 6
7.5 OHM 12 V
J2B
26
AUX CTRLR
C437 WIRING SCHEMATIC

27 2360/BRN 2 GND TWO SPEED
J1A
4360/LGN 1 SIG
MAKEUP SOLENOID
8.8 OHM 12V TRACK 2 SPEED
(STANDARD MACHINE)
ADAPTER (SEE
GWY CTRLR
26 2350/BRN
C441
2 GND TWO SPEED
ADDITIONAL
OPTIONS SHEET)
SOLENOID
4350/LGN 1 SIG
5.1 OHM 12 V (S/N A3P911001 AND ABOVE)
25 26
J1B
Sheet 13 of 13
GWY CTRLR
CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C446 HYDRAULIC FAN 2 7 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C449 LEFT JOYSTICK (CAB HARN) 4 5 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C450 RIGHT JOYSTICK (CAB HARN) 4 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C453 RIGHT QUAD A DRIVE 4 15
C106 ENGINE SPEED SENSOR 2 6 C454 LEFT QUAD DRIVE 4 15 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C467 LIFT PEDAL LOCK 3 14 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C468 TILT PEDAL LOCK 3 14 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C469 TILT HANDLE 3 14 J2B AUX CONTROLLER 26 3-5,7,10,13
C110 ALTERNATOR 2 6 C470 TILT PEDAL 3 14
C112 HYD OIL FILTER SWITCH 2 7 C471 LIFT PEDAL 3 14 J1-ACS ACS CONTROLLER 8 14, 15
C126 HORN 2 13 C472 LIFT HANDLE 3 14 J2-ACS ACS CONTROLLER 10 14, 15
C129 CAB ACCESSORY 3 9 C474 BRAKE LIGHT 1 15 J3-ACS ACS CONTROLLER 10 14, 15
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 J5 DRIVE CONTROLLER 50 15
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW1 BRAKE SWITCH 6 8
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW2 BEACON SWITCH 6 13
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW3 HAZARD SWITCH 6 13
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C308 BRAKE SOLENOID 2 7 C492 ACS/SJC/AWS-MFR HARN 8 3,5,9 SW5 POWER BOBTACH SWITCH 6 13
C350 AC EVAPORATOR SWITCH 2 12 C493 ACS/SJC/AWS-MFR HARN 4, 15 3,4 SW6 BUCKET POSITION SWITCH 6 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C497 SJC HORN/BLINKER 3 13 SW9 TRAVEL CONTROL SWITCH 6 8
C404 BU ALARM-MFR HARN 2 3,10 C499 PTOL 4 8 SW10 BLOWER SWITCH 5 12
C405 AIR FILTER SWITCH 2 6 C500 RH KEY SWITCH 6 8 SW11 AC SWITCH 3 12
C406 FUEL SENDER 2 6 C501 A22 PUMP HARNESS 8 15
C408 CAB - MFR HARN CONNECTOR 48 3-5,8-9,11-13 C503 RH DLX PANEL 6 5,8 T1 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C542 LEFT SWASHPLATE 3 15 T2 BUZZER GROUND 1 8
C410 LEFT HANDLE 10 10 C543 RIGHT SWASHPLATE 3 15 T3 FLASHER 2 13
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C544 LEFT FORWARD DRIVE 2 15 T6 BATT GROUND 1 4
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C545 LEFT REVERSE DRIVE 2 15 T8 BATT GROUND 1 4
C415 HIGH FLOW SOLENOID 2 13 C546 RIGHT FORWARD DRIVE 2 15 T13 BUZZER POWER 1 8
C418 FRONT ROD (MALE) 2 7 C547 RIGHT REVERSE DRIVE 2 15 T14 PRE HEATER 1 6
C419 FRONT BASE (FEMALE) 2 7 T15 RIGHT REAR WORK LIGHT(+) 1 11
C420 HYD LOCK 2 7 T16 RIGHT REAR WORK LIGHT(-) 1 11
C440 RF BASE 2 14 C602 LEFT REAR TAIL LIGHT 2 11 T17 LEFT REAR WORK LIGHT (+) 1 11
C422 TILT SPOOL LCOK 3 10 C603 RIGHT REAR TAIL LIGHT 2 11 T18 LEFT REAR WORK LIGHT (-) 1 11
C423 BUCKET POSITION 2 13 C606 POWER BOBTACH OPEN 2 13 T19 BACKUP ALARM 1 10
C425 BRAKE SOLENOID 3 7 C607 POWER BOBTACH CLOSE 2 13 T20 BACKUP ALARM (GND) 1 10
C426 CAN (Remote Start Tool, ACD) 7 5 C610 HVAC DUCT FAN 2 12
C428 TILT ACTUATOR 8 14, 15 C611 BLOWER MOTOR 4 12
C429 LIFT ACTUATOR 8 14,15 C630 THERMOSTAT 3 12
C434-1 LEFT WORKLIGHT 1 2 11 C635 HEATER VALVE 6 12
C434-2 LEFT WORKLIGHT 2 2 11 C667 DOOR 6 9
C435-1 RIGHT WORKLIGHT 1 2 11 C670 EXTERIOR BEACON 6 13
C435-2 RIGHT WORKLIGHT 2 2 11 C676 RADIO 6 13
C437 TWO SPEED MAKEUP 2 13
C441 TWO SPEED 2 13 C707 OBW STOP BRAKE LIGHT 3 15

WIRING SCHEMATIC
move 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7 (ACS / SJC MACHINE)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9 T770 (S/N A3P811001 AND ABOVE)
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13
Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT SJC PAGE 15
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 A-29
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

EXMF 7199263
MAINFRAME
LF 7196823
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TAILGATE DOM 7175271
TRK BRAKE ADP 7165061
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 2 of 15
Printed In U.S.A. 7197682 Printable Version Click Here
1240/RED/WHT WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SHEET 8 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1400/RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB-MFR HARN SHEET 9
C667 DOOR HARNESS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1450/RED/WHT 17 1450/RED/WHT 1420/RED/WHT BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
SHEET 8
C500 RH KEY SWITCH CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
FC1 FUSE CENTER 1440/RED/WHT MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
2 SHEET 8
FUSE 1 25 A 1110/RED/WHT J1B HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C479 LH PANEL
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
+12V 1025/RED
FUSE 2 25 A
1160/RED/WHT 1150/RED/WHT 3
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
100.0 Amps COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATT_CABLE FUSE 3 25 A 1
1270/RED 1170/RED/WHT LEGEND
SCHEMATIC INDEX
C493 PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
SJC/ACS/AWS-MFR HARN
FUSE 4 25 A POWER PAGE 3
1280/RED 1235/RED/WHT 2 (4 PIN)
GROUND PAGE 4
1010/RED
SHEET 6 CAN BUS PAGE 5
STARTER FC2 FUSE CENTER ENGINE PAGE 6
CONNECTOR
FUSE 1 25 A HYDRAULICS PAGE 7
1190/RED 1165/RED/WHT CAB DISPLAY PAGE 8
SHEET 5
C426 REMOTE RUN, ACD CAB PAGE 9
FUSE 2 25 A MANUAL CONTROLS PAGE 10
1040/RED 1490/RED/WHT 1410/RED/WHT WIRE BREAK
SHEET 13
(TWO WIRE BREAKS LIGHTS PAGE 11
C408 CAB-MFR CONN (OPTIONS)
FUSE 3 OPEN JOIN ONE WIRE) HVAC PAGE 12
1460/RED/WHT
SHEET 13 SHEET # OPTIONS PAGE 13
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
1290/RED 1370/RED/WHT
SHEET 9 SJC PAGE 15
C408 CAB-MFR CONN (ACCESSORIES)
FRC1 FUSE RELAY CENTER
1050/RED
FUSE 5 30 A
1350/RED/WHT
SHEET 6
SHEET 6 1060/RED FRC1 FUEL SHUTOFF RELAY
FUSE 6 30 A
FRC1 PRE HEATER RELAY 1310/RED 1360/RED/WHT
SHEET 7
1030/RED FRC1 TRACTION LOCK RELAY
SHEET 6
FRC1 STARTER RELAY
SHEET 11
FRC1 REAR LIGH RELAY
1340/RED SHEET 11
C404
FUSE 11 25 A BU ALARM-MFR HARN 1620/RNG/WHT
1300/RED 1140/RED/WHT 1720/RNG/WHT B SHEET 8
SHEET 12 (SEE ADDITIONAL C479 LH PANEL
FUSE1 25 A FRC1 HVAC RELAY OPTIONS SHEET)
1750/RNG/WHT 1940/RNG/WHT
SHEET 8
A T13 LH PANEL BUZZER
1760/RNG/WHT FUSE 2 25 A 1850/RNG/WHT 1780/RNG/WHT C489
SHEET 9 MFR ACCESSORY 1930/RNG/WHT
C408 CAB-MFR CONN (FR WIPER) SHEET 8
FUSE 3 15 A C499 RH PANEL PTOL
1550/RNG/WHT C408
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
FUSE4 5 A 1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
43
SHEET 8
1530/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
C410 LEFT HANDLE 1950/RNG/WHT
1570/RNG/WHT 1520/RNG/WHT SHEET 10 SHEET 8
C409 RIGHT HANDLE J2B C500 RH PANEL KEY SWITCH
FUSE 7 25 A 1560/RNG/WHT 22
1795/RNG/WHT 1730/RNG/WHT AUX CTRLR
SHEET 9
C426 REMOTE RUN, ACD SW4 H/ISO SWITCH
FUSE 8 25 A
FRC1 1580/RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050/RED 30
87
J1A
GWY CTRLR 1790/RNG/WHT
C110 ALT EXCITATION WIRING SCHEMATIC
SHEET 12
85 86 FRC1 HVAC RELAY
SHEET 6
2055/BLK
2030/BLK
3380/LBL 4 C408
CAB-MFR HARN (ACS / SJC MACHINE)
SHEET 12
1920/RNG/WHT 6 1840/RNG/WHT
1920/RNG/WHT
SHEET 5
C449 LH JOYSTICK
1830/RNG/WHT
1740/RNG/WHT 6 C492
SHEET 5
C450 RH JOYSTICK (S/N A3P911001 AND ABOVE)
(8 PIN)
Sheet 3 of 15
Printed In U.S.A. 7197682 Printable Version Click Here
LEGEND
GROUND
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
C493
2080/BLK
SHEET 5 SJC/ACS/AWS-MFR HARN
C449 LH JOYSTICK (4 PIN)
2070/BLK
SHEET 5
C450 RH JOYSTICK 3 2235/BLK
2920/BLK C408 4 2240/BLK
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940/BLK 2950/BLK 32 2950/BLK
SHEET 8
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8 2765/BLK
C503 RH DELUXE PANEL SHEET 11
16 2540/BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745/BLK BATT GND
2930/BLK AUX CTRLR 2550/BLK 2090/BLK SHEET 12
SHEET 8 C408 CAB-MFR CONN (HVAC)
SW1 BRAKE SWITCH 2790/BLK
2830/BLK 2900/BLK 42 2900/BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SW6 BKT POSITION SWITCH SHEET 11 2105/BLK
2780/BLK
SHEET 8 2700/BLK FRC1 FRONT LIGHT RELAY SHEET 13
SW9 TRAVEL CONTROL SWITCH 2530/BLK 2000 C408 CAB-MFR CONN (OPTIONS)
SHEET 10
2785/BLK C409 RIGHT HANDLE 2730/BLK
SHEET 13 SHEET 9
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
SHEET 10 2520/BLK
2620/BLK C410 LEFT HANDLE

SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630/BLK C489
SHEET 11 TAILGATE HARN B 2720/BLK
T18 LH REAR LIGHT MFR ACCESSORY
2650/BLK 2600/BLK B 2600/BLK
SHEET 10
T20 BU ALARM 2400/BLK 2390/BLK
SHEET 6
2640/BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200/BLK
C602 LH REAR LIGHT SHEET 7
2610/BLK C425 BRAKE
SHEET 11 2770/BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455/BLK
2170/BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710/BLK 2300/BLK
2160/BRN SHEET 5
SHEET 6 C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320/BRN
SHEET 7
C112 HYD OIL FILTER SWITCH
2370/BRN J1B Printable Version Click Here
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR
SHEET 7
2220/BRN 2230/BRN 17 WIRING SCHEMATIC
C108 HYD TEMP SENDER
SHEET 7 2190/BRN (ACS / SJC MACHINE)

C105 HYD CHG PRESSURE SENDER
SHEET 6
2180/BRN T770 (S/N A3P811001 AND ABOVE)
C355 FUEL HARN (FUEL SENDER)
2140/BRN
SHEET 6
C107 ENG OIL PRESS SENDER Sheet 4 of 15
2150/BRN
SHEET 6
C405 AIR FILTER SWITCH (PRINTED NOVEMBER 2010)
LEGEND
CAN BUS
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 (TWO WIRE BREAKS * DLX CAB HARN 7196753 ONLY
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200/PUR 9270/PUR 9210/PUR 9280/PUR 9230/PUR 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4
CAN LO C479
CAN HI 9 9100/PUR/WHT 9170/PUR/WHT 9110/PUR/WHT 9180/PUR/WHT 9130/PUR/WHT 7 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
120 OHM 120 OHM
RESISTOR C492 RESISTOR
(8 PIN)
C426 1 9260/PUR 4
9240/PUR C503
Remote Run Tool, ACD 9160/PUR/WHT 2
9140/PUR/WHT 4 ACS CTRLR RIGHT DELUXE PANEL
14 9500/PUR/WHT A
CAN HI
20 9600/PUR B
CAN LO
21 3090/LBL D REMOTE RUN KEY 9290/PUR 7
1830/RNG/WHT 1
C 9190/PUR/WHT 8 SHEET 3
SHEET 3
1730/RNG/WHT E SWITCHED POWER
DRIVE CTRLR
SHEET 4
2070/BLK
9560/PUR/WHT
2
3
* C450
RIGHT JOYSTICK
1165/RED/WHT F (SJC/AWS ONLY)
SHEET 3 UNSWITCHED POWER 9660/PUR 4
2710/BLK G GROUND 9220/PUR 8
SHEET 4 J2B
9120/PUR/WHT 9
AUX CTRLR
1840/RNG/WHT 1
SHEET 3
SHEET 4
2080/BLK
9540/PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640/PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 5 of 15
ENGINE
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
FRC1
STARTER RELAY C109
30 S/R ADAPTER STARTER
1030/RED A
SHEET 3 87 8200/TAN TAN S M
B SHEET 3
3560/LBL B TAN R
85 86 8210/TAN 1015/RED
SHEET 12 2005/BLK
C110
B S 1020/RED
ALTERNATOR G
L 1800/RNG/WHT SHEET 3
EXCITATION
2015/BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100/TAN B
1350/RED/WHT 30 8120/TAN PULL 0.33 OHM
SHEET 3 87 3410/LBL
2400/BLK 2800/BLK C GND
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 8800/TAN A HOLD
24.5 OHM
FRC1 T14
GLOW PLUG PRE HEATER
RELAY 8500/TAN
1060/RED 30
SHEET 3 87
2016/BLK 85 86
2055/BLK
SHEET 3
6 8510/TAN
14 3420/LBL
3 8110/TAN
30 3410/LBL
7 8210/TAN
22 3560/LBL
C107
5140/YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140/LBL C SIG ENGINE OIL PRESSURE
2140/BRN A GND SENDER (0.5-4.5V)
SHEET 4
C405
2150/BRN B GND
SHEET 4 AIR FILTER
16 3150/LBL A SIG
SWITCH (NC)
C106
15 3160/LBL A
SHEET 4 2160/BRN B
SIG
GND
ENGINE SPEED SENSOR
(163 OHM)
WIRING SCHEMATIC
C104
ENGINE COOLANT
(ACS / SJC MACHINE)
2170/BRN B GND
SHEET 4
18 3170/LBL A SIG
SENSOR (500-3000 OHM)
(8 VOLT) T770 (S/N A3P811001 AND ABOVE)
4 8800/TAN
J1B C355
GWY CTRLR
3180/LBL
FUEL HARN
C406
A
Sheet 6 of 15
12 C 3180/LBL OR 3100 LBL SIG
FUEL SENDER
2180/BRN B
SHEET 4
D 2180/BRN OR 3110 LBL GND (30 - 270 OHM) (PRINTED NOVEMBER 2010)
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
GROUND PAGE 4
HYDRAULICS PAGE 7
CAB PAGE 9
HVAC PAGE 12
ACS PAGE 14 C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100/LGN 4200/LGN A 4200/LGN A SOLENOID
RELAY TRACK 2 SPEED
2200/BLK C 2200/BLK B 9.8 OHM ADAPTER (SEE
1360/RED/WHT 30 SHEET 4
SHEET 3 3430/LBL 12 V ADDITIONAL
87
2025/BLK WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035/BLK 4110/LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
C WHEEL SINGLE SPEED
8
TRACTION LOCK
13
C108
2220/BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 4
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND HYDRAULIC
SHEET 4
3190/LBL C SIG CHARGE
5190/YEL A +8V PWR PRESSURE
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330/BRN 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330/LGN
3.3 OHM PWM
C419
(ACS / SJC MACHINE)
1 2340/BRN 2 GND
4340/LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) T770 (S/N A3P811001 AND ABOVE)
3.3 OHM PWM
19 13 Sheet 7 of 15
J2B
AUX CTRLR (PRINTED NOVEMBER 2010)
OVERVIEW PAGE 1,2
CAB DISPLAY
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
POWER PAGE 3
GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CAN BUS PAGE 5
ENGINE PAGE 6 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 SHEET #
SJC PAGE 15
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3 C499
LEFT PANEL
Press To Operate Loader
7040/WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930/RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940/BLK 3
7040/WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920/BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960/RNG/WHT 1440/RED/WHT 1 20 3030/LBL 1 3030/LBL OR 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
*
SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5 SWITCHED POWER
J1A
19 2380/BRN 37 2380/BRN OR 9370, PUR 4
PTOL LED
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT
SHEET 13 GWY CTRLR
C500
5 6 3500/LBL 8
4 SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
2700/BLK 2 3 3650/LBL 7 24 8130/TAN 4 8130/TAN OR 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
3600/LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040/LBL 40 4
3040/LBL OR 9350, PUR RUN/ENTER SWITCH
3610/LBL OR 9310, PUR 4 5 GWY CTRLR
SHEET 3 1775/RNG/WHT 6
1950/RNG/WHT 5
SHEET 4 2930/BLK C480 SHEET 3 SWITCHED POWER
LEFT PANEL (GRAY) 1420/RED/WHT 1
3620/LBL 12 2960/BLK 3
SHEET 9 DOOR SIGNAL SHEET 4 GROUND
11
10
9 C503
3610/LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590/RNG/WHT 5
7 SHEET 3 SWITCHED POWER
6 1240/RED/WHT 1
5 2250/BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 8 of 15
LEGEND
PARTIAL CONNECTOR
CAB
GROUND PAGE 4
HYDRAULICS PAGE 7
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC
OPTIONS
PAGE 12
PAGE 13
JOIN ONE WIRE)
SHEET #
(NOT IN STD CAB HARN 7165991)
ACS PAGE 14
SJC PAGE 15
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 3 3
2060/BLK 5 6
SHEET 9
4
C492
SHEET 10 4230/LGN C408
(8 PIN) CAB-MFR HARN
SHEET 10 4240/LGN
5
3
4220/LGN
4275/LGN
4235/LGN 2
3
4235/LGN
4275/LGN
*C212
POWER
SOCKET
2 4550/LGN 5 4550/LGN 2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
SHEET 4
2790/BLK 24 2790/BLK 2790/BLK 2010/BLK
* C209
B GND
1370/RED/WHT 23 1370/RED/WHT 1390/RED/WHT A +12V PWR DOME
SHEET 3
3640/LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210/RED/WHT A +12V BATT PWR
1580/RNG/WHT 16 1580/RNG/WHT 1865/RNG/WHT B +12V SW PWR
SHEET 3
2820/BLK C GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT SHEET 13
2210/BLK SHEET 13
2885/BLK SHEET 13
2060/BLK
SHEET 4
2730/BLK 33 2730/BLK
SHEET 9
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620/LBL 3630/LBL 4
SHEET 8 DOOR SIGNAL
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
6
1850/RNG/WHT 27 1850/RNG/WHT 1850/RNG/WHT 1

SHEET 3 WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B SENSOR 7310/WHT 3
2370/BRN 45 2370/BRN OR 3910, LBL A GND WASHER SIGNAL
GWY CTRLR SHEET 4
11 3370/LBL 46 3370/LBL OR 3920, LBL B SIG * C252
L SIG
WASHER Printable Version Click Here
24 5100/YEL 5370/YEL 44 5370/YEL OR 3900, LBL C +5V PWR X MOTOR
+5V 2845/BLK GND
SHEET 6 5140/YEL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 9 of 15
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
ACS PAGE 14
SJC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530/BLK K
SHEET 4
AUX CTRLR SHEET 9 4230/LGN G
1520/RNG/WHT A
SHEET 3
30 4940/LGN H
C404 31 4930/LGN J SKI CTRL
C103
BU ALARM-MFR HARN 4920/LGN E
TAILGATE HARN DETENT FLOW
T19 TERMINAL (+) 13 4910/LGN F
(SEE ADDITIONAL A 7100/WHT C 7100/WHT TWO SPD
OPTIONS SHEET)
4310/LGN C
BACK UP
4320/LGN D
2650/BLK ALARM PWM
SHEET 4 4300/LGN B (8 VOLT)
T20 TERMINAL (-)
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421 AUX CTRLR K
J1A 10 2670/BRN 3 GND 20 4640/LGN D
GWY CTRLR 4670/LGN 1 SIG TILT SPOOL LOCK 28 4840/LGN C
2 7.8 OHM 12V 22 4830/LGN B SKI CTRL
12 4820/LGN G
C422 11 4810/LGN F SIDE SHIFT
2 2680/BRN 3 GND 1530/RNG/WHT A
LIFT SPOOL LOCK SHEET 3
4680/LGN 1 SIG J
7.8 OHM 12V
2 4240/LGN H
SHEET 9
2520/BLK E
SHEET 4
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 10 of 15
LEGEND
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT PAGE 15
SJC C434-1
2735/BLK B GND LEFT FRONT
C408
37.00 Watts
CAB-MFR HARN
C434-2
2765/BLK 28 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000/PNK 25 6000/PNK 6120/PNK A SIG RIGHT FRONT
37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
2610/BLK 2 GND
1330/RED/WHT 30 SHEET 4 RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 SIG
2640/BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 4 RIGHT REAR
6210/PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
RELAY
1320/RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200/PNK H 6200/PNK SIG LEFT REAR
2630/BLK GND WORK LIGHT
2045/BLK 85 86 SHEET 4
2035/BLK T18 TERMINAL (-)
SHEET 7
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 11 of 15
Page 666 - OSS# 6300032016 - All rights reserved by Bobcat Company - 01/30/2014 - 06:31:27 - Produced by Ken Cook Co. with media1off 7197682 Printable Version Click Here
Printed In U.S.A.
LEGEND
PARTIAL CONNECTOR
HVAC
HYDRAULICS PAGE 7
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11
WIRE BREAK
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS
ACS
PAGE 13 SHEET # (NOT IN STD CAB HARN 7165991)
PAGE 14
SJC PAGE 15
2440/BLK * C610
2
#
GND HVAC DUCT
7440/WHT 1 SIG FAN (NOT IN STD FUEL HARN 7149219)
C483
2560/BLK * C BLK
7420/WHT A DBL POTENTIOMETER
7425/WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130/BLK C GND HEATER
7430/WHT A +12V PWR VALVE
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3
SHEET 6
2005/BLK
1790/RNG/WHT
6
3 7530/WHT
* C611
1 14.00 Amps High
SHEET 3 7410/WHT 7520/WHT 2 7.50 Amps Med BLOWER
SW11 7510/WHT 3 5.00 Amps Low MOTOR
21 3450/LBL
SHEET 4
2745/BLK 22 2745/BLK *
AC SWITCH 2580/BLK 4
J1A 7015/WHT 1 C 7400/WHT

GWY CTRLR 2100/BLK 3
11 7021/WHT 7020/WHT 34
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570/BLK 2

SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C355
FUEL HARN # C486 Printable Version Click Here
A 7024/WHT 7025/WHT 1 SIG
2290/BLK 2280/BLK
2 GND
MAGNET CLUTCH
(COMPRESSOR) WIRING SCHEMATIC
SHEET 13
D4
(ACS / SJC MACHINE)
Sheet 12 of 15
LEGEND
OVERVIEW PAGE 1,2
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
MANUAL CONTROLS PAGE 10
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11
WIRE BREAK
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
C355
POWER
# C607
1 4470/LGN OR 7010, WHT
FUEL HARN
E
C408
10 CAB-MFR HARN 4470/LGN
#
SIG 4470/LGN
BOB-TACH
CLOSE
GND 2 2470/OR 2770, BLK 2770/OR 2751, BLK B 2770/BLK
SHEET 4 4480/LGN (NOT IN STD FUEL HARN 7149219)
2290/BLK
SHEET 12
#
*POWER
SW5 2 1
3
C606 BOBTACH
POWER 5 4
SIG 2 2480/OR 2775, BLK SWITCH 6
BOB-TACH 1 4480/LGN OR 7000, WHT 4480/LGN 9
GND F
OPEN
1380/RED/WHT
1410/RED/WHT 26 1410/RED/WHT 1200/RED/WHT
SHEET 3
X T3
C411
B 6010/PNK 15
1430/RED/WHT
6010/PNK L
* FLASHER CONN
C 3500/LBL
SHEET 8 D1
LEFT HANDLE A 6515/PNK 6500/PNK 36 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
(BLINKER / FLASHER) E 6540/PNK
5 PIN D2 SWITCH
D 6415/PNK 6400/PNK 29 6400/PNK 6430/PNK
3400/LBL 2725/BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
2850/BLK
INSULATED) 6
EURO TAIL LIGHTS E 6410/PNK C670
(SEE ADDITIONAL D 6510/PNK * E
OPTIONS SHEET) 2780/BLK 30 D
2780/BLK 2420/BLK BEACON/FLASHER
SHEET 4
6440/PNK F EXTERIOR HARNESS
6540/PNK B (SEE ADDITIONAL
1550/RNG/WHT 13 1550/RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820/WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450/LGN D3 4455/LGN 35 4455/LGN 1
4
2 *BUCKET
SW6 SPEAKER
-
2 7830/WHT 4
2830/BLK 5 POSITION C278 RADIO CONN
SOLENOID GND B 2450/BLK 2455/BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6 2 7810/WHT 6
RIGHT -
C126 SPEAKER 1 7800/WHT 5
SHEET 4 2785/BLK + 1885/RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885/BLK 2
LEFT HANDLE B 7210/WHT 38 7210/WHT A SIG HORN SHEET 9 GND
(HORN) A 1460/RED/WHT
2 PIN
SHEET 3 C277
* 1
2
C497 3
5 7200/WHT C SJC 4 PWR
HORN/BLINKER AIR RIDE
4 6420/PNK A 2210/BLK 5 GND
(SEE ADDITIONAL SHEET 9 SEAT
J2A 3 6520/PNK B OPTIONS SHEET) 6
AUX CTRLR
C415
26 2460/BRN B GND HIGH FLOW
A SIG
SOLENOID
4460/LGN Printable Version Click Here
7.5 OHM 12 V
J2B
26
AUX CTRLR
WIRING SCHEMATIC
C437
27 2360/BRN 2 GND TWO SPEED
MAKEUP SOLENOID
(ACS / SJC MACHINE)
4360/LGN 1 SIG
J1A
GWY CTRLR C441
8.8 OHM 12V TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
26 2350/BRN
4350/LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
OPTIONS SHEET) (S/N A3P911001 AND ABOVE)
5.1 OHM 12 V
25 26
Sheet 13 of 15
J1B (PRINTED NOVEMBER 2010)
GWY CTRLR
Printed In U.S.A.
7197682
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
K TILT PEDAL K TILT MOTOR 2
ACS HARNESS 7164144
J1-ACS
CONTROLLER
H 2280/BLK
2280/BLK
SEE MANUAL CONTROL
2240/BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170/RED/WHT C409 C466
C492 C493 J3-ACS K A
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER HANDLE
G B
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 2250/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GRD LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C 5980/YEL 3 +5V PWR
SIG TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4645/LGN 5
2760/BRN 2 4
GND
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 HALL SENSOR 2990/BRN 1 GND
+5V PWR
3990/LBL 2 SIG
5750/YEL
5650/YEL 5980/YEL
2250/YEL 5990/YEL
WIRING SCHEMATIC
H
E
3980/LBL
3990/LBL
(ACS / SJC MACHINE)
Sheet 14 of 15
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
SJC PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN

A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
6 ISO LITE
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
13 LF ANGLE
HARNESS PART NUMBER LIFT 14 RF ANGLE
C429 ACTUATOR
SJC WHEEL 7159325 S630, S650 S730, S750, S770 15 LR ANGLE
4600/LGN 5
SJC TRACK 7159458 T630, T650, T730, T750, T770 16 H PAT LITE
J5 - DRIVE SUSP JSTK 7163706 S630, S650, S730, S750, S770, 4610/LGN
6
8 17 RR ANGLE
T630, T650, T730, T750, T770
CONTROLLER 2980/BRN 1
4
GND 18
19
L JOYSTICK X
L JOYSTICK Y
C454 3980/LBL 2 SIG 20 R JOYSTICK X
29 2890/BRN 2880/BRN 3 7
GND 21 L FWD DRIVE
5880/YEL 1 +5V PWR 5980/YEL 3 +5V PWR
LEFT SPEED 22 CAN LOW
33 3880/LBL 2 SIG SENSOR
C428 23 R QUAD A DRIVE
34 3885/LBL 4 SIG TILT ACTUATOR
5990/YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890/YEL C453 4 25 TWO SPEED 1
+5V
5970/YEL
5870/YEL 1 +5V PWR 3990/LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870/BRN 3 GND 6
23 3870/LBL 2 RIGHT SPEED 27 GROUND
SIG 2990/BRN 1 GND
SENSOR 28 GROUND
24 3875/LBL 4 SIG 4640/LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970/BRN
5810/YEL 2 C543 4650/LGN 8
2810/BRN 4 2810/BRN or BLK 1 GND
31 L REV DRIVE
8 3810/LBL 3 3810/LBL or 4720, LGN 3 SIG 32 CAN SHIELD
1710/RNG/WHT 1 1710/RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860/YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860/BRN 4 2860/BRN or BLK 1 GND 36 BACKUP ALARM
F
7 3860/LBL 3 3860/LBL or 4950, LGN 3 SIG 37 R JOYSTICK Y
G
1770/RNG/WHT 1 1770/RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260/LGN 1 4260/LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
2660/BRN or BLK
ACS CONTROLLER
42 2660/BRN 2 2 A 41 L REV RETURN
42 R FWD RETURN
C547
44 4250/LGN 3 4250/LGN 1 A 43 R FWD DRIVE
RIGHT REVERSE DRIVE +5V 44 R REV DRIVE
45 2650/BRN 4 2650/BRN or BLK 2 G
J1-ACS
F 45 R REV RETURN
C545 9240/PUR E 46 TWO SPEED 2
31 4280/LGN 5 4280/LGN 1
9140/PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN 6 2680/BRN or BLK 2 LEFT REVERSE DRIVE
1760/RNG/WHT B 48 UNSWITCHED BATTERY
2280/BLK H
49 SPARE PWN COIL 6
C544 C
21 4270/LGN 7 4270/LGN 1 50 SWITCHED BATTERY
11 2670/BRN 8 2670/BRN or BLK 2 LEFT FORWARD DRIVE
K
C460
TO SJC BRAKE A 1 1
C474 1830/RNG/WHT +12V PWR
HARNESS D 2 2
26 4210/LGN A C450 2070/BLK GND
J3-ACS
(SEE ADDITIONAL OPTIONS F RIGHT
RIGHT JOYSTICK 4 9660/PUR 4 CAN LO
SHEET)
2270/BLK H (CONNECTS TO JOYSTICK
2260/BLK J DLX CAB HARNESS)
C492 3 9560/PUR/WHT 3 CAN HI
1180/RED/WHT C
12 9190/PUR/WHT 8
1190/RED/WHT B
22 9290/PUR 7 C459
E
4 4550/LGN 2 1 1840/RNG/WHT 1 +12V PWR
G
6 4220/LGN 5
C449 2 2080/BLK 2 GND
16 4275/LGN 3 LEFT JOYSTICK
9140/PUR/WHT 4
LEFT
(CONNECTS TO 4 9640/PUR 4 CAN LO
9240/PUR 1 DLX CAB HARNESS) JOYSTICK
50 1750/RNG/WHT 1740/RNG/WHT 6
MAINFRAME 3 9540/PUR/WHT 3 CAN HI
HARNESS
27 2470/BLK C493
28 2490/BLK 2235/BLK 3
47 1250/RED/WHT 1235/RED/WHT 2
48 1260/RED/WHT 1170/RED/WHT 1
2240/BLK 4 WIRING SCHEMATIC
(ACS / SJC MACHINE)
1760/RNG/WHT
2280/BLK
2270/BLK
2260/BLK (S/N A3P911001 AND ABOVE)
1180/RED/WHT
1190/RED/WHT Sheet 15 of 15
C404
36 7100/WHT A (CONNECTS TO BACKUP
ALARM C404 ON MFR
B
HARNESS)
7197682
Printed In U.S.A.
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
- positions will be specified depending
NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
O FF
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6
DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at
high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning

light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects rpm.
B

Standard Cab Harness Connectors
C129 C479
C480 C434-1
C434-2
C482
T13
T2
C499
C503
SW1
C435-1
C435-2
C500
C408
C126
MS2824

Deluxe Cab Harness Connectors
C209
C670 C479 C434-1

C480 C434-2
C499
T13
C482 T2
SW1
SW3
C500
C503 SW2
SW6
C435-1
C435-2
SW4
C667
C426
SW5
SW9
C611 C252
C630
C635
C126
C129 C253
C277 C279
C449 C483
C450 S3
T3
C278
C676
C212
MS2827

Mainframe Harness Connectors
C426
C405
C103 C 350
408
T11 T6
T1
T8 C355
T10 T4
C101 C105
C110 C104
C362
T12 C107
FRC1
C486 C446
FC1
C108 FC2
C423 C362
C441 C489
C415 C497
J2A
C409 J2B
C419 J1A
C420 C410 J1B
C418 C404 C411
C421 C437 C412
C422
C425
C492
C493
MS2825

Description
Figure 60-10-1
P-13849
P-90658
The loader has a 12 volt, negative ground, alternator

charging system.
The electrical system is protected by fuses located in the

operator cab and a 100 ampere master fuse (inset)
located above the battery in the engine compartment
[Figure 60-10-1].
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-4
Fuse And Relay Location / Identification
Figure 60-10-2
P100416
1
Remove the covers to check or replace the fuses [Figure
P100414 60-10-4].
A decal is located inside the access panel to show

The fuse / relay panels are located behind an access location and amperage ratings.
panel near the left foot pedal / footrest. Pull the panel at
each end (Item 1) [Figure 60-10-2] to remove. Install the fuse panel covers [Figure 60-10-3].
Figure 60-10-3 Line up the clips on the back of the access panel with the
slots provided and push the panel into place when
finished. A locating pin prevents the panel from being
installed upside down [Figure 60-10-2].
A table is provided with details on amperage ratings and

circuits affected by each fuse and relay [Figure 60-10-5].
P100415
The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-3].

ELECTRICAL SYSTEM (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
Figure 60-10-5
1 13 21 25
17
5 7 9 11
2 22 26
14 18
3 15 19 23 27
6 8 10 12
4 16 20 24 28
NA3151
The location and amperage ratings are shown in the table below and on the decal [Figure 60-10-5]. Relays are identified
by the letter “R” in the AMP column.
REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 Alternator 15 11 Glow Plugs R 21 Bobcat Controller 25
2 Heater / HVAC 25 12 Fuel Shutoff R 22 ACS Controller 25
Cab Switched
3 Front Lights 20 13 5 23 Attachments 25
Power
4 Rear Lights 15 14 Bucket Position 15 24 Not Used --
Auxiliary
5 Starter R 15 Wiper / Washer 25 25 25
Controller
Switched Power Drive Controller

6 Front Lights R 16 and Non-SJC 25 26 and SJC Back-up 25
Back-up Alarm Alarm
Accessories and
7 Heater / HVAC R 17 Switched Power 25 27 25
Front Horn
8 Rear Lights R 18 Switched Power 25 28 Power Port 15
9 Switched Power R 19 Traction 30
10 Traction R 20 Fuel Shutoff 30

Solenoid Testing
Figure 60-10-6
P9175

10-6]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

60-10-12
T770 Service Manual
BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807 metal parts with the battery terminals.
Connect the negative (-) cable last to prevent sparks.

Stop the engine and open the rear door.
Connect and tighten the battery cables.
Figure 60-20-1
Install and tighten the battery hold down clamp.
WARNING
1
BATTERY GAS CAN EXPLODE AND CAUSE
Keep arcs, sparks, flames and lighted tobacco away
2 from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

P100285 battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Disconnect the negative (-) cable (Item 1) [Figure 60-20- lean over battery while boosting, testing or charging.
1]. W-2066-0910
Remove the battery hold down clamp (Item 2) [Figure

60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.

BATTERY (CONT’D)
Servicing
Figure 60-20-3
P-09589 P-09590
The battery cables must be clean and tight. Check

electrolyte level in the battery. Add distilled water as
needed. Remove acid or corrosion from battery and
cables with sodium bicarbonate (baking soda) and water
solution [Figure 60-20-3].
Put Bobcat Battery Saver or grease on the battery
terminals and cable ends to prevent corrosion.
WARNING

In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONT’D) After the engine has started, remove the negative (-)
cable (Item 4) first. Remove the cable from the positive
Using A Booster Battery (Jump Starting) terminal (Item 2) [Figure 60-20-4].
If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables. IMPORTANT
The key switch must be OFF or the STOP button must be
pressed. The booster battery must be 12 volt. Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
WARNING charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
BATTERY GAS CAN EXPLODE AND CAUSE connected wrong.
SERIOUS INJURY OR DEATH I-2023-1285
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
Figure 60-20-4
2
4
3 1
P-90660A
Connect the end of the first cable (Item 1) to the positive

(+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-4] to the
positive terminal on the loader starter.
Connect the end of the second cable (Item 3) to the

negative terminal of the booster battery. Connect the
other end of the same cable (Item 4) [Figure 60-20-4] to
the engine.
Keep cables away from moving parts. Start the engine.

60-20-4
T770 Service Manual
ALTERNATOR Move the alternator toward the engine as far as it will go
and remove the belt from the pulleys. Inspect the pulleys
Belt Adjustment for wear.
The alternator belt is a special maintenance free type Install new belt.
that is pretensioned over the pulleys. This belt eliminates
the need for a tensioning device and does not require Figure 60-30-3
periodic adjustment.
Belt Replacement
Stop the engine and open the rear door. (See REAR
Remove the air conditioning belt. (See Compressor Drive

Belt Replacement on Page 80-20-2.)
Figure 60-30-1 1
P100038
1 Use a prybar (Item 1) [Figure 60-30-3] to move the

alternator until the bottom alternator mounting bolt (Item
2) [Figure 60-30-2] can be installed.
3 Tighten the top alternator mounting nut (Item 1) and

bottom alternator mounting bolt (Item 2) [Figure 60-30-

2].
P100231
Install the air conditioning belt. (See Compressor Drive
Remove the clamp nut and bolt (Item 1). Remove the belt
shield mounting nuts and bolts (Item 2) and remove the Install the belt shield, mounting nuts and bolts, and clamp
belt shield (Item 3) [Figure 60-30-1]. nut and bolt [Figure 60-30-1].
Figure 60-30-2 Close the rear door.
P100034
Remove the bottom alternator mounting bolt (Item 2) and

loosen the top alternator mounting nut (Item 1) [Figure
60-30-2].

ALTERNATOR (CONT'D) Figure 60-30-4
Charging System Inspection
WARNING
2

In case of eye contact get prompt medical attention P-85914
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities Check the condition and tension of the alternator belt.
of water or milk! DO NOT induce vomiting. Get (See Belt Adjustment on Page 60-30-1.) Replace belt if
prompt medical attention. worn or deteriorated.
W-2065-0807
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and
tight.
WARNING Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair / replace. If fuse is in
doubt, remove it and check for continuity.
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH Check the electrolyte level in the battery. Add distilled
Keep arcs, sparks, flames and lighted tobacco away water as needed. (Does not apply to maintenance free
from batteries. When jumping from booster battery batteries.)
Verify the charge of the battery. Make sure battery is fully
Do not jump start or charge a frozen or damaged charged.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before Disconnect the battery cables (negative first, then
connecting or disconnecting cables to battery. Never positive). Inspect the cable clamps and battery posts for
lean over battery while boosting, testing or charging. corrosion. Remove acid or corrosion from the battery
W-2066-0910 and cables with a sodium bicarbonate and water
solution. Put grease on the cable ends and battery
terminals to prevent corrosion. Reconnect the cable to
the positive terminal.
IMPORTANT
Damage to the alternator can occur if:
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR (CONT'D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-6

procedure:

Figure 60-30-5
P-85914
Turn engine OFF and remove the L & S terminal

connector (Item 1) [Figure 60-30-6] from the alternator.
Turn the remote start tool key to the ON position.

P-85916
Figure 60-30-7
Open rear door.


7217666 on Page 10-61-1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+ 2
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature). 1
P-85915
If the voltage is higher that 14.7 volts, proceed to the
following high voltage test.
Check the voltage across the “L” terminal (Item 1) and
If the voltage is lower than 13.5 volts, run the engine at ground (Item 2) [Figure 60-30-7]. The voltage should be
high idle and recheck voltage. If voltage is still below 13.5 what the battery voltage is. If not, check wire harness,
volts, proceed with the following low voltage test. relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

ALTERNATOR (CONT'D)
High Voltage Testing
Figure 60-30-8
P-85917
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-6] off the alternator.
Check the continuity between the “S” terminal (Item 1)

[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair.

ALTERNATOR (CONT'D) Figure 60-30-10
Remove the air conditioning belt. (See Compressor Drive

IMPORTANT 2
Damage to the alternator can occur if:

disconnected.
• Battery cables are connected when using a fast P-85718
charger or when welding on the loader. (Remove
• Extra battery cables (booster cables) are Remove the alternator rain shield mounting nut and bolts
connected wrong. (Item 1) and remove the alternator rain shield (Item 2)
I-2023-1285 [Figure 60-30-10].
Figure 60-30-11
Figure 60-30-9
1
2
2
1
P-85609
P-85914
Remove the belt shield mounting nuts and bolts (Item 1)

Disconnect the negative (-) cable from the battery. and remove the belt shield (Item 2) [Figure 60-30-11].
Disconnect the red wire (Item 1) [Figure 60-30-9] from
the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2)

[Figure 60-30-9] from the alternator.

ALTERNATOR (CONT'D)
Figure 60-30-12
P-85611
Remove the top alternator mounting bolt (Item 1) and the

bottom alternator mounting bolt (Item 2) [Figure 60-30-
12].
Remove the belt and alternator from the loader.

ALTERNATOR (CONT’D)
1. Nut
2. Washer
3. Pulley
4. Spacer
6
5. Bolt
6. Case Half 5
7. Bearing
8. Retainer
9. Rotor
10. Stator 3
11. Case Half
12. Sleeve
13. Regulator 5
1 4
14. Rectifier
15. Cover
16. Spacer 11 12
2
10 5
7
9
8
7
15 1
14
16
13
C-3529

60-30-8
T770 Service Manual
STARTER Removal And Installation
Testing Open the rear door.
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
The battery must be at full charge. Figure 60-40-3

The cable connections on the battery must be clean and 2
tight.
3
Figure 60-40-1
Bat 1
S
M
3
Cranking
Motor P101566
Disconnect the positive (+) cable (Item 1) [Figure 60-40-

3] from the starter solenoid.
A-1992
Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -

12.3 ft-lb) torque.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].

Disconnect the wire connector (Item 2) [Figure 60-40-3]
If the starter turns but does not turn the engine, the from the two solenoid wires.
starter drive has a defect.
Remove the three bolts (Item 3) [Figure 60-40-3].
Figure 60-40-2
Remove the starter from the engine.
Bat
S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT'D)
1. Bolt 12 13. Washer

2. O-ring 14. Nut
3. Bracket 15. Shaft
4. Snap ring 16. Ball
5. Stop 17. Armature
6. Gear 14 18. Bearing
13
7. Spring 19. Boot
8. Holder 11 20. Yoke
9. Lever 21. Holder
10. Plate 3
11. Lever 8 10
12. Switch 7
7
2
1 9
17
3
2 18
7
6
6 16
4 5
15
6
4
1
13
6
1
15
2
19
13 3
2 21
20
B-19824

INSTRUMENT PANELS
Left Panel (Earlier Models)
Figure 60-50-1
2 3 12
7
1
16
4 13
6 8 9 11
10 15
5 14
17 20
18 19
21 22
23
P-90726B
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT AND TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and right
green LEDs will be off.)
Press and hold 5 seconds to display software version in display screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED will
light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On startup)
• Engine rpm
• Battery voltage
• Maintenance clock (Press and hold for 7 seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers or
joystick(s) to move the loader forward or backward when using the
backhoe attachment. (See TRACTION LOCK OVERRIDE in this manual.)
Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold 3 seconds to access Drive Response and Steering Drift
Compensation adjustment menus. (See DRIVE RESPONSE and
STEERING DRIFT COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all loaders) Press the top to engage the Parking Brake. Press the bottom to
disengage. (See PARKING BRAKE in this manual.)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)

INSTRUMENT PANELS (CONT’D)
Left Panel (Later Models)
Figure 60-50-2
2 3 12
13
1 7
4 14 17
6 8 9 10 11 16
5 15
18 21
19 20
22 23
24
P-90726G
The left panel [Figure 60-50-2] is the same for all machines regardless of options and accessories.
REF. NO. DESCRIPTION FUNCTION / OPERATION

1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light is on when the seat bar is UP.
10 LIFT AND TILT VALVE The light is on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light is on when the loader cannot be driven.

Left Panel (Later Models) (Cont’d)
REF. NO. DESCRIPTION FUNCTION / OPERATION

12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
13 DIESEL PARTICULATE FILTER Not used.
(DPF) / DIESEL EXHAUST FLUID
(DEF)
14 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
15 HYDRAULIC SYSTEM Hydraulic system malfunction or failure. (See Service Codes*)
MALFUNCTION
16 FUEL Fuel level low or sensor error.
17 FUEL GAUGE Shows the amount of fuel in the tank.
18 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green
LED lights.) Press a second time to add REAR work lights. (Left and
right green LEDs light.) Press a third time to turn all lights off. (Left and
right green LEDs off.)
Press and hold 5 seconds to display software version in display screen.
19 AUTO IDLE Not used.
Move cursor to the left inside the DISPLAY SCREEN when using
certain INFORMATION button menus.
20 AUXILIARY HYDRAULICS without Press once to activate the auxiliary hydraulic system. (Left green LED
high-flow option lights.) Press a second time to deactivate the system.
AUXILIARY HYDRAULICS with Press once to activate the auxiliary hydraulic system. (Left green LED
high-flow option lights.) Press a second time to engage the HIGH-FLOW auxiliary
hydraulics. (Left and right green LEDs light.) Press a third time to
deactivate auxiliary hydraulics. (Left and right green LEDs off.)
Move cursor to the right inside the DISPLAY SCREEN when using
certain INFORMATION button menus.
21 INFORMATION Cycles through (after each button press):
• Hourmeter (On startup)
• Engine rpm
• Battery voltage
• Drive response menu
• Steering drift compensation menu
• Maintenance clock (Press and hold 7 seconds when displayed to
reset the maintenance clock.)
• Service codes*
22 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
or joystick(s) to move the loader forward or backward when using the
backhoe attachment. (See TRACTION LOCK OVERRIDE in this
manual.) Press a second time to lock the brakes.
23 PRESS TO OPERATE LOADER Press to activate the BICS™ when the seat bar is down and operator is
seated in operating position. Button will light.
24 PARKING BRAKE (Standard on all Press the top to engage the Parking Brake. Press the bottom to
loaders) disengage. (See PARKING BRAKE in this manual.)
* This manual contains a table with Service Code descriptions. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

Display Screen
The display screen can display the following information:
• Operating hours.
• Engine revolutions per minute (rpm).
• Speed management setting.
• Maintenance clock countdown.
• Battery voltage.
• Service codes.
• Engine preheat countdown.
• Steering drift compensation setting.
• Drive response setting.
Figure 60-50-3
1
3 4 5 6 7
P-76461A
The display screen is shown in [Figure 60-50-3]. The

data display will show operating hours upon startup.
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine Revolutions Per Minute
6. Battery / Charging Voltage
7. Service

FUNCTION /
Right Panel (Standard Key Panel) REF. DESCRIPTION
OPERATION
Figure 60-50-4 ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
Controls.
SELECTABLE Press the top to select

JOYSTICK ‘ISO’ Control Pattern;
CONTROLS (SJC) bottom to select ‘H’
(Option) Control Pattern.
FOUR-WAY Press the top to turn

1 FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING BEACON Press the top to turn
2 (Option) light ON; bottom to
or turn OFF.
STROBE LIGHT
(Option)
P-85285
This machine may be equipped with a Standard Key

Panel [Figure 60-50-4].
The Standard Key Panel has a key switch (Item 1)

[Figure 60-50-4] used to turn the loaders electrical
system on and off, and to start and stop the engine.
The switch location (Item 2) [Figure 60-50-4] can have

different functions depending on machine configuration.
See the following table for more information.

Right Panel (Keyless Start Panel)

FUNCTION /
REF. DESCRIPTION
OPERATION
Figure 60-50-5
ADVANCED Press the top to select
Controls.
SELECTABLE Press the top to select

2 3 (Option) Control Pattern.

(Option) turn OFF.
5 ROTATING BEACON Press the top to turn

(Option) light ON; bottom to
or turn OFF.
STROBE LIGHT
P-90819H (Option)
This machine may be equipped with a Keyless Start

Panel [Figure 60-50-5].
1. Keypad (keys 1 through 0): Used to enter a number Figure 60-50-6

code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
2. LOCK Key: Used to lock keypad. The lock key will
display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
3. UNLOCK KEY: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. Key Switch: Used to turn the loaders electrical

system on and off, and to start and stop the engine. P-90214B
The switch location (Item 5) [Figure 60-50-5] can have Earlier models used a push button switch assembly
different functions depending on machine configuration. [Figure 60-50-6] instead of a key switch.

Right Panel (Deluxe Instrumentation Panel) FUNCTION /
REF. DESCRIPTION
OPERATION
Figure 60-50-7
ADVANCED Press the top to select
1
Controls.
3 SELECTABLE Press the top to select

(Option) Control Pattern.

(Option) turn OFF.
6
ROTATING BEACON Press the top to turn
(Option) light ON; bottom to
or turn OFF.
STROBE LIGHT
P-90212J (Option)
This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-7]. Figure 60-50-8
1. Keypad (1 through 0): The keypad has two
functions:
- To enter a number code (password) to allow starting
the engine.
- To enter a number as directed for further use of the
display screen.
2. Display Screen: The Display Screen is where all
system setup, monitoring and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen
choices.
4. ENTER Button: Used to make selections on the P-90214B
display screen.
5. Key Switch: Used to turn the loaders electrical Earlier models used a push button switch assembly
system on and off, and to start and stop the engine. instead of a key switch [Figure 60-50-8].
The switch location (Item 6) [Figure 60-50-7] can have

different functions depending on machine configuration.

INSTRUMENT PANELS (CONT’D) Change Language
Right Panel (Deluxe Instrumentation Panel) (Cont’d) Press the left or right scroll button to cycle through the
languages. The language that is stopped on will be the
Figure 60-50-9 default language used for the deluxe instrumentation
panel [Figure 60-50-7].
The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-180-1.)
Enter The Password
Use the numbers on the keypad to enter the password,

then press the [ENTER] button. A symbol will appear on
the display screen for each number entered [Figure 60-
50-7]. The left scroll button can be used to backspace if
an incorrect number is entered.
If the correct password is not entered, [INVALID

NA3017 PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
The first screen you will see on your new loader will be as See CONTROL PANEL SETUP for further description of
shown in [Figure 60-50-9]. screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
When this screen is on the display you can enter the
password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See Changing The User
Passwords on Page 60-190-2.) Keep your
password in a safe place for future needs.

INSTRUMENT PANELS (CONT'D) Right Switch Panel
Left Switch Panel Figure 60-50-11
Figure 60-50-10
3
P-85320
P-85319
This machine may be equipped with a Right Switch Panel
[Figure 60-50-11].
This machine may be equipped with a Left Switch Panel
[Figure 60-50-10].
REF.
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER Press and hold the up arrow to
NO.
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
(Option)
3 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
POSITIONING bottom to disengage.
(Option)

INSTRUMENT PANELS (CONT’D) Right Side Lower Panel
Left Side Lower Panel Figure 60-50-13
Figure 60-50-12 1
2
4
3
1 2
4
P-85267D
P-85282
This machine may be equipped with a right side lower
This machine may be equipped with a left side lower
REF.
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER PORT Provides a 12 volt
NO.
receptacle for accessories.
1 FAN MOTOR Turn clockwise to increase
2 RADIO (Option) See Radio in this manual.

(Option) fan speed;
counterclockwise to 3 HEADPHONE JACK Used to connect
decrease. There are four (Option) headphones to the optional
positions; OFF-1-2-3. radio output. Automatically
silences speakers when
2 AIR CONDITIONING Press top of switch to start;
used.
/ DEFROST SWITCH bottom to stop. Switch will
(Option) light when started. Fan 4 SPEAKER (Option) Right speaker used with
Motor (Item 1) must be ON optional radio.
for A/C to operate.
3 TEMPERATURE Turn clockwise to increase
CONTROL (Option) the temperature;
counterclockwise to
decrease.
4 SPEAKER (Option) Left speaker used with
optional radio.

INSTRUMENT PANELS (CONT’D) Right Panel (Standard Key Panel) Removal And
Installation
Left Panel Removal And Installation
Figure 60-50-16
Figure 60-50-14
1 1
1 1 2
2
P-85929
P-85928
Remove the two mounting bolts (Item 1) and the fastener

Remove the two mounting bolts (Item 1) and the fastener (Item 2) [Figure 60-50-16].
(Item 2) [Figure 60-50-14].
Installation: Be careful to not overtighten the instrument
Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded
panel mounting bolts to prevent stripping of the threaded holes in the panels. Tighten the panel screws to 3 - 4
holes in the panels. Tighten the panel screws to 3 - 4 N•m (25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
NOTE: Inspect and replace the seal as needed (Item 3) [Figure 60-50-16].
3) [Figure 60-50-14].
Figure 60-50-17
Figure 60-50-15
1 P-85931
P-85930
Pull the right instrument panel down and disconnect the

Pull the left instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-17].
wire harness connectors (Item 1) [Figure 60-50-15] from
the panel. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Right Panel (Deluxe Instrumentation Panel) Removal
And Installation
Right Panel (Keyless Start Panel) Removal And
Installation Figure 60-50-20
Figure 60-50-18
3
3
1
1 1
1
2
2 P-90527
P-90819A
(Item 2) [Figure 60-50-20].
(Item 2) [Figure 60-50-18]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 3 - 4
panel mounting bolts to prevent stripping of the threaded N•m (25 - 35 in-lb) torque.
holes in the panels. Tighten the panel screws to 3 - 4
N•m (25 - 35 in-lb) torque. NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-20].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-18]. Figure 60-50-21
Figure 60-50-19
P-90530
P-90818A
wire harness connector (Item 1) [Figure 60-50-21].
wire harness connector (Item 1) [Figure 60-50-19]. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Alarm Disassembly And Assembly
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-23
Disconnect the key switch wiring harness.
Figure 60-50-22
2
P-85947
Remove the left side instrument panel.

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-23] from
the loader alarm.
Remove the key (Item 1) from the switch. Remove the
switch retaining nut (Item 2) [Figure 60-50-22] from the Remove the alarm from the loader instrument panel.
switch.
Remove the switch from the control panel.

INSTRUMENT PANELS (CONT'D) Right Switch Panel Removal And Installation
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) Removal And Installation on Page 60-50-12.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-12.) Figure 60-50-26
Figure 60-50-24
1 2
1
P-85943
1
P-85945
Remove the two fasteners (Item 1) and the knob (Item 2)
[Figure 60-50-26].
Remove the two fasteners (Item 1) [Figure 60-50-24].
Figure 60-50-27
Figure 60-50-25
1 1
P-85944
P-85946
Remove the fastener (Item 1) and the right side panel

Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-27].
(Item 2) [Figure 60-50-25].

60-50-16
T770 Service Manual
LIGHTS Figure 60-60-3
Front Removal And Installation 1
Disconnect the negative(-) cable from the battery. (See

Figure 60-60-1
1
P-85436
1
Figure 60-60-4
P-85433
Installation: Tighten the two bolts to 22 - 27 N•m (40 - 45

in-lb) torque.
Figure 60-60-2
P-85435
1
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
1 turn.
NOTE: Two different light bulbs are used, take note

when removing to assure correct installation.
Reverse the above procedure to install the bulb.
P-85434
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness connectors.

LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-7
Figure 60-60-5
1 2
P-85274
P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light to far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.
1
P-85437 P-85783
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Reverse this procedure for installation.

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)
Description
The Gateway controller is the main controller, it provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.

AUXILIARY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL

17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO-SPEED GROUND
27 2360 BLACK TWO-SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL
12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO-SPEED MAKEUP
26 4350 LGN TWO-SPEED SIGNAL

Auxiliary Controller
1 1
34 26
J2A J2B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND

17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLERS (GATEWAY AND Figure 60-70-2

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

1.)
Remove the left inside access panel. (See Removal And

Installation (Left) on Page 50-120-1.)
P-85901
Figure 60-70-1
Remove the controller mounting bolts (Item 1) [Figure

60-70-2] from the left fender.
2
Installation: Tighten the controller mounting bolts to 16 -
19 N•m (12 - 14 ft-lb) torque.
Remove the Gateway and Auxiliary controllers from the

loader.
1
P-85900
NOTE: Before unplugging any controller the key

switch must be off.
Unplug the two harness connectors (Item 1) [Figure 60-

70-1] from the Gateway controller.
Unplug the two harness connectors (Item 2) [Figure 60-

70-1] from the Auxiliary controller.
NOTE: The connectors are keyed and will only plug

in one way.

BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS

or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.

BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
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
P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-2

1
1.)
Figure 60-71-1
1 P-85902

from the controller.
Remove the controller from the loader.
1 NOTE: The calibration procedure must be followed

when replacing a controller. (See Lift And Tilt
Calibration (ACS) on Page 60-160-11.)
P-85903
NOTE: Before unplugging any controller the key

switch must be off.
Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.
NOTE: The connectors are keyed and will only plug

in one way.

60-71-4
T770 Service Manual
BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same as those used on
drive functions. the ACS system.
The drive controller is located behind the right side The hydrostatic drive pump has two electromagnetic coils
access panel near the operator’s right foot. on each of the two pumps to control the drive of the
loader. The coils will direct the forward and reverse
The drive controller monitors the position of the left outputs of the pump to the drive motors. The hydrostatic
joystick, pump swash plate angles and the output of the drive pump is equipped with position sensors mounted to
wheel speed sensors. (If equipped) the bottom of the swash plates to provide feedback to the
controllers to sense uncommanded swash plate
The drive controller works along with the ACS controller movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
HYDRAULIC
DRIVE MOTOR
CONTROL
ACS
RIGHT CONTROL
HAND SPEED SENSOR
LIFT/TILT (EARLY MODELS ONLY)
PANEL ACTUATORS
RIGHT
JOYSTICK
FWD/REV
SWASH PLATE
LEFT SENSORS
JOYSTICK
LEFT
HAND
PANEL AUXILIARY DRIVE PUMP
CONTROL SPEED SENSOR
(EARLY MODELS ONLY)
GATEWAY ACS HYDRAULIC

CONTROL CONTROL MOTOR
EXTERNAL
CAN BUS
NA5677

Connector Identification
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
60-72-2
P-64295
T770 Service Manual

Connector Identification (Cont'd)

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
60-72-3
P-64296
T770 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4
Remove the three bolts (Item 1) [Figure 60-72-1] that

secure the controller.

Figure 60-72-2
J S
P-64325
Remove the drive controller [Figure 60-72-4].

1
P-64324
Remove the screw and wire harness (Item 1) [Figure 60-

72-2].
Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

SPEED SENSORS (SJC) Figure 60-80-2
Description
NOTE: Speed sensors have been eliminated on late

model machines. Earlier models may or may
not have been upgraded to eliminate the
speed sensors.
Updating the software version to 79.7 or newer allows the

speed sensors to be eliminated. Both sensors must be 1
disconnected and then a hydrostatic pump calibration 2
must be performed.
NOTE: When disconnecting the speed sensor, cap

the main harness connector. P-85924
Testing
Locate the electrical connector (Item 1) [Figure 60-80-2]
The tools listed will be needed to do the following for the left rpm speed sensor.
procedure:
Disconnect the rpm speed sensor wire connector (Item
MEL1609-rpm Speed Sensor Test Harness [Figure 60- 1), from the loader harness wire connector (Item 2)
80-1] [Figure 60-80-2].
Multimeter Connect the rpm speed sensor test harness (Item 1)
[Figure 60-80-1] in line, between the loader wiring
Raise the lift arms and install an approved lift arm harness and the speed sensor harness.
Turn the remote start key to ON position without starting

Raise the operator cab. (See Raising on Page 10-30-2.) the loader.
Connect the remote start tool. (See REMOTE START Take a voltage reading, with the multimeter, at the speed
TOOL KIT- MEL1563 on Page 10-60-1.) or (See sensor test harness, between pin 1 and pin 3 [Figure 60-
REMOTE START TOOL (SERVICE TOOL) KIT - 80-1].
7217666 on Page 10-61-1.)
The voltage should be 5 volts.
Figure 60-80-1
Repeat the procedure for the opposite side speed sensor.
(If needed.)
1
P-28302

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-5

1
Remove the loader track. (See Track Removal And

Installation on Page 40-20-4.) 1
Figure 60-80-3
2 P-48741
Remove the access cover mount bolts (Item 1) [Figure

60-80-5].
1
Remove the speed sensor access cover from the loader.
Figure 60-80-6
P-85927
Remove the four access cover mount bolts (Item 1)
[Figure 60-80-3]. 1
Remove the access cover (Item 2) [Figure 60-80-3] from 2

the loader.
Figure 60-80-4
1
P-48742
Clean the area around the speed sensor, to prevent

1 contamination from getting into the hydrostatic motor
after the speed sensor is removed.
Remove the two-speed sensor mount bolts (Item 1)

[Figure 60-80-6].
Installation: Lubricate the speed sensor O-ring with oil

before installing. Seat the sensor into the motor port prior
to installing the bolts. Tighten down the bolts, alternate
P-48740 tightening from left to right to evenly load the O-ring.
Tighten the speed sensor mount bolts to 9,94 N•m (88 in-
lb) torque.
At the back side of the hydrostatic motor mount (Item 1)
[Figure 60-80-4], locate the speed sensor access cover. Remove the speed sensor (Item 2) [Figure 60-80-6] from
the motor.

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-9
Figure 60-80-7
4 1
1
3 2
2 P-26294
With a thin screwdriver lift the tabs and remove the wires
P-85924 from the connector [Figure 60-80-9].
Wire Code
Remove the zip tie (Item 1) [Figure 60-80-7] from the
wiring harness. 1 Red
2 White
Disconnect the speed sensor harness (Item 2) [Figure 3 Black
60-80-7] from the loader harness. 4 Blue
Remove the speed sensor from the loader.

Figure 60-80-8
P-26293
The electrical connector can be replaced.
The connector can be found in the harness repair kit.
Remove the connector wedge (Item 1) [Figure 60-80-8].

60-80-4
T770 Service Manual
DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions which can damage your machine.
The last 40 codes stored in history can also be viewed
Figure 60-90-1 using the Deluxe Instrumentation Panel.
Press a scroll button (Item

1 1) repeatedly until the
Active Warnings screen
icon (Inset) is highlighted.
1 1
The ACTIVE WARNINGS

screen displays active
2
service codes. Press [9]
to view the next service
code if more than one is
NA3181
present. Press [4] to
display a history of service
Press the Information button (Item 2) to cycle the data codes.
display (Item 1) [Figure 60-90-1] until the service code The WARNINGS
screen is displayed. If more than one service code is HISTORY screen will list
present, the codes will scroll on the data display. the Service Code Number
(CODE), Hourmeter
When no service code is present, [NONE] is displayed reading when the error
[Figure 60-90-1]. occurred (HOUR), and the
User (USER) who was
NOTE: Corroded or loose grounds can cause logged in to operate the
multiple service codes and / or abnormal machine when the error
symptoms. All instrument panel lights occurred.
flashing, alarm sounding, headlights and Press [9] to view the next eight service codes.
taillights flashing, can indicate a bad ground.
The same symptoms can apply if the voltage A total of 40 codes can be stored. When more than 40
is low, such as loose or corroded battery codes occur, the oldest code will disappear and the
cables. If you observe these symptoms, check newest code will be in the number 1 position.
grounds and positive leads first.
Press the list number next
to the service code for
more detail.
Press the left scroll button

to back up one screen.

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-2 The following word errors may be displayed:
[REPLY] One or both instrument panel(s) not

1 2
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
NA3077 only.)
NA3084
NA3181
[SHTDN] A shutdown condition exists.
Service codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-90-2]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A0618 Wheel speed out of range A8403 ACD output ‘E’ error OFF
A3623 ACD not programmed A8405 ACD output ‘E’ short to battery
A4621 5 volt sensor supply out of range high A8406 ACD output ‘E’ short to ground
A4622 5 volt sensor supply out of range low A8407 ACD output ‘E’ open circuit
A4721 8 volt sensor supply out of range high A8432 ACD output ‘E’ overcurrent
A4722 8 volt sensor supply out of range low A8502 ACD output ‘F’ error ON
A7701 Machine key active A8503 ACD output ‘F’ error OFF
A7901 E-Stop active A8505 ACD output ‘F’ short to battery
A8002 ACD output ‘A’ error ON A8506 ACD output ‘F’ short to ground
A8003 ACD output ‘A’ error OFF A8507 ACD output ‘F’ open circuit
A8005 ACD output ‘A’ short to battery A8532 ACD output ‘F’ overcurrent
A8006 ACD output ‘A’ short to ground A8602 ACD output ‘G’ error ON
A8007 ACD output ‘A’ open circuit A8603 ACD output ‘G’ error OFF
A8032 ACD output ‘A’ overcurrent A8605 ACD output ‘G’ short to battery
A8102 ACD output ‘B’ error ON A8606 ACD output ‘G’ short to ground
A8103 ACD output ‘B’ error OFF A8607 ACD output ‘G’ open circuit
A8105 ACD output ‘B’ short to battery A8702 ACD output ‘H’ error ON
A8106 ACD output ‘B’ short to ground A8703 ACD output ‘H’ error OFF
A8107 ACD output ‘B’ open circuit A8705 ACD output ‘H’ short to battery
A8132 ACD output ‘B’ overcurrent A8706 ACD output ‘H’ short to ground
A8202 ACD output ‘C’ error ON A8707 ACD output ‘H’ open circuit
A8203 ACD output ‘C’ error OFF A8802 Reverse solenoid error ON
A8205 ACD output ‘C’ short to battery A8803 Reverse solenoid error OFF
A8206 ACD output ‘C’ short to ground
A8207 ACD output ‘C’ open circuit D3905 Left joystick X-axis not in neutral
A8232 ACD output ‘C’ overcurrent D3907 Left joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D4007 Right joystick Y-axis not in neutral
A8303 ACD output ‘D’ error OFF D7501 Drive CAN joystick information error
A8305 ACD output ‘D’ short to battery D7504 Drive no communication from drive controller
A8306 ACD output ‘D’ short to ground D7505 Drive left joystick X-axis not in neutral
A8307 ACD output ‘D’ open circuit D7507 Drive left joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7508 Drive right joystick Y-axis not in neutral
Drive operating mode switch short to ground or
A8402 ACD output ‘E’ error ON D7509
battery

Service Codes List (Cont’d)

D7510 Drive improper joysticks installed D7555 Drive right forward drive solenoid error OFF
D7511 Drive left speed sensor not connected D7556 Drive right reverse drive solenoid error OFF
D7512 Drive right speed sensor not connected D7557 Drive right front steer extend short to ground
D7513 Drive right front wheel angle sensor stuck D7558 Drive right front steer retract short to ground
D7514 Drive left front wheel angle sensor stuck D7559 Drive left front steer extend short to ground
D7515 Drive right rear wheel angle sensor stuck D7560 Drive left front steer retract short to ground
D7516 Drive left rear wheel angle sensor stuck D7561 Drive right rear steer extend short to ground
D7517 Drive left swash plate not in neutral D7562 Drive right rear steer retract short to ground
D7518 Drive right swash plate not in neutral D7563 Drive left rear steer extend short to ground
D7519 Drive left joystick X-axis out of range high D7564 Drive left rear steer retract short to ground
D7521 Drive left joystick Y-axis out of range high D7565 Drive steer pressure short to ground
D7522 Drive right joystick Y-axis out of range high D7566 Drive back-up alarm error OFF
Drive right front wheel angle sensor out of range
D7523 D7567 Drive no communication from Bobcat controller
high
Drive left front wheel angle sensor out of range
D7524 D7568 Drive angle sensors not calibrated
high
Drive right rear wheel angle sensor out of range
D7525 D7569 Drive battery voltage out of range high
high
Drive left rear wheel angle sensor out of range Drive interrupted power (also occurs after
D7526 D7570
high software updates)
D7527 Drive left swash plate out of position D7571 Drive battery voltage out of range low
D7528 Drive right swash plate out of position D7572 Drive pump not calibrated
Drive operating mode switch flipped while
D7529 Drive left joystick X-axis out of range low D7573
operating
D7531 Drive left joystick Y-axis out of range low D7574 Drive right wheel speed uncommanded motion
D7532 Drive right joystick Y-axis out of range low D7575 Drive left wheel speed uncommanded motion
Drive right front wheel angle sensor out of range
D7533 D7576 Drive no communication from ACS controller
low
Drive left front wheel angle sensor out of range
D7534 D7577 Drive left speed sensor out of range high
low
Drive right rear wheel angle sensor out of range
D7535 D7578 Drive right speed sensor out of range high
low
Drive left rear wheel angle sensor out of range
D7536 D7579 Drive left speed sensor out of range low
low
D7537 Drive 5 volt sensor supply 1 out of range low D7580 Drive right speed sensor out of range low
D7538 Drive 5 volt sensor supply 2 out of range low D7581 Drive right front steer retract short to battery
D7539 Drive left swash plate sensor out of range high D7582 Drive left front steer retract short to battery
D7540 Drive left swash plate sensor out of range low D7583 Drive right rear steer retract short to battery
D7541 Drive right swash plate sensor out of range high D7584 Drive left rear steer retract short to battery
D7542 Drive right swash plate sensor out of range low D7585 Drive 5 volt sensor supply 1 out of range high
D7543 Drive left forward drive solenoid error ON D7586 Drive 5 volt sensor supply 2 out of range high
D7544 Drive left reverse drive solenoid error ON D7587 Drive software update required
D7545 Drive right forward drive solenoid error ON D7588 Drive switched power stuck ON
D7546 Drive right reverse drive solenoid error ON D7589 Drive switched power error OFF
D7547 Drive right front steer extend short to battery D7590 Drive calibration performed
D7548 Drive left front steer extend short to battery D7591 Drive left swash plate sensor reversed
D7549 Drive right rear steer extend short to battery D7592 Drive right swash plate sensor reversed
D7550 Drive left rear steer extend short to battery D7593 Drive unresponsive right speed sensor
D7551 Drive steer pressure short to battery D7594 Drive unresponsive left speed sensor
D7552 Drive back-up alarm error ON D7595 Drive left speed sensor reverse direction
D7553 Drive left forward drive solenoid error OFF D7596 Drive right speed sensor reverse direction
D7554 Drive left reverse drive solenoid error OFF D7597 Drive controller programmed


D7598 Drive controller in calibration mode H4012 Right joystick thumb switch not in neutral
Drive AWS controller in wheel position
D7599 H4013 Right joystick grip no communication
calibration mode
H4016 Right joystick no communication
H1221 Right thumb switch out of range high H4028 Right joystick internal failure
H1222 Right thumb switch out of range low H4048 Right joystick multiple
H1224 Right thumb switch not in neutral H4302 Horn error ON
H1321 Left thumb switch out of range high H4303 Horn error OFF
H1322 Left thumb switch out of range low H4423 Auxiliary not programmed
H1324 Left thumb switch not in neutral H4497 Auxiliary controller programmed
H2005 Boost solenoid short to battery H4502 Right blinker error ON
H2006 Boost solenoid short to ground H4503 Right blinker error OFF
H2007 Boost solenoid open circuit H4602 Left blinker error ON
H2032 Boost solenoid overcurrent H4603 Left blinker error OFF
H2305 Rear base output short to battery H4721 8 volt sensor supply out of range high
H2306 Rear base output short to ground H4722 8 volt sensor supply out of range low
H2307 Rear base output open circuit H7404 Main controller no communication
H2332 Rear base output overcurrent
H2405 Rear rod output short to battery L0102 Lights button error ON
High-flow enable / auto idle enable button error
H2406 Rear rod output short to ground L0202
ON
H2407 Rear rod output open circuit L0302 Auxiliary enable button error ON
H2432 Rear rod output overcurrent L0402 Information button error ON
H2505 Diverter #2 short to battery L7404 Main controller no communication
H2506 Diverter #2 short to ground L7672 Left display panel needs programming
H2507 Diverter #2 open circuit
H2605 Front base output short to battery M0116 Air filter not connected
H2606 Front base output short to ground M0117 Air filter plugged
H2607 Front base output open circuit M0216 Hydraulic / Hydrostatic filter not connected
H2632 Front base output overcurrent M0217 Hydraulic / Hydrostatic filter plugged
H2705 Front rod output short to battery M0309 System voltage too low
H2706 Front rod output short to ground M0310 System voltage too high
H2707 Front rod output open circuit M0311 System voltage extremely high
H2732 Front rod output overcurrent M0314 System voltage extremely low
H2805 Diverter short to battery M0322 System voltage out of range low
H2806 Diverter short to ground M0409 Engine oil pressure too low
H2807 Diverter open circuit M0414 Engine oil pressure extremely low
H2905 High-flow short to battery M0415 Engine oil pressure in shutdown
H2906 High-flow short to ground M0421 Engine oil pressure out of range high
H2907 High-flow open circuit M0422 Engine oil pressure out of range low
H2932 High-flow overcurrent M0509 Hydraulic charge pressure too low
H3028 Controller memory failure M0510 Hydraulic charge pressure too high
H3128 Interrupted power failure M0511 Hydraulic charge pressure extremely high
H3648 Multiple ACD conflict error M0514 Hydraulic charge pressure extremely low
H3904 Left joystick in error M0515 Hydraulic charge pressure in shutdown
H3912 Left joystick thumb switch not in neutral M0521 Hydraulic charge pressure out of range high
H3913 Left joystick grip no communication M0522 Hydraulic charge pressure out of range low
H3916 Left joystick no communication M0610 Engine speed too high
H3928 Left joystick internal failure M0611 Engine speed extremely high
H3948 Left joystick multiple M0613 Engine speed no signal
H4004 Right joystick in error M0615 Engine speed in shutdown


M0618 Engine speed out of range M2202 Starter output error ON
M0634 Engine speed invalid information from ECU M2203 Starter output error OFF
M0710 Hydraulic oil temperature too high M2207 Starter output open circuit
M0711 Hydraulic oil temperature extremely high M2228 Starter output failure
M0715 Hydraulic oil temperature in shutdown M2302 Starter relay error ON
M0721 Hydraulic oil temperature out of range high M2303 Starter relay error OFF
M0722 Hydraulic oil temperature out of range low M2402 Fuel pull relay error ON
M0810 Engine coolant temperature too high M2403 Fuel pull relay error OFF
M0811 Engine coolant temperature extremely high M2502 Traction pull relay error ON
M0815 Engine coolant temperature in shutdown M2503 Traction pull relay error OFF
M0821 Engine coolant temperature out of range high M2602 Glow plug relay error ON
M0822 Engine coolant temperature out of range low M2603 Glow plug relay error OFF
M0909 Fuel level too low M2721 Throttle primary sensor out of range high
M0921 Fuel level out of range high M2722 Throttle primary sensor out of range low
M0922 Fuel level out of range low M2821 Throttle secondary sensor out of range high
M1016 Hydraulic charge filter not connected M2822 Throttle secondary sensor out of range low
M1017 Hydraulic charge filter plugged M3028 Controller memory failure
M1121 Seat bar sensor out of range high M3128 Interrupted power failure
ACS (AHC) no communication to Bobcat
M1122 Seat bar sensor out of range low M3204
controller
M1128 Seat bar sensor failure M3304 Deluxe panel no communication
M1305 Fuel hold solenoid short to battery M3404 Deluxe panel in error
M1306 Fuel hold solenoid short to ground M3505 Hydraulic fan short to battery
M1307 Fuel hold solenoid open circuit M3506 Hydraulic fan short to ground
M1402 Fuel pull solenoid error ON M3507 Hydraulic fan open circuit
M1403 Fuel pull solenoid error OFF M3532 Hydraulic fan overcurrent
M1407 Fuel pull solenoid open circuit M3705 Two-speed second output short to battery
M1428 Fuel pull solenoid failure M3706 Two-speed second output short to ground
M1502 Traction lock pull output error ON M3707 Two-speed second output open circuit
M1503 Traction lock pull output error OFF M3732 Two-speed second output overcurrent
M1507 Traction lock pull output open circuit M3805 Auxiliary hydraulic lock short to battery
M1528 Traction lock pull output failure M3806 Auxiliary hydraulic lock short to ground
M1605 Traction lock hold solenoid short to battery M3807 Auxiliary hydraulic lock open circuit
M1606 Traction lock hold solenoid short to ground M3832 Auxiliary hydraulic lock overcurrent
M1607 Traction lock hold solenoid open circuit M4109 Alternator too low
M1705 Hydraulic lock valve short to battery M4110 Alternator high
M1706 Hydraulic lock valve short to ground M4111 Alternator extremely high
M1707 Hydraulic lock valve open circuit M4304 Keyless panel no communication
M1732 Hydraulic lock valve overcurrent M4404 Auxiliary no communication
M1805 Lift spool lock output short to battery M4510 Water in fuel sensor too high
M1806 Lift spool lock output short to ground M4511 Water in fuel sensor extremely high
M1807 Lift spool lock output open circuit M4521 Water in fuel sensor out of range high
M1832 Lift spool lock output overcurrent M4522 Water in fuel sensor out of range low
M2005 Two-speed primary solenoid short to battery M4621 5 volt sensor supply out of range high
M2006 Two-speed primary solenoid short to ground M4622 5 volt sensor supply out of range low
M2007 Two-speed primary solenoid open circuit M4721 8 volt sensor supply out of range high
M2032 Two-speed primary solenoid overcurrent M4722 8 volt sensor supply out of range low
M2102 Glow plug output error ON M4802 Front light relay error ON
M2103 Glow plug output error OFF M4803 Front light relay error OFF
M2107 Glow plug output open circuit M4902 Rear light relay error ON
M2128 Glow plug output failure M4903 Rear light relay error OFF


DPF automatic regeneration active (Operate
M5002 Front light output error ON M8542
machine under load)
M5003 Front light output error OFF M8551 DPF regeneration needed - inhibit active
DPF regeneration needed - inhibit active
M5007 Front light output open circuit M8552
(Operate machine under load)
DPF remote parked regeneration required
M5028 Front light output failure M8553
(Remote regeneration kit required)
DPF service regeneration required (Contact
M5102 Rear light output error ON M8554
Bobcat dealer)
M5103 Rear light output error OFF M8555 DPF service required
M5107 Rear light output open circuit M8560 DPF service regeneration active
M5128 Rear light output failure M8561 DPF service regeneration active
M5202 Press to operate button error ON M8562 DPF service regeneration active
M5221 Press to operate button out of range high M8563 DPF service regeneration active
M5222 Press to operate button out of range low M8564 DPF service regeneration active
M5305 Press to operate light short to battery M8615 Engine speed derate in shutdown
M5306 Press to operate light short to ground M8625 Engine speed derate unresponsive
M5405 Tilt spool lock short to battery
M5406 Tilt spool lock short to ground R7404 Main controller no communication
M5407 Tilt spool lock open circuit
M5432 Tilt spool lock overcurrent T9002 Service tool output ‘C’ error ON
M5902 DPF regeneration switch error ON T9003 Service tool output ‘C’ error OFF
M6002 DPF inhibit regeneration switch error ON T9102 Service tool output ‘D’ error ON
M6102 Remote parked regeneration switch error ON T9103 Service tool output ‘D’ error OFF
M6402 Switched power relay error ON T9202 Service tool output ‘E’ error ON
M6403 Switched power relay error OFF T9203 Service tool output ‘E’ error OFF
M6505 ECU power short to battery T9302 Service tool output ‘F’ error ON
M6506 ECU power short to ground T9303 Service tool output ‘F’ error OFF
M6507 ECU power open circuit
ACS (AHC) no communication to Bobcat
M6604 ECU no communication W3204
controller
M6702 HVAC output error ON W3223 ACS (AHC) calibration required
M6703 HVAC output error OFF W3224 ACS (AHC) calibration performed
M6707 HVAC output open circuit W3225 ACS (AHC) actuator calibration failed
M6728 HVAC output failure W3231 ACS (AHC) tilt actuator
M6802 HVAC relay error ON W3232 ACS (AHC) tilt actuator wiring
M6803 HVAC relay error OFF W3233 ACS (AHC) tilt handle wiring
M7002 Switched power output error ON W3234 ACS (AHC) tilt actuator not in neutral
M7003 Switched power output error OFF W3235 ACS (AHC) tilt handle / pedal not in neutral
M7007 Switched power output open circuit W3236 ACS (AHC) lift actuator
M7028 Switched power output failure W3237 ACS (AHC) lift actuator wiring
M7304 Remote control no communication W3238 ACS (AHC) lift handle wiring
M7316 Remote control no communication to transmitter W3239 ACS (AHC) lift actuator not in neutral
M7423 Main controller not programmed W3240 ACS (AHC) lift handle / pedal not in neutral
M7472 Main controller needs programming W3241 ACS (AHC) no communication
M7497 Main controller programmed W3249 ACS (AHC) lift actuator short to ground
M7504 Drive no communication W3250 ACS (AHC) tilt actuator short to ground
M7604 Left display panel no communication W3251 ACS (AHC) lift actuator short to battery
M7748 Key switch multiple W3252 ACS (AHC) tilt actuator short to battery
M7839 Hourmeter changed W3253 ACS (AHC) lift handle / pedal short to ground
M7974 Door open W3254 ACS (AHC) tilt handle / pedal short to ground
M8541 DPF automatic regeneration active W3255 ACS (AHC) lift handle / pedal short to battery


W3256 ACS (AHC) tilt handle / pedal short to battery W3268 ACS (AHC) lift handle information error
W3257 ACS (AHC) lift actuator reduced performance W3270 ACS (AHC) right drive handle short to ground
W3258 ACS (AHC) tilt actuator reduced performance W3271 ACS (AHC) right drive handle short to battery
W3259 ACS (AHC) lift actuator wrong direction W3274 ACS (AHC) left joystick X-axis out of range
W3260 ACS (AHC) tilt actuator wrong direction W3275 ACS (AHC) interrupted unswitched power
W3261 ACS (AHC) handle lock short to ground W3276 ACS (AHC) CAN joystick information error
W3262 ACS (AHC) handle lock short to battery W3277 ACS (AHC) remote control information error
W3263 ACS (AHC) pedal lock short to ground W3297 ACS (AHC) controller programmed
W3264 ACS (AHC) pedal lock short to battery W3905 Left joystick X-axis not in neutral
W3265 ACS (AHC) sensor supply voltage out of range W4005 Right joystick X-axis not in neutral
W3266 ACS (AHC) battery voltage out of range W4007 Right joystick Y-axis not in neutral
W3267 ACS (AHC) switch flipped while operating

60-90-8
T770 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Figure 60-100-1
1 2 3
4
3
P-85413C
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system
consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-100-1] of the loader cab.
The Press To Operate button (Items 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS™ (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
Figure 60-100-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 PRESS TO OPERATE LOADER button.
2 3
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
4 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5
brake is disengaged.
6 Inspecting The Lift Arm Bypass Control

P-85413E
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob 90°
1. Sit in operator’s seat. Turn key switch to RUN or press
clockwise. Pull up and hold lift arm bypass control
RUN button. Lower seat bar and disengage parking
knob until lift arms slowly lower.
brake. Press the PRESS TO OPERATE LOADER
button (Item 6). Two BICS™ lights (Items 1 and 2)
Inspecting Deactivation Of Lift And Tilt Functions
[Figure 60-100-2] [SEAT BAR and LIFT AND TILT
(ACS And SJC)
VALVE] on left instrument panel must be OFF. The
PRESS TO OPERATE LOADER button will light.
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
2. Raise seat bar fully. All three BICS™ lights (Items 1,
LOADER button.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT AND
TILT VALVE and PARKING BRAKE] on left
10. Raise lift arms about 2 m (6 ft) off the ground.
instrument panel must be ON. The PRESS TO
OPERATE LOADER button light will turn OFF.
11. Turn key switch OFF or press STOP button and wait
for the engine to come to a complete stop.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
12. Turn key switch ON or press RUN button. Press the
PRESS TO OPERATE LOADER button, move the
3. Sit in operator’s seat, lower seat bar and press the
control (foot pedal, hand control or joystick) to lower
PRESS TO OPERATE LOADER button (Item 6).
the lift arms. Lift arms must not lower.
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
13. Move the control (foot pedal, hand control or joystick)
60-100-2]. Raise the seat bar. The light must be OFF.
to tilt the bucket (or attachment) forward. The bucket
(or attachment) must not tilt forward.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt. WARNING
5. Start engine and operate at low idle. Press the
PRESS TO OPERATE LOADER button. While raising AVOID INJURY OR DEATH
the lift arms, raise the seat bar fully. The lift arms must The Bobcat Interlock Control System (BICS™) must
stop. Repeat using the tilt function. deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-1111

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

60-100-4
T770 Service Manual
SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:
Connect the seat bar sensor adapter leads (MEL1567) to

the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operators seat.
Figure 60-110-5
1
2
P100745
Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-110-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-110-7].
2
P100742
Remove the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5]. Disconnect the sensor wiring
Figure 60-110-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-110-6].
NOTE: Approximately 4 turns of the clevis bolt

should be adequate to release the spring
tension. When tension is released, the clevis
pin can easily be rotated using the retaining
pin.

SEAT BAR SENSOR (CONT'D) Remove and save the metal pivot bushing (Item 6)
[Figure 60-110-9].
Figure 60-110-10
Figure 60-110-8
3
1
4
P100748
P100746
Install the new keyed bushing (Item 1), magnet bushing

Pull the front of the seat bar down slightly from the top of (Item 2) and seat bar sensor (Item 3) [Figure 60-110-10].
the cab, while raising the sensor end of the seat bar up, Reinstall the metal pivot bushing (Item 4) [Figure 60-
away from the mount [Figure 60-110-8]. 110-10].
NOTE: The sensor end of the seat bar will raise easily NOTE: The sensor must be centered on the metal
ONLY if the front of the seat bar is pulled pivot bushing. When centered, the assembly
slightly down from the top of the cab. will slide freely into the mount.
Figure 60-110-9 Figure 60-110-11
3 3
1
6 1
2
2
P100747 P100749
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9] Position the clevis (Item 1) over the mount (Item 2) and
on the cab side screen to hold the seat bar above the lower the end of the seat bar until the mounting bolt (Item
mount. 3) [Figure 60-110-11] is resting on the top of the mount.
Remove the clevis pin bushing (Item 2) [Figure 60-110- Remove the nut from the mounting bolt. Remove the
9]. Apply grease to the shoulder of the bushing to help mounting bolt and lower the seat bar until the seat bar
retain it during assembly. Reinstall the clevis pin bushing. and mount holes align and the clevis is over the clevis pin
bushing. Reinstall the seat bar mounting bolt. Apply
Remove and dispose of the keyed bushing (Item 3), Loctite® 243 to the nut threads. Install the nut and tighten
magnet bushing (Item 4), and seat bar sensor (Item 5) to 34 ft-lb (46 N•m) torque.
[Figure 60-110-9].

SEAT BAR SENSOR (CONT'D)
Figure 60-110-12
1
2
P100751 3
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-110-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5] and tighten to 6,8 N•m (60 in-lb)
torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.

Bobcat Interlock Control System (BICS™) Circuit

Test
Figure 60-110-13
3
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-14] on the sensor tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-110-13].
NOTE: The sensor test light (Item 3) [Figure 60-110-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)
Figure 60-110-15
P-85413
The BICS™ seat bar indicator light (Item 1) [Figure 60-

110-15] should turn OFF.
Figure 60-110-16
P-4699
Move the toggle switch (Item 1) [Figure 60-110-16] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-15] should

illuminate.
If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.

60-110-8
T770 Service Manual
TRACTION LOCK
Description
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS™).

TRACTION LOCK (CONT'D)
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 #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.
(See ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Check the brake solenoid mounting nut for correct torque.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check the flywheel rpm sensor and wiring.

TRACTION LOCK (CONT'D) Figure 60-120-2
Inspecting
Figure 60-120-1
P-85923
1
Inspect the wire connections at the engine speed sensor
P-85413 (Item 1) [Figure 60-120-2].
NOTE: When the Traction Lock Override Button is

Fasten the seat belt, disengage the parking brake button, activated, the Traction Lock Override Control
press the PRESS TO OPERATE LOADER Button (Item System will NOT engage the Traction Lock if
1) and raise the Seat Bar fully. Move the steering levers the engine stops.
slowly forward and backward. The TRACTION lock (Item
1) should be engaged. Lower the Seat Bar. Press the
PRESS TO OPERATE LOADER Button (Item 1) [Figure
60-120-1].
Engage the parking brake pedal and move the steering

levers slowly forward and backward. The TRACTION lock
should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

60-120-4
T770 Service Manual
CONTROL SYSTEM (ACS)
Description
The ACS option allows the operator to quickly switch

between foot and hand control modes. It uses the electric
actuators to control the lift and tilt spools, foot sensors,
handle sensors and a specially designed control handle.

CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
1
3
2
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be
removed from the handle sensor wires, use the following 1-Terminal - Red
procedure. 2-Terminal - Black
3-Terminal - Green
Figure 60-130-2
1 1
1 1
P13725
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

Switch Handle Removal
Figure 60-130-4
3 1
2
P13735
2 1
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.
130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
P13725 P13732

harness connector (Black) that connects to the handle
1 lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

Switch Handle Removal (Cont'd)
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 152,4 mm (6 in) piece of
heat shrink tube side on the end of the wires. Remove
Cut the wires (Item 2) [Figure 60-130-12] below the the heat shrink tube from the end of the wires before
switch handle and remove switch handle. routing through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Pull harness (Item 1) [Figure 60-130-13] out the bottom

of the control lever tube.

CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont’d) Right Switch Handle
Figure 60-130-15 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
1 F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700 C-Terminal - Purple/White
Left Switch Handle

Install the new switch handle and wires from the top of
the control lever. Ten-Pin Connector
A-Terminal - Orange
Route wire (Item 1) [Figure 60-130-15] through the B-Terminal - Dk. Blue
casting, along side the handle sensor and into the control C-Terminal - White
lever tube. D-Terminal - Purple
E-Terminal - Yellow/Red
NOTE: Do not pull the wire harness tight, allow a F-Terminal - Tan
small amount of slack or slight bend at the G-Terminal - Pink
handle pivot area. Verify the control handle H-Terminal - Orange/Black
returns to neutral position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Remove tape from wires for installation and install the

152,4 mm (6 in) of heat shrink tube (Item 1) [Figure 60-
130-16] approximately 76,2 mm (3 in) into the control
lever. Apply heat to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
1 P13735
Install the wires into the connectors as listed below:

P-90995
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18 1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
Figure 60-130-20
1
1
1
1
3
P-90994 2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
P13735
connectors.
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

Switch Handle Installation (Cont'd)
Figure 60-130-21
N-17741
Installation: Install the wires into the connector as listed

P-21804 below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Connect the handle harness connectors to the sensor Lift And Tilt Actuator
and lock solenoid connectors [Figure 60-130-21]. 1. Terminal-Black/Green-Larger diameter wire (16
gauge)
Actuator Connector Disassembly And Assembly 2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
NOTE: Actuator shown removed for clarity. Not gauge)
necessary for procedure. 4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)

Figure 60-130-22 6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)
1
P-66842
Inspect the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.

CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
130-24] from the handle lock solenoid connector. Figure 60-130-27
Figure 60-130-25
1
P-21789
1
P-21832
Replace the O-ring (Item 1) [Figure 60-130-27].
Remove the two screws (Item 1) [Figure 60-130-25]

holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38

in-lb) torque.
Remove handle lock solenoid assembly from handle.

Foot Sensor Removal And Installation
Figure 60-130-28
2
1
1
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].

Remove the hairpin clip and the pin (Item 1) [Figure 60-
130-28] from the foot sensor.
Figure 60-130-29
1
P-90982
Disconnect the wire harness (Item 1) [Figure 60-130-29]

from the foot sensor.

CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Lock Solenoid Removal And Installation
Foot Sensor Disassembly And Assembly Figure 60-130-33
Figure 60-130-31
1 1
P-90992
1
P-24269
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Tighten the bolts to 10,2 N•m (90 in-lb) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite® #242 to the threads. and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-32
Figure 60-130-34
5
4
3 1
2
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130- Replace the O-ring (Item 1) [Figure 60-130-34].
32].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-32]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA1014A / B-15781E
REF. NO. DESCRIPTION

1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 ENGINE SPEED CONTROL
6 STEERING LEVERS
7 LIFT ARM PEDAL
8 TILT PEDAL
9 LIFT ARM BYPASS CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for

more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
12, 13,
B-16447 14 B-16448
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA1164A / B-15781E

4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9 TILT PEDAL
13 NOT USED

ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front 11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA1165A / B-19874A

1 SPEED MANAGEMENT
Also: TWO-SPEED CONTROL
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE

4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 ENGINE SPEED CONTROL (HAND)
9 JOYSTICKS
10 FOOTRESTS
11 ENGINE SPEED CONTROL (FOOT)
14 NOT USED
16 NOT USED
18 FLOAT CONTROL

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2

procedure:
MEL1563 - Remote Start TooL Kit

MEL1566 - Service Tool Harness Communicator 2
(Computer Interface)
Figure 60-150-1
1 2
3
1
P-76450
3
procedure:
Order from Bobcat Parts P/N: 7217666 - Remote Start

Tool (Service Tool) Kit
P16119 Kit Includes:
7022042 - Remote Start Tool (Service Tool)

The Service PC (Item 1) with the Remote Start Tool (Item 6689747 - Loader Service Tool Harness
2) [Figure 60-150-1]. When connected to the loader, the 6689746 - Computer Service Tool Harness
Service PC is used to monitor, conduct diagnostics, and 6689745 - BOSS® Service Tool Harness
upgrade software. NOTE: Make all connections with the key in the OFF
position.
NOTE: Make all connections with the key in the OFF
position. The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-150-2]. When
Connect the Service Tool Harness Communicator connected to the loader, the Service PC is used to
(MEL1566) (Item 3) [Figure 60-150-1] to the designated monitor, conduct diagnostics, and upgrade software.
serial port on the Service PC.
Connect the Remote Start Tool (Service Tool) Computer
NOTE: The recommended serial cable length should Service Tool Harness (Item 3) [Figure 60-150-2] to the
not exceed 4,6 m (15 ft). A serial cable longer designated serial port on the Service PC.
than 4,6 m (15 ft) will create a degraded signal
causing communication errors. NOTE: The recommended serial cable length should
not exceed 4,6 m (15 ft). A serial cable longer
Connect the other end to the connector on the Remote than 4,6 m (15 ft) will create a degraded signal
Start Tool. causing communication errors.
Connect the remote start tool to the loader. (See Connect the other end to the connector on the Remote
REMOTE START TOOL KIT- MEL1563 on Page 10-60- Start Tool (Service Tool).
1.)
NOTE: Refer to BobcatNET for PC requirements and loader. (See REMOTE START TOOL (SERVICE TOOL)
the latest Service Analyzer software. KIT - 7217666 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and

the latest Service Analyzer software.

60-150-2
T770 Service Manual
CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting
controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)

controller or actuator.
NOTE: Password protected machines must have the
The Hydrostatic Pump Calibration (SJC) provides set password entered to perform the calibration
points to the Drive controller to actuate the hydrostatic procedure.
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a If a Service PC is not available, (See Lift And Tilt
desired travel path cannot be attained or replacing the Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
hydrostatic pump, hydrostatic motor, or controller. After Calibration (ACS) on Page 60-160-11.).
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the NOTE: Warm the hydraulic oil to room temperature
hydrostatic pump control. 22°C (72°F), stop the engine and clear all
active service codes before running the test.
For more information on Steering Drift Compensation
(See STEERING DRIFT COMPENSATION on Page 60- Once the test is initiated, an automatic calibration
161-1.) sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
NOTE: The Actuator Test is the only test that uses a Service PC (Laptop) monitor.
Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
If the Actuator Test failed due to a slow return to neutral
• Actuator did not fully extend / retract. During the test, after checking the probable causes in Column 1 [Figure
the spool was not able to fully stroke in both 60-160-2], check the following probable causes in
directions. Column 2 [Figure 60-160-2].
• Actuator out of neutral. The spool did not return to the • Contamination in the spool.
neutral window during the test.
• The spool end cap may be defective or the centering
NOTE: A time out will occur if the test cannot be spring may be broken. Inspect the end cap and the
completed within 8 seconds. If this happens, centering spring, replace if necessary.
retry the test.
• The wire harness or connectors may have an
Figure 60-160-2 intermittent short. Check the connections and wire
Run Actuator Test harnesses.
• The controller may be defective, replace the

Pass Fail controller.
Retest With Warm Hydraulic Oil
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.
• The actuator may be defective, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.


CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.

password entered to perform the calibration
procedure.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See P-85958 P-85958
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed Move the right joystick to the forward-right corner position
when replacing the hydraulic control valve, lift [Figure 60-160-4] and hold in position.
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
Figure 60-160-3
SJC
1
P-85307
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
P-85413C
P-85493A
At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the key switch (Item 1) (Item 1) [Figure 60-160-7] while holding the right joystick
[Figure 60-160-5] to the RUN position. Machines in position.
equipped with the deluxe panel, press run / enter.
Release the joystick.
NOTE: Do not start the engine.
NOTE: During the calibration cycle, the system will
Figure 60-160-6 beep. Once the calibration is complete, code
W3224 (Calibration Performed) or W3225
SJC (Calibration Failure) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-85307
The loader Control Pattern Switch (Item 1) [Figure 60-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.

CALIBRATION (CONT'D) Figure 60-160-9
Hydrostatic Pump Calibration (SJC)
WARNING
W-2017-0286 P-85493A
NOTE: If the speed sensors are removed or

With the seat bar down, turn the key switch (Item 1)
disconnected the drive calibration procedure
[Figure 60-160-9] to the RUN position. Machines
must be performed.
equipped with the deluxe panel press run / enter.
NOTE: If swash plate sensors have been removed and
NOTE: Do not start the engine.
reinstalled, replaced or adjusted the drive
calibration procedure must be performed.
Figure 60-160-10
Place the loader on jackstands. (See Procedure on Page SJC
10-10-1.)

procedure.
Operator must be in the seat and the seat bar down.
Close the cab door. (If equipped.)
Figure 60-160-8 1
SJC
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

10] will start flashing.
P-85307
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-8] in the ISO position.
Verify that the parking brake switch is in the OFF position.

Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-11
B-19873
P-85960
B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-160-13] and hold in position.
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
P-85413C
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-160-12] while holding the left joystick in
position.
Audible beeps will sound, release handle.

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC
Figure 60-160-15
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-85961 17] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Allow the left joystick to go to the neutral position [Figure Figure 60-160-18
60-160-15].
Figure 60-160-16
1
P-85760A
1
P-85413C Move the engine speed control (Item 1) [Figure 60-160-

18] to high idle.
Press the PRESS TO OPERATE LOADER Button (Item NOTE: If at any time, during calibration, the operator
1) [Figure 60-160-16]. needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
Audible beeps will sound. neutral position.
Start the engine from the RUN, RUN / ENTER position. The calibration procedure will stop.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be To return to calibration mode, the operator
repeated. must start the complete procedure from the
beginning.

Hydrostatic Pump Calibration (SJC) (Cont'd)
1 2
WARNING
W-2017-0286
Figure 60-160-19 P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-20] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-20] until it reaches full speed and then
come to a stop.
Loaders with software version (79.7 or newer). The

loader tires or tracks will momentarily reverse then rotate
forward and “stair step” the speed (Item 2) [Figure 60-
160-20] until it reaches full speed and then “stair step”
B-19873 down and come to a stop.

P-85962
Continue to hold the left joystick in the forward position
until the loader wheels or tracks come to a stop and an
Move and hold the left joystick to the forward position audible beep is heard.
[Figure 60-160-19] until the forward calibration is
completed. Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.

CALIBRATION (CONT'D) Continue to hold the left joystick in the reverse position
until the loader wheels or tracks come to a stop and an
Hydrostatic Pump Calibration (SJC) (Cont'd) audible beep is heard.
Figure 60-160-21 Reverse calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Reverse in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
There will be an audible beep, the PRESS TO OPERATE

LOADER button light will remain on. The TRACTION light
will illuminate, the SEAT BAR, and LIFT AND TILT lights
will be off. The D7598 error code will clear. There should
be no other codes in the display area.
B-19873 Allow the joystick to go to the neutral position.

P-85963
Once the calibration procedure is complete the Steering
Drift Compensation values will be reset to [S----] or
Move and hold the left joystick to the reverse position neutral.
[Figure 60-160-21] until the reverse calibration is
completed. Press the PRESS TO OPERATE LOADER button. Move
the left joystick to forward position [Figure 60-160-19]
Figure 60-160-22 and check for normal forward wheel or track rotation.
Move the left joystick to the reverse position [Figure 60-
160-21] and check for normal reverse wheel or track
1 2 rotation.
Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
P-64321 If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
The loader speed will “ramp up” quickly (Item 1) or [S-L10], see the electrical and hydrostatic
[Figure 60-160-22] and slow down 3 times in a row. troubleshooting. (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 60-10-8.)
The loader will then “stair step” the speed (Item 2)
[Figure 60-160-22] until it reaches full speed and then
come to a stop.
Loaders with software version (79.7 or newer). The

loader tires or tracks will momentarily reverse then rotate
forward and “stair step” the speed (Item 2) [Figure 60-
160-20] until it reaches full speed and then “stair step”
down and come to a stop.

Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool 1
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.

procedure.
P-85493A
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See With the seat bar down, turn the key switch (Item 1)
Actuator Testing on Page 60-160-1.) [Figure 60-160-24] to the RUN position. (Deluxe
Instrumentation Panel press RUN / ENTER).
NOTE: This calibration procedure must be followed
when replacing a hydraulic control valve, NOTE: Do not start the engine.
actuator or ACS controller. Failure to calibrate
after component replacement may result in Figure 60-160-25
poor performance or reduced life of
actuator(s).
Figure 60-160-23
ACS
P-85413C
1
Push the PRESS TO OPERATE button (Item 1) [Figure

P-85307B 60-160-25] to unlock the hand controls.
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-23] in

the hand control mode.
Close the cab door. (If loader is equipped.)

Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-26
Stroke Both Handles Fully In and Hold Them
P-85413C
Push the PRESS TO OPERATE button (Item 1) [Figure

B-16628 60-160-27] to begin calibration.
NOTE: The ACS icon will light up and if you listen

Fully stroke both control handles in toward the center of closely the cycling of the actuators can be
the cab and hold the handles [Figure 60-160-26]. heard. The ACS icon will stay lit until the key
switch is cycled or the loader is started and a
Lift the seat bar, high enough for the PRESS TO function is operated.
OPERATE light (Item 1) [Figure 60-160-27] to go OFF.
NOTE: During the calibration cycle, the system will
Lower the seat bar. beep. Once the calibration is complete, code
W3224 (Calibration Performed) or W3225
(Calibration Failure) will be generated.
Release the control handles.
Calibration is complete.

STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to activate the BICS™.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as track 3. Place joysticks in neutral position.
tension and track wear.
4. Start the engine.
• Using side shift attachments such as trenchers,
planers and silt fence installers. 5. Press the PRESS TO OPERATE LOADER button.
• Driving on uneven terrain such as crowned road 6. Current drive response setting will be displayed briefly
surfaces. in the data display.
Figure 60-161-1 NOTE: Raising the seat bar or changing control

mode (ISO / H) will cause the machine to
STEERING DRIFT COMPENSATION disengage from steering drift compensation.
The last displayed setting will remain in effect
until the machine is turned OFF.
B-23580D
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

STEERING DRIFT COMPENSATION (CONT’D) Press the right scroll button on the left panel or the right
button on the left joystick to adjust the machine back
Operation (Cont’d) toward center. The display will decrease down to neutral
displayed as [S----] (Item 5). Another press of the upper
Figure 60-161-2 right button will cause [S-R01] (Item 6) to appear in the
data display (Item 1) [Figure 60-161-2]. The number will
increase by one each time you press the button up to a
maximum of [S-R10]. The higher the number, the greater
the amount of steering drift compensation to the right.
Forward steering drift compensation setting can be

2 adjusted with the steering controls in neutral or during
forward travel. Reverse steering drift compensation
setting can be adjusted during reverse travel.
3
Saving The Steering Drift Compensation Setting:
1
NA3172
The current steering drift compensation setting can be
saved by pressing the Information button (Item 3) [Figure
4 5 6 60-161-2] to exit from the steering drift compensation
adjustment menu.
NA3080 / NA3082 / NA3081
OR
Left Joystick Right Joystick
If no buttons are pressed for 10 seconds, the steering
drift compensation setting will be saved and the display
screen will change to the hourmeter.
P107005D P107006D
Press the Information button (Item 3) to cycle the data

display until the steering drift compensation menu is
displayed. The current steering drift compensation setting
will appear in the data display (Item 1) [Figure 60-161-2].
Press the left or right scroll button (Item 2) [Figure 60-

161-2] on the left panel to adjust the setting. Adjustments
to steering drift compensation are effective immediately.
OR
Press the left or right button (Item 7) [Figure 60-161-2]

on the left joystick to adjust the setting. Adjustments to
the steering drift compensation are effective immediately.
Press the left scroll button on the left panel or the left
button on the left joystick to adjust the machine left.
[S-L01] (Item 4) through a maximum of [S-L10] will
appear in the data display (Item 1) [Figure 60-161-2].
The number will increase by one each time you press the
button. The higher the number, the greater the amount of
steering drift compensation to the left.

FLYWHEEL RPM SENSOR Turn the jam nut (Item 2) [Figure 60-170-2] until it
contacts the flywheel housing. Do not tighten the nut at
Description this time.
The flywheel rpm sensor has a magnet located on the Figure 60-170-3
end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
controller which registers the rpm of the engine.
2
The flywheel rpm sensor is located just above the starter
on the left side of the engine.
Removal
Figure 60-170-1
1
2
1 P101576
Turn the rpm sensor and the jam nut out from the
flywheel. Adjust the sensor until a clearance of 1,27 mm
(0.050 in) between the nut and the housing using a feeler
gauge (Item 1) [Figure 60-170-3] is obtained.
Tighten the nut (Item 2) [Figure 60-170-3] to 20,3 N•m

(15 ft-lb) torque.
P103574
NOTE: New rpm sensors have a plastic tip which is
used as a gauge during installation. The
Disconnect the wire harness (Item 1). Loosen the jam nut plastic tip is designed to come off after the
(Item 2) [Figure 60-170-1] and remove the rpm sensor. engine is started.
Installation NOTE: When installing a new rpm sensor, install the

rpm sensor into the flywheel housing until the
Figure 60-170-2 tip of the rpm sensor touches the flywheel.
Tighten the jam nut to 20,3 N•m (15 ft-lb)
torque and connect the wire harness. No
additional adjustments are necessary.
2
1
P103573
Turn the rpm sensor (Item 1) [Figure 60-170-2] in until it

makes contact with the engine flywheel.

60-170-2
T770 Service Manual
CONTROL PANEL SETUP Vitals
Right Panel Setup (Deluxe Instrumentation Panel)
Icon Identification Press a scroll button (Item

1) repeatedly until the
Figure 60-180-1 Vitals screen icon (Inset)
is highlighted.
1 1
Displays select system

operating levels.
You can monitor real-time displays of:
Engine Speed
NA3189 Engine Oil Pressure
Engine Coolant Temperature
System Voltage
ICON DESCRIPTION Hydraulic Charge Pressure
Hydraulic Fluid Temperature
DATE / TIME
The Deluxe Instrumentation Panel is easy to use.
USER / HOURMETER Continue to set your own preferences for operating /
monitoring your Bobcat loader.

CURRENT JOB HOURS
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
HOME icon (Return to MAIN screen)
LEFT SCROLL button
RIGHT SCROLL button
ENTER button

CONTROL PANEL SETUP (CONT’D) Languages
Right Panel Setup (Deluxe Instrumentation Panel)

(Cont’d)
Date And Time 1) repeatedly until the
Display screen icon (Inset)
is highlighted.
1 1
1) repeatedly until the Select [2. LANGUAGES].
is highlighted.
1 1
Select [1. CLOCKS].
Select the desired

language.
Select [1. TIME].

English / Metric Display
Use the keypad to enter Press a scroll button (Item
time. 1) repeatedly until the
Select AM / PM / 24hr. is highlighted.
1 1
Press [ENTER] to
continue.
Select [4. DISPLAY

SETTINGS].
Select [2. DATE].
Use the keypad to enter Press [1] to cycle between

date. ENGLISH and METRIC.
Press [ENTER] to
continue.

CONTROL PANEL SETUP (CONT’D)
Right Panel Setup (Deluxe Instrumentation Panel) (Cont’d)
Job Clock Reset Machine Lockouts
Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Security screen icon Security screen icon
(Inset) is highlighted. (Inset) is highlighted.
1 1 1 1
Select [1. PASSWORDS /

LOCKOUTS]. Select [1. PASSWORDS /
LOCKOUTS].
Enter owner password

and press [ENTER]. Enter owner password
and press [ENTER].
Select [1. USER

SETTINGS]. Select [3. HIGH FLOW].
Select [4. TWO-SPEED].
Select user. HIGH FLOW
Press user number to

cycle between LOCKED
and UNLOCKED.
Select [3. RESET JOB

STATISTICS]. TWO-SPEED
Press user number to

cycle between LOCKED
and UNLOCKED.
Press [9] to reset job
statistics.
Press left scroll button or NOTE: High Flow and Two-Speed lockouts for the
[0] to exit without saving. owner are active even if the Password
Lockout feature is unlocked.

60-180-4
T770 Service Manual
PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Password Setup is available on machines with a Deluxe

Instrumentation Panel. Press a scroll button (Item
Password Description Security screen icon
(Inset) is highlighted.
All new machines with a Deluxe Instrumentation Panel
1 1
arrive at Bobcat dealerships with the keypad in locked
mode. Locked mode means that a password must be
used to start the engine.
For security purposes, your dealer may change the Select [1. PASSWORDS /
password and set the keypad in the locked mode. Your LOCKOUTS].
dealer will provide you with the password.
Master Password:
A permanent, randomly selected password set at the

factory that cannot be changed. This password is
used for service by the Bobcat dealer if the owner Enter owner password
password is not known or to change the owner and press [ENTER].
password.
Owner Password:
Allows for full use of the loader and to set up the

Deluxe Instrumentation Panel. There is only one
Select [1. USER
owner password. The owner password must be used

to change the owner or user passwords. Owner SETTINGS].
should change the password as soon as possible for
security of the loader.
User Password:
Allows starting and operating the loader; cannot

change password or any of the other setup features. Select [1. OWNER].
For the procedures to change passwords (See Changing

The Owner Password on Page 60-190-1.) and (See
Changing The User Passwords on Page 60-190-2.)
Select [2. CHANGE

PASSWORD].
Enter new owner

password and press
[ENTER].
You will be prompted to

reenter the new owner
password.

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Passwords feature so that a password does not need to be used
every time the engine is started.

Security screen icon Press a scroll button (Item
(Inset) is highlighted. 1) repeatedly until the
1 1 Security screen icon
(Inset) is highlighted.
1 1

LOCKOUTS].
LOCKOUTS].

and press [ENTER].
and press [ENTER].
Select [1. USER
SETTINGS].
Select [2. MACHINE
LOCK].
Select user. NOTE: The procedure above can be followed to reset

the machine lock so that the machine requires
a password to start the engine.
Select [2. CHANGE

PASSWORD].
Enter new user password

and press [ENTER].

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Turn the key switch to the RUN position to turn on the
factory that cannot be changed. This password is loaders electrical system.
used for service by the Bobcat dealer if the owner
password is not known or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-191-2
Allows for full use of the loader. Must be used to

change the owner password.
Changing The Owner Password
Turn the key switch to the RUN position to turn on the

loaders electrical system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.
1 2
Figure 60-191-1
P-90805
Press the unlock key (Item 2) [Figure 60-191-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2
The loader can now be started without using a password.
P-90805
NOTE: Use the following procedure to reset the
machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for 2 seconds. Turn the key switch to the RUN position to turn on the
loaders electrical system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].
Enter a new five digit owner password using the number The lock key red light will flash and the left panel display
keys (1 through 0). An asterisk will show in the left panel screen will show [CODE].
display screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit owner password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.

60-191-2
T770 Service Manual
MAINTENANCE CLOCK Figure 60-200-2
Description
The Maintenance Clock alerts the operator when the next

service interval is due. EXAMPLE: The maintenance
clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
1
Figure 60-200-1
1 NA3195
The Deluxe Instrumentation Panel (if equipped) will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.
3
This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
NA3086 maintenance clock is reset.
Figure 60-200-3
During machine operation, a 2 beep alarm will sound
when there are less than 10 hours until the next planned
maintenance.
The remaining hours before maintenance is required

(Item 1) will appear in the data display for 5 seconds
while the service icon (Item 3) and the hourmeter icon
(Item 2) [Figure 60-200-1] flash.
NOTE: The display will show negative numbers after

counting down to zero.
1
The display will revert to the previous display and will
appear for 5 seconds every time the machine is started
until the maintenance clock is reset.
NA3198
The Deluxe Instrumentation Panel (if equipped) will

display a bar (Item 1) [Figure 60-200-3] showing the time
remaining until next service. This bar will turn red when
service is past due. NEXT MAINTENANCE DUE will
change to MAINTENANCE PAST DUE and display the
number of hours past due.
Keys [4] and [9] can be used to adjust the service

interval when the owner is logged in [Figure 60-200-3].

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.
Figure 60-200-5
2
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.

Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
200-11] to reset and set the maintenance clock.

Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
NA3199
Press the Information button (Item 2) [Figure 60-200-16]

until the display screen shows the maintenance clock.
Press and hold the Information button (Item 2) for 7

seconds until [RESET] (Item 1) [Figure 60-200-16]
appears in the display screen.
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.

60-200-6
T770 Service Manual
BACK-UP ALARM SYSTEM Inspecting
The Back-up Alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
Figure 60-210-1
P-90644
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-2]. Replace if required.
1
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
P-85645B
Move both steering levers or joystick(s) into the reverse
position. The back-up alarm must sound when both
The back-up alarm (Item 1) [Figure 60-210-1] is located tracks are moving in reverse.
on the inside of the rear door.

The back-up alarm is located on the inside of the rear
A back-up alarm is not a substitute for looking to the door.
rear when operating the loader in reverse, or for
keeping bystanders away from the work area. Figure 60-210-3
Operators must always look in the direction of travel,
including reverse, and must also keep bystanders away
from the work area, even though the loader is equipped
with a back-up alarm.
Operators must be trained to always look in the direction

of travel, including when operating the loader in
reverse and to keep bystanders away from the work
1
area. Other workers should be trained to always keep
away from the operator’s work area and travel path.
2
P100048
Inspect the back-up alarm electrical connections (Item 1)

[Figure 60-210-3], wire harness (Item 2) [Figure 60-210-
3] and back-up alarm switches (if equipped) (Item 1)
[Figure 60-210-4] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on Page 60-210-2.)

BACK-UP ALARM SYSTEM (CONT’D) Figure 60-210-5
Adjusting Switch Position

1
NOTE: Joystick equipped machines do not have
back-up alarm switches and cannot be
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound. 2
Standard Controls And ACS (If Equipped) 3
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Place the steering levers in the neutral position.

P-85723A
Figure 60-210-4
Loosen the screws (Item 3) [Figure 60-210-5] securing

1
the back-up alarm switch. (Left side shown)
Position the back-up alarm switch so that the roller (Item

1) just makes contact with the bellcrank (Item 2) [Figure
60-210-5] without compressing the switch spring.
Torque the screws (Item 3) [Figure 60-210-5] securing

the switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Repeat adjustment procedure for the other switch.
P-85722 3.)
Inspect back-up alarm system for proper function. (See

The back-up alarm switches (Item 1) [Figure 60-210-4] Inspecting on Page 60-210-1.)
are located alongside the steering bellcranks. Both
switches must be adjusted properly for the back-up alarm
to operate correctly.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The back-up alarm or switch wires are disconnected.

5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches.
Standard Controls and ACS (If Equipped)
Figure 60-210-6
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
2 Figure 60-210-7
P-85280
1
Disconnect the alarm connector (Item 1) [Figure 60-210-

6] from the alarm.
P-85723A
Remove the two nuts (Item 2) [Figure 60-210-6].
Remove the alarm and bracket from the loader. Place the steering levers in the neutral position.
Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch (Item 2) [Figure 60-210-7] off
the mounting bracket.
Mark the wires for ease of assembly and disconnect

them from the switch.
Installation: Slide the alarm switches onto the mounting

bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjust the switches (See
Adjusting Switch Position on Page 60-210-2.) and inspect
back-up alarm operation (See Inspecting on Page 60-
210-1.) are required.

60-210-6
T770 Service Manual
FRONT HORN Figure 60-220-3
NOTE: Two different style horns are used.
Remove the left side lower panel. (See Removal And

Figure 60-220-1
1
1
1
P-90886
1
Remove the two bolts and nuts (Item 1) [Figure 60-220-

2 3].
2
3
Remove the front horn from the bracket.
P-90885 P-90901
Figure 60-220-2
2
3
1 3
P-90903 P-90902
Disconnect wire harness (Item 1) [Figure 60-220-1] and

[Figure 60-220-2] from the front horn.
Remove the two bolts and nuts (Item 2) [Figure 60-220-

1] and [Figure 60-220-2].
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].

FRONT HORN (CONT’D)
W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6, 7

2. The front horn switch is damaged.
3. The front horn is damaged.
4. The front horn or switch wires are disconnected.
5. Check the fuses.
7. The joystick controller is not working correctly. (SJC Equipped Machines)

FRONT HORN (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6

2. The front horn is damaged.
3. The front horn wires are disconnected.
4. Check the fuses.
6. The joystick controller is not working correctly.

60-220-4
T770 Service Manual
ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
ENGINE SPEED CONTROL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-2
Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Hydraulic Fan Motor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-9
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-20
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-24
Fuel Injector Nozzle Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-25
Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-26
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-26
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Intake Air Heater - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Intake Air Heater Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-5
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2

70-04
T770 Service Manual
ENGINE INFORMATION
Description
Figure 70-10-1
P100153
The T770 has a Kubota direct injected V3800-DI-T turbo

diesel engine with a displacement of 3,8 L (230 in ). The
engine is rated at an SAE Gross 68,6kW (92.0 hp) and
has an open crankcase ventilation system [Figure 70-10-
1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped

with an air intake heater and mechanical timer with cold
start advance function for assisting in cold starts. Engine
block heaters are also available from Bobcat Parts.
To meet emission regulations it is also equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic /
hydrostatic fluid temperature sensor.

ENGINE INFORMATION (CONT’D)
Specifications
Valve Springs
Free Length (Intake and Exhaust) 35,1 - 35,6 mm (1.39 - 1.40 in)
Allowable Limit 34,6 mm (1.36 in)
Fitted Length (Intake and Exhaust) 31,5 mm (1.24 in)
Setting Load / Setting Length (Intake and Exhaust) 63,5 N / 31,5 mm (14.3 lb / 1.24 in)
Allowable Limit 45,9 N / 31,5 mm (10.3 lb / 1.24 in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 mm (0.039 in)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 45 degrees B.B.D.C.
(Close) 17 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 15,973 - 15,984 mm (0.62886 - 0.62929 in)
I.D. of Rocker Arm Bushings 16,000 - 16,018 mm (0.62993 - 0.63062 in)
Oil Clearance Between Rocker Arm And Bushing 0,016 - 0,045 mm (0.00063 - 0.0017 in)
Camshaft
Journal O.D. 45,934 - 45,950 mm (1.8085 - 1.8090 in)
Bearing I.D. 46,0 - 46,025 mm (1.8111 - 1.8120 in)
Oil Clearance 0,050 - 0,091mm (0.002 - 0.0035 in)
Alignment Allowable Limit 0,01 mm (0.0004 in)
Cam Lobe Height (Intake) 37,63 mm (1.481 in)
Allowable Limit (Intake) 37,13 mm (1.462 in)
Cam Lobe Height (Exhaust) 38,96 mm (1.534 in)
Allowable Limit (Exhaust) 38,46 mm (1.514 in)
Side Clearance Allowable Limit 0,30 mm (0.012 in)
Tappet
Oil Clearance Between Tappet And Guide 0,020 - 0,062 mm (0.0079 - 0.0024 in)
Tappet O.D. 23,959 - 23,980 mm (0.94321 - 0.94409 in)
Tappet Guide I.D. 24,000 - 24,021 mm (0.94489 - 0.94570 in)

Specifications (Cont’d)
Cylinder Bore
Cylinder Bore I.D. 100,000 - 100,022 mm (3.93701 - 3.93787 in)

Oversized Cylinder Bore I.D. 100,500 - 100,522 mm (3.95670 - 3.95755 in)
Piston Rings
Ring Gap (Top Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (2nd Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (Oil Ring) 0,25 - 0,45 mm (0.0099 - 0.017 in)
Side Clearance of Ring Groove:
Top Ring 0,05 - 0,09 mm (0.002 - 0.003 in)
Second Ring 0,0930 - 0,120 mm (0.00367 - 0.00472 in)
Oil Ring 0,020 - 0,060 mm (0.00079 - 0.0023 in)
Pistons
Piston Pin Bore 30,000 - 30,013 mm (1.1811 - 1.1816 in)
Connecting Rod
Piston Pin O.D. 30,006 - 30,011 mm (1.1814 - 1.1815 in)
Small End Bushing I.D. 30,031 - 30,046 mm (1.1824 - 1.1829 in)
Oil Clearance Between Piston Pin And Small End Bushing 0,020 - 0,040 mm (0.00079 - 0.0015 in)
Connecting Rod Alignment Allowable Limit 0,05 mm (0.002 in)
Oil Pump
Oil Pressure Rated RPM 199,9 - 386,1 kPa (1,9 - 3,9 bar) (29 - 56 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (0,48 bar) (7 psi)
Clearance Between Inner Rotor And Outer Rotor 0,040 - 0,16 mm (0.0016 - 0.0062 in)
Clearance Between Outer Rotor And Pump Body 0,100 - 0,184 mm (0.00394 - 0.00724 in)
End Clearance Between Inner Rotor And Cover 0,025 - 0,075 mm (0.00099 - 0.0029 in)

Specifications (Cont’d)
Crankshaft
Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)

Oil Clearance Between Journal And Bearing 0,00071 - 0,0024 mm (0.018 - 0.062 in)
Limit Permitted 0,020 mm (0.0079 in)
Journal O.D. 74,977 - 74,990 mm (2.9519 - 2.9523 in)
Oil Clearance Between Crank Pin And Bearing 0,018 - 0,051 mm (0.00071 - 0.0020 in)
Crank Pin O.D. 52,977 - 52,990 mm (2.0857 - 2.0862 in)
Crank Pin I.D. (Blue) 56,010 - 56,020 mm (2.2052 - 2.2055 in)
Crank Pin I.D. (No Color) 56,000 - 56,010 mm (2.2048 - 2.2051 in)
Crankshaft Side Clearance 0,018 - 0,051 mm (0.00071 - 0.0020 in)
Timing Gear
Timing Gear Backlash:
Crank Gear - Idle Gear 0,0490 - 0,193 mm (0.00193 - 0.00759 in)
Idle Gear - Cam Gear 0,0490 - 0,189 mm (0.00193 - 0.0074 in)
Idle Gear - Injection Pump Gear 0,0300 - 0,165 mm (0.00119 - 0.00649 in)
Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing: 0,050 - 0,091 mm (0.0020 - 0.0035 in)
Idle Gear Bushing I.D. 45,025 - 45,050 mm (1.7727 - 1.7736 in)
Idle Gear Shaft O.D. 44,959 - 44,975 mm (1.7701 - 1.7706 in)
Idle Gear Side Clearance 0,15 - 0,30 mm (0.0059 - 0.011 in)
Thermostat
Valve Opening Temperature 74,5 - 78,5°C (166.1 - 173°F)
Valve Fully Open 90°C (194°F)

Torque Values
Thread Size Material

(Dia. x Pitch)
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is misfiring. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

ENGINE INFORMATION (CONT’D) Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Engine Removal And Installation
Figure 70-10-2
DANGER
2 1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P100305

can cause lift arms to drop. (SJC Controls Equipped)
unless supported by an approved lift arm Loosen the engine speed control cable adjustment nuts
support. Replace if damaged. (Item 1) and remove the engine speed control cable from
D-1009-0409 the ball pivot (Item 2). [Figure 70-10-2].
Figure 70-10-3
WARNING

W-2059-0598
2 1
Put jackstands under the rear corners of the loader.

support device. (See Installing on Page 10-20-1.) P100304

(Manual Controls Equipped)
Replacing Hydraulic Fluid on Page 10-120-2.) Loosen the engine speed control cable adjustment nuts
(Item 1) and remove the engine speed control cable from
Remove the battery from the loader. (See Removal And the ball pivot (Item 2) [Figure 70-10-3].
Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-3.)
NOTE: If compressor is being removed for engine

removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor.

ENGINE INFORMATION (CONT’D) Figure 70-10-6
Engine Removal And Installation (Cont'd)
Figure 70-10-4
1
5 4
1 2
3
2
P100312
Disconnect fuel shut-off solenoid connector (Item 1)

P100307 [Figure 70-10-6].
Remove the bolts for the wiring harness hold down

Disconnect engine ground cable (Item 1) and chassis
clamps (Item 2) [Figure 70-10-6].
ground cable (Item 2) [Figure 70-10-4].
Figure 70-10-7
Disconnect the engine starter positive cable (Item 3)
[Figure 70-10-4].
Disconnect the starter wiring harness connector (Item 4) 1

[Figure 70-10-4].
Disconnect flywheel rpm sensor (Item 5) [Figure 70-10-
4].
Figure 70-10-5
P100311
2 Disconnect fuel line (Item 1) [Figure 70-10-7] for lift

pump and plug.
2 3 Engine speed control cable bracket removed for photo

clarity.
P100309
Disconnect engine oil pressure sender connector (Item 1)

[Figure 70-10-5].
Disconnect the alternator wiring (Item 2) [Figure 70-10-

5].
Disconnect the engine ground cable (Item 3) [Figure 70-

10-5].


2
Figure 70-10-8
P100323
Remove the two bolts (Item 1), coolant tube assembly

P100310 (Item 2) and hose (Item 3) [Figure 70-10-10].
Figure 70-10-11
Disconnect and plug fuel return line (Item 1) [Figure 70-
10-8].
Figure 70-10-9 1
2
P100314
Disconnect coolant return line (Item 1) [Figure 70-10-

P100313 11].
Disconnect radiator hose (Item 2) [Figure 70-10-11] from

Disconnect radiator hose (Item 1) [Figure 70-10-9]. the thermostat housing.

Engine Removal And Installation (Cont'd) 1

2
Figure 70-10-12
2
1 1
P100319
2
Mark and disconnect the drive motor hoses (Item 1)

P100315 [Figure 70-10-14].
Disconnect the tandem pump case drain hose (Item 2)

Disconnect coolant temperature connector (Item 1) [Figure 70-10-14].
[Figure 70-10-12] from thermostat housing.
Disconnect Heater hoses (Item 2) [Figure 70-10-12] (If
equipped). NOTE: The hydraulic fittings (Item 1) [Figure 70-10-
17] on the hydrostatic pump must be
Figure 70-10-13 tightened to 128 - 138 N•m (94 - 102 ft-lb)
torque.
Figure 70-10-15
2
1 1
1
P100729
Remove and cap fan inlet hose (Item 1) [Figure 70-10-

P-85907
13].
Remove and cap fan outlet hose (Item 2) [Figure 70-10- Disconnect tandem pump suction hoses (Item 1) [Figure
13]. 70-10-15].
Disconnect the charge pump inlet hose (Item 2) [Figure

70-10-15].

Figure 70-10-16
1 P100321
Remove the mounting bolt (Item 1) [Figure 70-10-18]

P-85908 from the left engine mount.
Installation: Tighten the mounting bolt (Item 1) [Figure

Disconnect hydraulic control valve inlet hose (Item 1) 70-10-18] to 122 - 135 N•m (90 - 100 ft-lb) torque.
[Figure 70-10-16].
Figure 70-10-19
Figure 70-10-17
P100322
P100320 Remove the mounting bolt (Item 1) [Figure 70-10-19]

from the right engine mount.
Remove rear engine mounting bolt (Item 1) [Figure 70- Installation: Tighten the mounting bolt to 122 - 135 N•m
10-17]. (90 - 100 ft-lb) torque.
Installation: Tighten the mounting bolt to 122 - 135 N•m



1
Figure 70-10-20
P100302
Install the engine removal attachments (MEL1653-2)

(Item 1) and (MEL1686) (Item 2) [Figure 70-10-22] on
the engine.
Figure 70-10-23
P-76872
Use the engine removal tool (MEL1653-1) [Figure 70-10-

20] and the attachments (MEL1653-2), (MEL1686)
P100303
[Figure 70-10-22] and (MEL1711) [Figure 70-10-21] to
aid in the removal and installation of the engine.
Install the engine removal attachment (MEL1686) (Item
Figure 70-10-21 1) [Figure 70-10-23] on the right hand side of the engine
in place of the coolant tube assembly.
Tighten all the bolts and nuts that hold the engine
removal attachment onto the engine.
P100332

Figure 70-10-24
1 3
2
P100300
Install the engine removal attachment (Item 1) on the left

hand muffler support bracket (Item 2), exhaust manifold
(Item 3) and engine removal bracket (Item 4) [Figure 70-
10-24].
Installation: Use 9,525 x 38,1 mm (0.375 x 1.5 in) bolts

and nuts grade 5 minimum.
Figure 70-10-25
P100324
Install the engine removal tool (Item 1) into the

attachment (Item 2) and insert the pin (Item 3) [Figure
70-10-25].
Install the chain hoist on the eyelet [Figure 70-10-25] of

the removal tool.

the loader.

Engine Mount Replacement Washer

Engine
Figure 70-10-26 Mounting
Bracket
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-28].
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
Use the following procedure to install new rear engine lb) torque.
mount:
Figure 70-10-28
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 1
locations. 4
Replace all three engine mounts one rear and two sides.
5 2
Use the parts shown to install the new engine mounts
[Figure 70-10-26]: 6 3
Hex Nut - (Item 1) 7
Washer - (Item 2)
Cup Washer - (Item 3)

P-85990A
Engine Mount - (Item 4)
Tube Spacer - (Item 5) Use the parts shown to install the new side engine
mounts [Figure 70-10-26].
Mounting Bolt - (Item 1)
Mounting Bolt - (Item 8)
Tube Spacer - (Item 4)
Retaining Nut - (Item 7)

Engine Mount Replacement (Cont’d)

1
Figure 70-10-29
Washer
Engine
Mounting
Bracket
Engine
Mount
Snubbing P100685
Washer
Spacer Figure 70-10-32
Loader
Frame P-85987
1
Install the new engine mount as shown in the cut away
side view [Figure 70-10-28].
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft- 2
lb) torque.
Compression - Checking
Figure 70-10-30
P100352
1
Engage the starter 7 - 10 seconds until a maximum
compression reading is obtained.
Repeat this procedure multiple times per cylinder until a

average compression reading is recorded.
If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the nozzle
hole and measure the compression pressure again.
P-37196
If the compression pressure increase after applying oil.
check the cylinder wall and piston rings.
After warming up the engine, stop the engine and remove
the muffler, high pressure pipes, cylinder head cover, If the compression pressure is still less than the allowable
overflow pipe, all nozzle holders and all nozzle gaskets. limit, check the top clearance, valve and cylinder head.
NOTE: Disconnect the fuel shutoff solenoid wiring NOTE: Check the compression pressure with the
harness. specified valve clearance.
Always use a fully charged battery for
Install a compression tester and nozzle adaptor performing this test.
(MEL1614) for diesel engines into the nozzle holder hole
(Item 1) [Figure 70-10-30]. Variances in cylinder compression values
should be under 10%.

Compression - Checking (Cont’d)
Compression Factory 3475 kPa / 250 rpm

pressure spec. (34,7 bar / 250 rpm)
(504 psi / 250 rpm)
Allowable 2558 kPa / 250 rpm
limit (25,579 bar / 250 rpm)
(371 psi / 250 rpm)
Tightening Nozzle holder 18 - 20 N•m

Torque clamp nut (13 - 15 ft-lb)
Overflow pipe 9,8 - 11,2 N•m
assembly retain- (7.24 - 8.31 ft-lb)
ing bolt
Cylinder head 6,9 - 11,2 N•m
cover bolt (5.1 - 8.31 ft-lb)
Injection pipe 23 - 36 N•m
retaining nut (17 - 26 ft-lb)

ENGINE SPEED CONTROL Disassembly And Assembly
Figure 70-20-1
1 2
P-85791
P-85789
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the handle (Item 3) [Figure 70-20-3].
Figure 70-20-2
Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].
Installation: Tighten the nut (Item 1) [Figure 70-20-3]

until the speed control lever moves backward and forward
2 1 at a comfortable tension.
3
Figure 70-20-4
P-85790
The speed control cable (Item 1) is connected to the

speed control handle (Item 2) by a ball and socket end
[Figure 70-20-2].
Disconnect the speed control cable (Item 1) from the

speed control handle (Item 2) [Figure 70-20-2].
P-85792
Loosen the jam nut (Item 3) [Figure 70-20-2] from the
speed control cable.
Inspect and replace any damaged parts [Figure 70-20-
Remove the cable from the speed control handle. 4].

ENGINE SPEED CONTROL (CONT’D) Figure 70-20-7
Cable Removal And Installation

2
Remove the speed control lever. (See Removal And


3
Figure 70-20-5
P100304
1 The speed control cable is connected to the linkage by a

ball and socket end [Figure 70-20-7].
Loosen the jam nut (Item 1) [Figure 70-20-7] from the

speed control cable.
Disconnect the speed control cable (Item 2) from the

linkage (Item 3) by rolling the cable away from the engine
[Figure 70-20-7].
P100326
Remove the speed control cable.
Remove the tie strap (Item 1) [Figure 70-20-5].
Figure 70-20-6
P100325
Remove the four bolts (Item 1) [Figure 70-20-6] from the

clamps that secure the cable.

ENGINE SPEED CONTROL (SJC) Figure 70-21-3

1
Figure 70-21-1
2 1
1
P-90735
Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-21-3].
P-90733 Lay the assembly down.
Figure 70-21-4
Remove the two mounting nuts (Item 1) [Figure 70-21-1]
from the right side foot rest.
Remove the foot rest from the loader.

1
Figure 70-21-2
2
1 P100359
2
Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
P-90734
Remove panel assembly from the loader.
Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-21-2].
Installation: Install the engine speed control foot pedal

(Item 2) but do not tighten the clamping bolt. Set the hand
engine speed control to high idle then place the foot
pedal to high idle and tighten the clamping bolt (Item 1)
[Figure 70-21-2].

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-7

4
Figure 70-21-5
2 1
2
5
3
P100381
1
Remove the nuts (Item 1) and pivot bolts (Item 2) from
P100382 the engine speed control hand bracket assembly (Item 3)
[Figure 70-21-7].
Remove the spring (Item 1) from the engine speed Remove the engine speed control hand cam lever (Item
control foot pedal pivot assembly (Item 2) and the engine 4) and engine speed control cable lever (Item 5) [Figure
speed control hand throttle bracket (Item 3) [Figure 70- 70-21-7].
21-5]
Figure 70-21-8
Figure 70-21-6
1
P100380
P-90755
The pivot assemblies shown disassembled [Figure 70-

Remove the two bolts (Item 1) [Figure 70-21-6] from the 21-8].
engine speed control hand assembly.
NOTE: No lubrication is necessary or recommended
on the engine speed control.

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-11
Figure 70-21-9
P100375
The engine speed control foot pedal pivot assembly roller

P-90736 bearing [Figure 70-21-11] shown disassembled.
Remove the snap ring (Item 1) [Figure 70-21-9] from the

engine speed control foot pedal pivot.
Figure 70-21-10
P100376
The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-21-10] replace worn
parts as needed.
NOTE: No lubrication is necessary or recommended

on the engine speed control.

70-21-4
T770 Service Manual
MUFFLER Figure 70-30-3
Open the rear door and remove the rear grille and side
panels. (See Removing on Page 50-60-1.)
Figure 70-30-1
1
2
P100405
1 1
Remove the muffler mounting bolts (Item 1) [Figure 70-
30-3] from the left side mounting bracket.
Figure 70-30-4
P100403
Remove the bolts (Item 1) from the engine cover (Item 2)

[Figure 70-30-1] and remove engine cover.
1 1
Figure 70-30-2
1
P100406
Remove the muffler mounting bolts (Item 1) [Figure 70-

30-4] from the exhaust manifold.
Remove the muffler from the loader.

P100404
Reverse procedure for installation.
Remove the muffler mounting bolt (Item 1) [Figure 70-

30-2] from right side mounting bracket.

70-30-2
T770 Service Manual
AIR CLEANER Figure 70-40-3
Remove the rear grille from the loader. (See Removing

on Page 50-60-1.)
Figure 70-40-1
1
1
2 3
P101601
Loosen the hose clamp (Item 1) and disconnect the hose

(Item 2) [Figure 70-40-3] from the air cleaner.

P100229 from the air cleaner sender.
Figure 70-40-4
Disconnect the scavenger hose (Item 1) [Figure 70-40-
1].
Figure 70-40-2 1
P101604
Remove the air cleaner (Item 1) [Figure 70-40-4] from

P101602 the loader.
Remove the bolts (Item 1) [Figure 70-40-2] and nuts

from the air cleaner assembly.
NOTE: Later models have four mounting bolts.

70-40-2
T770 Service Manual
ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation
Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)
1
Remove the oil cooler. (See Removal And Installation on
Page 20-90-1.)
WARNING
P107794
AVOID BURNS
Do not remove radiator cap when the engine is hot. Disconnect the coolant tank fill hose (Item 1) [Figure 70-
You can be seriously burned. 50-2].
W-2070-1203
Figure 70-50-3
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-90-3.)
Figure 70-50-1 1
2
1
P107793A
Remove the hardware (Item 1) from the fuel cooler (Item

P107792A 2) [Figure 70-50-3] and reposition cooler.
Disconnect the radiator air bleed hose (Item 1) [Figure

70-50-1].

ENGINE COOLING SYSTEM (CONT'D) Hydraulic Fan Description
Radiator Removal And Installation (Cont'd) The hydraulic fan is used to cool the engine and hydraulic
/ hydrostatic systems. The hydraulic fan consists of a fan
Figure 70-50-4 and hydraulic motor that is controlled by a proportioning
valve.
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from the engine and
hydraulic temperature sensors.
NOTE: The proportioning valve is factory set and can

1 not be adjusted.
The fan speed is determined by the engine coolant

temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed can
range from 0 - 4000 rpm.
P107336B
The hydraulic fan speed at cold engine startup will range
from 0 - 500 rpm until the engine coolant and the
Disconnect the radiator hose (Item 1) [Figure 70-50-4]. hydraulic fluid reach normal operating temperatures.
Figure 70-50-5 During normal operating temperatures the fan speed may
range from approximately 1900 - 3500 rpm.
2 1 2
P107796
Disconnect the radiator hose (Item 1) [Figure 70-50-5].
Remove radiator hold down bolts (Item 2) [Figure 70-50-

5].
Lift the radiator up and remove it from the loader.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Assembly Removal And
Installation
Fan Duct Removal And Installation
Figure 70-50-7
Figure 70-50-6
1 2
5
5
1
1 4
3
P100373
P100275
Remove the fan motor inlet hose (Item 1) and outlet hose
Unhook the rubber straps (Item 1) [Figure 70-50-6] and (Item 2) [Figure 70-50-7].
remove the lower fan duct.
Remove the fan case drain hose (Item 3) [Figure 70-50-
7].
Remove the charge pressure hose (Item 4) [Figure 70-

50-7].
Disconnect the wire harness (Item 5) [Figure 70-50-7].
Figure 70-50-8
1 1
P100373
Remove the four bolts (Item 1) [Figure 70-50-8].
Remove fan assembly (Item 2) [Figure 70-50-8].

ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-11
Hydraulic Fan Motor Removal And Installation
Figure 70-50-9 1
2 2
1
P-90069
1 Remove the cotter pins and nuts (Item 1) [Figure 70-50-

P-90313 11].
Remove the two washers (Item 2) [Figure 70-50-11].

Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-9]. Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb)
torque.
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
torque. Figure 70-50-12
Figure 70-50-10
1
P-90076
P-90065
Remove the motor.
Remove the nut (Item 1) [Figure 70-50-10] and washer
from the motor shaft. Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
torque.
Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)
torque. NOTE: Always install new bolts, nuts, cotter pins,
and rubber gasket when installing the fan
motor.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Disassembly And Assembly
Hydraulic Fan Motor Removal And Installation Figure 70-50-14

(Cont’d)
Figure 70-50-13
1
2 3
1 2
1
P-76714A
P-90062 Remove the filter cover (Item 1) [Figure 70-50-14].
Installation: Tighten filter cover to 47,5 - 54 N•m (35 - 40

Use the following procedure to remove the fan hub from ft-lb) torque.
the fan motor shaft:
Figure 70-50-15
Install a bushing (Item 1) [Figure 70-50-13] in the hub to
protect the fan motor shaft and threads during removal.
Install a puller (Item 2) [Figure 70-50-13] on the bushing

as shown. 4
Tighten the bolts and strike the puller with a hammer to

loosen the hub from the motor shaft.
3
P-76716A
Remove the nut (Item 1), coil (Item 2), and the coil valve
stem (Item 3) [Figure 70-50-15].
NOTE: The coil nut must be replaced each time it is

removed.
Installation: Tighten coil valve stem (Item 3) [Figure 70-

50-15] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Installation: Install the coil nut with the counterbored

space (Item 4) [Figure 70-50-15] facing towards the coil
and tighten securely by hand.

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-18
Hydraulic Fan Disassembly And Assembly (Cont’d)
Figure 70-50-16
P-76726
2

P-76637

[Figure 70-50-16].
Figure 70-50-17
1
P-76717
Remove the pressure transducer (Item 1) [Figure 70-50-

17].
Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-17] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.

ENGINE COOLING SYSTEM (CONT'D) Water Pump Removal And Installation
Blower Housing Removal And Installation Drain the fluid from the radiator. (See Removing And
Replacing Coolant on Page 10-90-3.)
Figure 70-50-20
IMPORTANT 1 3
clean the work area before disassembly and keep all 2
damage the system.
I-2003-0888
4
Remove the air conditioning condenser if equipped. (See
Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.) P107330
Remove the radiator. (See Radiator Removal And

Installation on Page 70-50-1.) Remove the alternator belt (Item 1) [Figure 70-50-20].
Figure 70-50-19 Remove the four bolts (Item 2) from the water pump
pulley (Item 3) [Figure 70-50-20].
Remove the water pump pulley (Item 3) [Figure 70-50-

20]
Remove the six water pump bolts (Item 4) [Figure 70-50-

20].
1 1 Figure 70-50-21
2
P-90063
Remove the four bolts (Item 1) [Figure 70-50-19].
Remove the blower housing (Item 2) [Figure 70-50-19]

from the loader.
NOTE: Engine and hydraulic fan assembly removed

for photo clarity. 3EEABAC1P120A
Remove the water pump (Item 1) and gasket (Item 2)

[Figure 70-50-21] from the gearcase.

ENGINE COOLING SYSTEM (CONT’D) Thermostat Housing Removal And Installation
Water Pump Disassembly And Assembly Figure 70-50-23
Figure 70-50-22
2
1
1
3
4
P100372
B-22926A
Remove the thermostat cover mounting bolts (Item 1),
and remove the thermostat cover (Item 2) [Figure 70-50-
NOTE: The water pump is not serviceable. Order a 23].
new pump assembly and gasket (Item 1)
[Figure 70-50-22]. Remove the thermostat assembly (Item 3) [Figure 70-
50-23].
Apply a liquid gasket only at the thermostat cover side of

the gasket (Item 4) [Figure 70-50-23].
Figure 70-50-24
P-37152
Attach the thermostat (Item 1) with the hole (Item 2)

facing toward the air suction side [Figure 70-50-24].

ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Testing
Push down the thermostat valve and insert a string

between the valve and the valve seat.
Figure 70-50-25
P-37172
Place the thermostat and a thermometer in a container

with water and gradually heat the water [Figure 70-50-
25].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s Factory 74,5 - 78,5°C

valve opening spec. (166.1 - 173.3°F)
temperature
Temperature at Factory 90°C
which thermostat spec. (194°F)
completely opens

70-50-10
T770 Service Manual
LUBRICATION SYSTEM Figure 70-60-3
Oil Pan Removal And Installation
Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-7.)
Figure 70-60-1
P-37127
Remove the oil strainer mounting bolts and remove the

oil strainer (Item 2) [Figure 70-60-3].
Install the oil strainer, using care not to damage the O-

ring.
P-37125
Apply liquid gasket to the oil pan (Item 3) [Figure 70-60-
2].
Remove the oil pan mounting bolts and remove the oil
pan (Item 1) [Figure 70-60-1]. Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
Figure 70-60-2
Carefully apply the adhesive evenly.
NOTE: When mounting the adhesive-applied parts,

take care to fit them to the mating parts.
Assemble the adhesive-applied parts within

ten minutes.
To avoid uneven tightening, tighten mounting

bolts in diagonal order from the center.
P-37126

LUBRICATION SYSTEM (CONT’D) Oil Pump Inspection
Oil Pump Removal And Installation Figure 70-60-5
Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70-
100-1.)
Figure 70-60-4
P-37220
1
Measure the clearance between lobes of the inner rotor

and the outer rotor with a feeler gauge [Figure 70-60-5].
P-100076 If the clearance exceeds the factory specifications,

replace the oil pump rotor assembly.
Remove the oil pump cover (Item 1) [Figure 70-60-4]. Clearance Factory spec. 0,040 - 0,16 mm
between (0.0016 - 0.0062 in)
inner rotor Allowable 0,03 mm (0.01 in)
and outer Limit
rotor

LUBRICATION SYSTEM (CONT’D) Figure 70-60-7
Oil Pump Inspection (Cont’d)
Figure 70-60-6
P-100077
Put a strip of plastigage onto the rotor face with grease

P-37218 [Figure 70-60-7].
Install the cover and tighten the screws with the specified
Measure the clearance between the outer rotor and the torque.
pump body with a feeler gauge [Figure 70-60-6].
Remove the cover carefully, and measure the amount of
If the clearance exceeds the factory specifications, the flattening with the scale and record the clearance.
replace the oil pump rotor assembly.
If the clearance exceeds the allowable limit, replace oil
Clearance Factory 0,100 - 0,184 mm pump rotor assembly and the cover.
between outer spec. (0.00394 - 0.00724 in)

rotor and Allowable 0,3 mm (0.01 in) Clearance Factory spec. 0,025 - 0,075 mm
pump body limit between (0.00099 - 0.0029 in)
rotor and Allowable 0,225 mm
cover limit (0.00886 in)
Tightening Oil pump cover 7,9 - 9,3 N•m

torque screw (5.8 - 6.8 ft-lb)

LUBRICATION SYSTEM (CONT’D) Oil Filter Cooler Removal And Installation
Oil Pump Inspection (Cont’d) Figure 70-60-9
Relief Valve 1
Figure 70-60-8
4 P100079
1
1 Remove the water pipe (Item 1) [Figure 70-60-9].
P100078
Remove the oil filter cartridge (Item 2) [Figure 70-60-9].
Remove the bolt (Item 1) [Figure 70-60-8]. Figure 70-60-10
Remove the relief valve (Item 2), the spring (Item 3) and
the packing (Item 4) [Figure 70-60-8].
Tightening Relief valve 69 - 78 N•m
torque (51 - 57 ft-lb)
P100080
Remove the oil cooler joint bolt (Item 1) [Figure 70-60-

10] and [Figure 70-60-11].
Installation: Tighten the oil cooler joint bolt to 40 - 44

N•m (29 - 32 ft-lb)

LUBRICATION SYSTEM (CONT’D) Figure 70-60-13
Oil Filter Cooler Removal And Installation (Cont’d)
Figure 70-60-11
1 P-76921
Install a pressure gauge [Figure 70-60-13].

P100081
Start the engine. After warming up, measure the oil
pressure of both idling and rated speeds.
Remove the oil cooler (Item 1) [Figure 70-60-11].
If the oil pressure is less than the allowable limit, check
Engine Oil Pressure - Testing the following:
Figure 70-60-12 Engine oil insufficient

Oil pump defective
Oil strainer clogged
Oil filter cartridge

Oil gallery clogged
Excessive oil clearance of bearing
Foreign matter in the relief valve
1 At idle speed Allowable limit 48,3 kPa

(0,48 bar)
(7 psi)
At rated Factory spec. 199,9 - 386,1 kPa

speed (1,99 - 3,86 bar)
P100082
(29 - 56 psi)
Allowable limit 144,8 kPa
(1,4 bar)
Remove the oil switch (Item 1) [Figure 70-60-12]. (21 psi)

70-60-6
T770 Service Manual
FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Testing Figure 70-70-3
Figure 70-70-1
3
1
P-76053
1 P-76053
Stop the engine and open the rear door. The fuel shutoff solenoid connector is located between
the fuel filter and the oil filter.
The fuel shutoff solenoid connector is located between
the fuel filter and the oil filter. Disconnect the fuel shutoff solenoid connector (Item 1)
[Figure 70-70-3].
Disconnect the fuel shutoff solenoid connector (Item 1)
[Figure 70-70-1]. Remove the two mounting bolts (Item 2) [Figure 70-70-3]
from the fuel stop solenoid.

Use an ohmmeter to test the fuel shutoff solenoid.
Remove the solenoid from the injection pump assembly
Figure 70-70-2 (Item 3) [Figure 70-70-3].
P100126
The reading between electrical connector terminal C and

terminal A must be approximately 15.6 ohm [Figure 70-
70-2].
The reading between electrical connector terminal C and

terminal B must be approximately 0.35 - 0.40 ohm.

Fuel Injection Pump Assembly Removal
Set the number four cylinder to Top Dead Center (T.D.C.)

compression stroke.
Figure 70-70-4
P100155
Timer Gear Puller (MEL1657)
Application: Use this puller for removing the timer gear

from the governor shaft.
P100154
Timer 0° Restoring Jig (MEL1656)
Application: Use this for restoring 0° in the timer gear.

Fuel Injection Pump Assembly Removal (Cont’d)
Figure 70-70-6
2
1
1
3
P-76996
With the number four piston at T.D.C. compression stroke

P-76933 place a mark on the timer gear and the idler gear where
the teeth engage (Item 1) [Figure 70-70-8].
Remove the lubrication tubeline (Item 1), the timer gear Pin the flywheel so that the engine does not turn.
cover mounting bolts (Item 2) and the timer gear cover
(Item 3) [Figure 70-70-6]. Figure 70-70-9
Figure 70-70-7
1 P-37513
1
P-76934
Remove the two flange bolts (Item 1) [Figure 70-70-9]
from the injection pump assembly.
Install the 0° Restoring Jig (MEL1656) (Item 1) on to the
timer gear (Item 2) [Figure 70-70-7].

Fuel Injection Pump Assembly Removal (Cont’d)
Figure 70-70-10 2
1 3
P-76936
Remove the timer gear nut and washer (Item 1) from the
P-37555 timer gear (Item 2) [Figure 70-70-12].
Install the timer gear puller (Item 4) onto the timer gear
Install two fuel camshaft lock bolts (Item 1 and 2) [Figure (Item 2) [Figure 70-70-12].
70-70-10] and [Figure 70-70-11] that are M8 X P1.25 X
L30 mm. Installation: Install the washer with the concave surface
(Item 3) [Figure 70-70-12] towards the timer gear.
Figure 70-70-11
Figure 70-70-13
2
1
P-37532
P-76937
Tighten the lower fuel camshaft lock bolt (Item 1) [Figure

70-70-11] until it comes into contact with the fuel Remove the timer gear (Item 1) [Figure 70-70-13].
camshaft.
NOTE: Timer Gear is not serviceable. If timer gear is
Tighten the upper fuel camshaft lock bolt (Item 2) [Figure damaged the entire assembly must be
70-70-11] until it comes into contact with the fuel replaced.
camshaft.
NOTE: Do not over tighten the lock bolts when in

contact with the camshaft.

Fuel Injection Pump Assembly Removal (Cont’d) 1

Figure 70-70-14
P-37540

P-76938 16] and move the fuel filter, to allow clearance for the
injection pump assembly to be removed.
Remove the timer gear assembly (Item 1) [Figure 70-70- Figure 70-70-17
14].
Figure 70-70-15 1
1
1
P-37539
P-76945 Remove the three injection pump assembly mounting

flange nuts (Item 1) [Figure 70-70-17]. (Two on the front
side and one on the back side of the injection pump
Disconnect the lubrication oil tubeline (Item 1) [Figure assembly.)
70-70-15].

FUEL SYSTEM (CONT’D) Fuel Injection Pump Assembly Installation
Fuel Injection Pump Assembly Removal (Cont’d) Set the number four cylinder to T.D.C. compression
stroke.
Figure 70-70-18
Figure 70-70-20
1
1
2
1
1
3
2
1
4 3
5
6
P100182
P-76939
Remove the three injection pump assembly support bolts

(Items 1) and the bracket (Item 2) [Figure 70-70-18]. Install the timer gear into the engine (Item 1) [Figure 70-
70-20].
Figure 70-70-19
NOTE: Align the marks on the timer gear to the idler
gear (Item 2) [Figure 70-70-20].
Install the 0° restoring jig (MEL1656) (Item 3) [Figure 70-
70-20] onto the timer gear.
Install the injection pump assembly into the engine (Item

4) [Figure 70-70-20].
1
NOTE: Align the key (Item 5) in the keyway of the
timer gear.
Install the timer gear nut and washer (Item 6) [Figure 70-
70-20] and tighten to 74 - 83 N•m (55 - 61 ft-lb) torque.
P-76081
Remove the injection pump assembly from the engine

(Item 1) [Figure 70-70-19].

Fuel Injection Pump Assembly Installation (Cont’d)
Figure 70-70-21 3
1
3
P-76940
Install the two flange bolts (Item 1) [Figure 70-70-23] and

P-37539 tighten to 24 - 28 N•m (17 - 20 ft-lb) torque.
Move the injection pump assembly clockwise (viewed

Install the three mounting flange nuts (Item 1) [Figure from gearcase side), align the injection timing marks
70-70-21] and finger tighten (Two on the front side and (Item 2) [Figure 70-70-23] on the injection pump
one on the back side of the injection pump assembly.) assembly and on the engine gearcase.
Figure 70-70-22 Tighten the injection pump assembly mounting flange

nuts (Item 3) [Figure 70-70-23] (two on the front side and
one on the back side of the injection pump assembly) to
18 - 20 N•m (13 - 15 ft-lb) torque.
Figure 70-70-24
1
2 1
1 1
P-37532
Remove the two fuel camshaft lock bolts (Item 1) [Figure

70-70-22].
P-76944
Install the three injection pump assembly support bolts

(Items 1) and the bracket (Item 2) [Figure 70-70-24].
Tighten the injection pump assembly support bolts (Item

1) [Figure 70-70-24] to 18 - 20 N•m (13 - 15 ft-lb) torque.

FUEL SYSTEM (CONT’D) Governor Housing Disassembly And Assembly
Fuel Injection Pump Assembly Installation (Cont’d) Figure 70-70-27
Figure 70-70-25
P-76945
P100105
Connect the lubrication oil tubeline (Item 1) [Figure 70-

70-25] and torque to 15,7 - 19,6 N•m (11.6 - 15.4 ft-lb). Jig for Governor Connecting Rod
Figure 70-70-26 Application: Use MEL1637 (Item 1) [Figure 70-70-27] for

connecting the governor connecting rod to the rack pin of
the fuel injection pump assembly.
2
3
1
P-76933
Install the gear cover (Item 1), the gear cover mounting
bolts (Item 2) and lubrication tubeline (Item 3) [Figure
70-70-26].
Tighten the mounting bolts (Item 2) [Figure 70-70-26] to

24 - 28 N•m (17 - 20 ft-lb) torque.

FUEL SYSTEM (CONT’D) NOTE: (See Fuel Injection Pump Removal on Page
70-70-14.) for proper alignment of the
Governor Housing Disassembly And Assembly governor connecting rod procedure. The
(Cont’d) procedure will require a special tool part
number MEL1637.
Figure 70-70-28
Figure 70-70-30
2
1
3
P100084
P100086
Remove the injection pump assembly from the engine.

Remove the governor connecting rod (Item 1) and
Remove the governor lubrication tubeline (Item 1) [Figure 70-70-30] from the rack pin of injection pump.
[Figure 70-70-28].
For convenience, temporarily hook the start spring on the
Remove the stop solenoid (Item 2) [Figure 70-70-28]. rack pin hole of the governor connecting rod.
Detach the sight cover (Item 3) [Figure 70-70-28] from Remove the governor housing mounting bolts.
the injection pump assembly
Figure 70-70-31
Figure 70-70-29
P100087
P100085
Detach the governor housing assembly (Item 1) [Figure

Unhook the start spring (Item 1) from the rack pin (Item 70-70-31] from the injection pump assembly.
2) [Figure 70-70-29] of injection pump assembly.
NOTE: The injection pump assembly is lubricated
Remove the nut (Item 3) [Figure 70-70-29]. with engine oil. Oil will leak when the
governor housing is removed from the
NOTE: Be careful not to drop the nut inside. injection pump assembly.

FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly Tightening 9,8 - 11,3 N•m

GOVERNOR
torque HOUSING (7.23 - 8.32 ft-lb)
Figure 70-70-32
MOUNTING BOLT
1
Fork Lever
4
Figure 70-70-33
1 2
P100088
When reassembling the governor housing assembly

(Item 1) [Figure 70-70-32], lightly oil each inside part.
P100089
NOTE: Use care when installing the start spring (Item
2) to the governor connecting rod (Item 3)
[Figure 70-70-32] Pull out the governor fork lever shaft (Item 1) with a bolt
(Dia. 4 mm, Pitch: 0,7 mm, Length: more than 25 mm)
After sliding on the governor connecting rod onto the rack (Item 2) [Figure 70-70-33].
pin, tighten the governor connecting rod nut to the
specified torque using the jig (MEL1637) to keep the Figure 70-70-34
governor connecting rod horizontal.
Installation: Tighten the governor connecting rod nut to 1 2

2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: The tool (JIG) part number is MEL1637 for the

governor connecting rod alignment tool (Item
1) [Figure 70-70-57].
After tightening the nut, hook the start spring on the rack
pin.
Check the movement of the control rack of the injection

pump assembly by the stop lever.
P100090
NOTE: When installing the governor housing
assembly (Item 1) to the injection pump
assembly, be careful not to damage the O-ring Unhook the governor spring (Item 1) at the governor fork
(Item 4) [Figure 70-70-32]. lever (Item 2) [Figure 70-70-34] side.
NOTE: When linking the governor connecting rod to

the rack pin of injection pump, use the jig tor
keep the governor connecting rod horizontal.
Otherwise the injection pump control rack
may become stuck, and will cause difficult
starting of the engine or hunting of idle.

FUEL SYSTEM (CONT’D) Governor Fork
Governor Disassembly And Assembly (Cont’d) Figure 70-70-37
Figure 70-70-35
3
1 2 3
P100093
P100091
Figure 70-70-38
Remove the governor fork lever assembly from the 3 1

governor housing (Item 1) [Figure 70-70-35].
After reassembling the governor housing assembly,

check the movement of the governor fork lever (Item 2),
the speed control lever, stop lever, governor spring (Item
3) and governor fork lever shaft (Item 4) [Figure 70-70-
35].
2
NOTE: When reassembling lightly oil the parts.
NOTE: Be careful not to deform the start spring.
Speed Lever P100094
Figure 70-70-36
Remove the governor lever assembly (Item 1) [Figure
1 2 70-70-38] from the governor housing.
Remove the start spring (Item 2) and the stop spring

(Item 3) [Figure 70-70-37] and [Figure 70-70-38].
P100092
Remove the speed control lever (Item 1) and the return

spring (Item 2) [Figure 70-70-36].

FUEL SYSTEM (CONT’D) Fuel Camshaft Removal And Installation
Governor Disassembly And Assembly (Cont’d) Figure 70-70-40
Stop Lever
Figure 70-70-39 1
1 2
P100096
3
Separate the governor housing assembly from the
P100095 injection pump assembly.
Remove the fuel feed pump from the injection pump

Remove the stop lever (Item 1) and the return spring assembly.
(Item 2) [Figure 70-70-39].
Remove the governor sleeve (Item 1) [Figure 70-70-40].
Remove the stop lever shaft (Item 3) [Figure 70-70-39].
Figure 70-70-41
1
P100097
Remove the injection pump (Item 1) [Figure 70-70-41].
Remove the fuel camshaft lock bolts.

Fuel Camshaft Removal And Installation (Cont’d)
Figure 70-70-42 2
3
1
P100100
2 Pull out the fuel camshaft (Item 1) and bearings (Item 2)

P100098 [Figure 70-70-44] together.
After removing the bearing’s snap ring (Item 3) [Figure

Fix the fuel camshaft with a open end wrench (Item 1), 70-70-44], press out the bearings.
and remove the governor weight mounting nut and the
governor weight (Item 2) [Figure 70-70-42]. Press the bearings into the fuel camshaft.
NOTE: Do not use the fuel camshaft lock bolts, when Install the snap ring at the gear side’s bearing.
remove the governor weight mounting nut.
Otherwise, the lock bolts or injection pump Install the fuel camshaft and bearings to the injection
housing might get damaged. pump housing.
Figure 70-70-43 Install the fuel camshaft stopper and tighten the fuel
camshaft stopper mounting screws to 7,9 - 9,3 N•m (5.8 -
1 6.9 ft-lb) torque.
Attach the governor weight to the fuel camshaft and

tighten the governor weight mounting nut to 63 - 72 N•m
P100099
Loosen the fuel camshaft stopper mounting screws and

remove the fuel camshaft stopper (Item 1) [Figure 70-70-
43].

FUEL SYSTEM (CONT’D) Fuel Injection Pump Removal
Fuel Camshaft Removal And Installation (Cont’d) Figure 70-70-46
Figure 70-70-45 3
1
2
1
4 P-76056
P100212
NOTE: The injection pump must be removed as a
complete assembly. Do Not remove individual
Fix the fuel camshaft with lock bolts so the key way on pump barrels. If individual pump barrels are
the fuel camshaft (Item 1) [Figure 70-70-45] is facing to removed, the pump must be recalibrated in a
the four o’clock position. certified injection shop.
Install the injection pump assembly to the injection pump NOTE: The injection pump can be replaced with the
housing. engine crankshaft in any position.
Attach the O-ring and the cover and tighten the cover Disconnect and plug the fuel hose (Item 1) and fuel
mounting bolts. overflow hose (Item 2) [Figure 70-70-46].
Install the governor sleeve to the fuel camshaft. Disconnect the four injection lines (Item 3) [Figure 70-70-
46] at the injection pump.
Check the movement of the governor sleeve.
Installation: Tighten the injection lines to 23 - 36 N•m
NOTE: Be careful not to damage the O-ring. (17 - 28 ft-lb) torque.
NOTE: Be careful the direction of the governor Remove the sight cover (Item 4) [Figure 70-70-46] from
sleeve. the injection pump assembly.
NOTE: When reassembling lightly oil the parts. NOTE: Mount the check valve (Item 2) [Figure 70-70-
46] with the arrow pointing towards the fuel
tank.

Fuel Injection Pump Removal (Cont’d)
Figure 70-70-47 1
1 1
P-37524
Disconnect the starter spring hook (Item 1) [Figure 70-

P-76946 70-49].
NOTE: Be careful to not deform the starter spring.

Disconnect the four injection lines (Item 1) [Figure 70-70-
47] at the injection nozzle assemblies. Figure 70-70-50
Remove the injection lines from the loader.

1
Figure 70-70-48
2
P-37525
Remove the governor connecting rod nut (Item 1)

P-76053 [Figure 70-70-50].
NOTE: Be careful not to drop the governor

Disconnect the electrical connector (Item 1) from the fuel connecting rod nut.
stop solenoid. Then remove the two mounting bolts (Item
2) [Figure 70-70-48] from the fuel stop solenoid. Installation: Tighten the governor connecting rod nut to
2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
Remove the solenoid (Item 3) [Figure 70-70-48] from the
injection pump.

Fuel Injection Pump Removal (Cont’d)

1
Figure 70-70-51
P-37527
With the injection pump mounting bolts and nuts loose,

P-37526 be sure the governor connecting rod (Item 1) [Figure 70-
70-53] clears the pin on the injection pump.
Disconnect the governor connecting rod (Item 1) [Figure Figure 70-70-54

70-70-51] from the injection pump.
Figure 70-70-52
1 1 2
1
1
2
P-37529
P-37528 Align the pin on the injection pump (Item 1) [Figure 70-
70-54] with the notch in the housing.
Remove the five injection pump mounting bolts (Item 1) Remove the injection pump from the injection pump
[Figure 70-70-52]. housing.
Remove the three injection pump mounting nuts (Item 2) NOTE: When taking out the injection pump, be
[Figure 70-70-52]. careful not to hit it against the governor
connecting rod.
Installation: Tighten the injection pump mounting bolts
to 24 - 28 N•m (17 - 20 ft-lb) torque. Tighten the injection
pump mounting nuts to 18 - 21 N•m (13 - 15 ft-lb) torque.

Fuel Injection Pump Installation

1
Figure 70-70-55
P100105
Figure 70-70-58
P100102
1
Install the injection pump (Item 1) [Figure 70-70-55] onto
the fuel injection pump assembly, and tighten the
mounting bolts and nuts.
Figure 70-70-56
P100106
Place the jig (Item 1) [Figure 70-70-57] and [Figure 70-

70-58] in the stop solenoid mounting hole of the injection
pump assembly.
NOTE: The tool (JIG) part number is MEL1637 for the

P100104 governor connecting rod alignment tool (Item
1) [Figure 70-70-57].
Hook the governor connecting rod (Item 1) [Figure 70-

70-56] to the rack pin of the injection pump assembly.
Installation: Tighten the governor connecting rod nut to

2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.

Fuel Injection Pump Installation (Cont’d) 1
Figure 70-70-59
2
1
P100111
Hook the start spring (Item 1) [Figure 70-70-61] and

P100107 [Figure 70-70-60] to the rack pin.
Make sure the permanent magnet at the top of the jig

(Item 1) is attracted to the governor connecting rod (Item
2) [Figure 70-70-59]. Turn the jig clockwise and
counterclockwise and look into the sight cover hole to see
if the governor connecting rod (Item 2) [Figure 70-70-59]
moves right and left accordingly.
Figure 70-70-60
2 1
P100110
Slightly tighten the governor connecting rod nut (Item 1)

on the governor connecting rod (Item 2) [Figure 70-70-
60].
Holding down the jig (Item 3) by hand, tighten up the

governor connecting rod nut (Item 1) [Figure 70-70-60]
to 2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.

FUEL SYSTEM (CONT’D)
Fuel Injection Pump Installation (Cont’d)
Figure 70-70-62
P100112
Figure 70-70-63
2
P100113
Move the stop lever (Item 1) [Figure 70-70-62] and

visually check to see if the fuel injection pump connecting
rack comes smoothly back to the start position by the
counter force of the start spring. At the same time,
visually check to see if there is no twist in the sliding point
(Item 2) [Figure 70-70-63] between the governor fork
lever and the governor connecting rod from the stop
solenoid mounting hole.
If the control rack fails to move back smoothly, remove

the start spring and the governor connecting rod nut, and
go through the above procedure starting with [Figure 70-
70-57].
Finally fit the sight cover and the stop solenoid back into
place.

Injection Pump - Timing
Figure 70-70-64
2
1
1
3
P-37538
Align the timing mark on the injection pump assembly

P-76933 (Item 1) [Figure 70-70-66] with the timing mark on the
gearcase housing.
Remove the lubrication tubeline (Item 1), the timer gear Figure 70-70-67
cover mounting bolts (Item 2) and the timer gear cover
(Item 3) [Figure 70-70-64].
Figure 70-70-65
2 1 1
2
P-76056
1
1 Disconnect the four injection lines (Item 1) [Figure 70-70-
P-76934 67] from the injection pump.

Install the 0° Restoring Jig (MEL1656) (Item 1) on to the (17 - 28 ft-lb) torque.
timer gear (Item 2) [Figure 70-70-65].

FUEL SYSTEM (CONT'D) Figure 70-70-70
Injection Pump - Timing (Cont’d)
Figure 70-70-68 1
P-37543
Install a short plastic tube (Item 1) [Figure 70-70-70] in

P-76946 the number one cylinder port of the injection pump. The
tube should fit securely and point upward.
Disconnect the four injection lines (Item 1) [Figure 70-70- Figure 70-70-71
68] from the injection nozzle assemblies.
Remove the injector lines from the engine.

2
1
Figure 70-70-69
P100707
Disconnect the wiring connector (Item 1) [Figure 70-70-

2 71] from the engine speed control sensor.
Remove the speed sensor (Item 2) [Figure 70-70-71]

from the engine.
1 P-76053

70-69] from the fuel shutoff solenoid.

from the fuel shutoff solenoid.
Remove the fuel shutoff solenoid from the engine (Item

3) [Figure 70-70-69].

Injection Pump - Timing (Cont’d)
Figure 70-70-72
P-37544
Check the location of the engine timing mark, by looking

P-37543 in the engine speed sensor hole on the engine flywheel
casting (Item 1) [Figure 70-70-74].
Turn the engine counterclockwise (viewed from flywheel Figure 70-70-75

end) until the fuel partially fills the plastic tube (Item 1)
[Figure 70-70-72].
Figure 70-70-73 2
1
P-37542B
The timing mark (Item 1) [Figure 70-70-75] should be

P-37543 located in the center of the engine speed sensor hole.
NOTE: The T.D.C. hole (Item 2) [Figure 70-70-75] in

After there is fuel rise seen in the plastic tube, rotate the the flywheel will not be visible in the speed
engine back (clockwise) at least 90°. sensor hole.
Slowly rotate the engine counterclockwise (viewed from If the timing mark is not located in the center of the hole,
flywheel end) and stop turning when the fuel begins to rotate the injection pump assembly until the injection
rise in the plastic tube (Item 1) [Figure 70-70-73]. timing is adjusted.
The injection timing is 0.128 rad (7°’s) before T.D.C.

FUEL SYSTEM (CONT'D) Remove the 0° Restoring Jig (MEL1656).
Injection Pump - Timing (Cont’d) Figure 70-70-78
Figure 70-70-76
2
1
2
3
1
P-76933
P-76073
Install the timer gear cover (Item 1), the gear cover
mounting bolts (Item 2) and lubrication tubeline (Item 3)
Make sure the injection pump assembly timing mark [Figure 70-70-78].
(Item 1) is aligned with the crankcase timing mark (Item
2) [Figure 70-70-76]. Tighten the mounting bolts (Item 2) [Figure 70-70-78] to
24 - 28 N•m (17 - 20 ft-lb) torque.
NOTE: If the injection timing is not within the
specification, rotate the injection pump Install flywheel rpm sensor. (See Installation on Page 60-
assembly to adjust the injection timing. 170-1.)
Figure 70-70-77
1
1
P-76079
Loosen the four fuel injection pump housing nuts (Item 1)

[Figure 70-70-77].
Rotate the injection pump (Item 2) [Figure 70-70-77]

counterclockwise (viewed from the flywheel side) to delay
the injection timing.
Rotate the injection pump (Item 2) [Figure 70-70-77]

clockwise (viewed from the flywheel side) to advance the
injection timing.

Fuel Injector Removal And Installation
Figure 70-70-79
1
P-37579
Remove the nut (Item 1) [Figure 70-70-81] from the

1 injection nozzle assembly hold down clamp.
P100114
Installation: Tighten the injection nozzle assembly hold

Remove the injection nozzle oil seal (Item 1) from the down clamp nut to 18 - 21 N•m (13 - 15 ft-lb) torque.
cylinder head cover (Item 2) [Figure 70-70-79].
Figure 70-70-82
Installation: Install new injection nozzle oil seals.
Remove the cylinder head cover (Item 2) [Figure 70-70-

79].
Installation: Tighten the valve cover bolts to 6,9 - 11,2
N•m (5.1 - 8.31 ft-lb) torque.
1
Figure 70-70-80
P-37580
1
1 Remove the nozzle hold down clamps (Item 1) [Figure
70-70-82] from the injection nozzle assembly.
P-37578
Remove the five over flow tubeline retaining bolts (Item 1)

[Figure 70-70-80].
Installation: Tighten the retaining bolts to 9,8 - 11,2 N•m

(7.24 - 8.31 ft-lb) torque.

FUEL SYSTEM (CONT'D) Fuel Injector Nozzle Pressure - Testing
Fuel Injector Removal And Installation (Cont’d) The tools listed below will be needed to do the following
procedures:
Figure 70-70-83
4200 - Injector Nozzle Tester
4201 - Injector Nozzle Tester Adapter Set
Figure 70-70-85
1
P-37581
Remove the injection nozzle assembly (Item 1) [Figure

70-70-83] from the engine.
P100115
Figure 70-70-84
Install the injection nozzle assembly onto the nozzle

tester (4200). Test the nozzle spraying condition.
1
Slowly move the tester handle to measure the pressure
at which fuel begins jetting out from the nozzle.
2
If the measurement is not within the factory
specifications, repair or replace the injection nozzle
assembly.
NOTE: injection nozzle assembly gasket must be

replaced when the injection nozzle assembly
is removed for testing.
P-37583
Injection Factory 1st 18637 - 19609 kPa

pressure specification stage (186,4 - 196,1 bar)
Remove the injection nozzle assembly O-rings (Item 1)
(2703 - 2844 psi)
and nozzle washer (Item 2) [Figure 70-70-84].
Always replace the injection nozzle assembly O-rings

and washer before installation.

FUEL SYSTEM (CONT'D) Valve Seat Tightness
Nozzle Spraying Condition The tools listed below will be needed to do the following
procedure:
The tools listed below will be needed to do the following
procedure: 4200 Injector nozzle tester
4201 Injector nozzle tester adapter set
4200 Injector nozzle tester
4201 Injector nozzle tester adapter set Figure 70-70-87
Figure 70-70-86
Correct Incorrect
P100117
P100116
Install the injection nozzle assembly on to a nozzle tester
(4200).
Install the injection nozzle assembly onto a nozzle tester
(4200), and test the nozzle spraying condition. Raise the fuel pressure, and keep at 16672 kPa (166,7
bar) (2418 psi) for 10 seconds.
If the spraying condition is defective, repair or replace the
injection nozzle assembly. If any fuel leak is found, repair or replace the injection
nozzle assembly.
Valve seat Factory No fuel leak at

tightness specification. 16672 kPa (166,7
bar) (2418 psi)

CYLINDER HEAD Intake Air Heater Removal And Installation
Intake Air Heater - Testing Figure 70-80-3
Figure 70-80-1
1 2 2
P100124
P100124
Disconnect the electrical wire from the intake heater lead
(Item 1) [Figure 70-80-3]
Disconnect the electrical wire (Item 1) [Figure 70-80-1]
from the air intake heater. Remove the four mount bolts (Item 2) [Figure 70-80-3]
from the intake air heater housing.
Figure 70-80-2
lb) torque.
Figure 70-80-4
1
2
P100127
Measure the resistance between + terminal (Item 1) and

intake air heater body (Item 2) [Figure 70-80-2].
P-37560
If the resistance is open, the intake air heater is faulty.

NOTE: When installing the intake air heater in the
Intake air Factory spec. Approx. 0.3 ohm housing, install the intake air heater so the
heater (At cold occasion) heater lines (Item 1) [Figure 70-80-4] are
resistance vertical, to prevent a short-circuit in the
system.

CYLINDER HEAD (CONT’D) Figure 70-80-7
Valve Clearance Adjustment
NOTE: Valve clearance must be checked and

adjusted when engine is cold. 1
Figure 70-80-5
P-37579
Remove the nut (Item 1) [Figure 70-80-7] from the

1 injector nozzle holder clamp.
Installation: Tighten the injector nozzle holder clamp nut

P-76089 to 18 - 20 N•m (13 - 15 ft-lb) torque.
Figure 70-80-8
Remove the high pressure pipes (Item 1) and the valve
cover (Item 2) [Figure 70-80-5].
Installation: Tighten the injection pipe retaining nut to 23
- 36 N•m (17 - 26 ft-lb) torque.
Installation: Tighten the cylinder head cover screw to

1
6,9 - 11,2 N•m (5.1 - 8.31 ft-lb) torque.
Figure 70-80-6
P-37580
1
Remove the nozzle holder clamps (Item 1) [Figure 70-
1 80-8] from the injector nozzle.
P-37578
Remove the five over flow pipe retaining bolts (Item 1)

[Figure 70-80-6].
Installation: Tighten the retaining bolts to 9,8 - 11,2 N•m

(7.24 - 8.31 ft-lb) torque.

Valve Clearance Adjustment (Cont’d)
Figure 70-80-9
2
2 P-37195
Loosen the lock nut (Item 1) of adjusting screw (Item 2)

P-37194 [Figure 70-80-10] (push rod side) and insert the feeler
gauge between the rocker arm and the bridge head. Set
the adjusting screw to the specified value, then tighten
Set number one piston to top dead center on the the lock nut.
compression stroke.
Valve clear- Factory spec. 0,23 - 0,27 mm
Before adjusting the valve clearance, adjust the bridge to ance (0.0091 - 0.010 in)
set the height of valves.
NOTE: After adjusting, tighten the lock nut (Item 2)
Loosen the lock nut (Item 2) and turn the adjusting screw
[Figure 70-80-10] securely.
(Item 1) [Figure 70-80-9] to adjust the bridge.
Apply pressure with your finger to the rocker arm and Adjustment IN. EX.
screw in the adjusting screw slowly until you feel the Location of piston cylinder
screw touch the top of valve stem, then tighten the lock When No. 1 piston is 1st * *
nut. at compression top 2nd *
dead center
3rd *
4th
When No. 1 piston is 1st
at overlap position 2nd *
3rd *
4th * *

Valve Timing - Checking
NOTE: Engine removed for photo clarity
Figure 70-80-11
1 2
P100143
Rotate the engine, until the timing mark on the injection

pump fuel cam gear (Item 1) is meshed with the idler
gear (Item 2) [Figure 70-80-13].
P100145
Look for a timing mark on the idler gear (Item 1), if one is
not present, mark the engaged teeth (Item 2) [Figure 70-
Remove the two bolts (Item 1) [Figure 70-80-11] from 80-13] to aid in reassembly.
the engine speed control linkage mount and the injection
pump gear cover. Figure 70-80-14
Figure 70-80-12
2 2
1 2
3
2
P100142
2 P100144
Any time the timing mark (Item 1) on the fuel cam gear is
meshed with the idler gear (Item 2) [Figure 70-80-14] the
Remove the timer lubricating pipe (Item 1) [Figure 70-80- engine is on top dead center of the compression stroke
12] from the injection pump gear cover and engine. on number four cylinder.
Remove the seven cover mounting bolts (Item 2) [Figure

70-80-12] from the injection pump gear cover.
Remove the injection pump gear cover (Item 3) [Figure

70-80-12] from the engine.

CYLINDER HEAD (CONT’D) Cylinder Head Removal And Installation
Valve Timing - Checking (Cont’d) Remove the fuel injectors. (See Fuel Injector Removal
Figure 70-80-15
Figure 70-80-17
1
1
3
P-37599
P-37201
Install a 9,5 mm (375 in) bolt through the hole in the

flywheel casting (Item 1) [Figure 70-80-15]. Remove the rocker arm assembly (Item 1) [Figure 70-80-
17].
Figure 70-80-16
Remove the push rods (Item 2) [Figure 70-80-17].
Remove the bridge arms (Item 3) [Figure 70-80-17].

Figure 70-80-18
1
P-37519
Remove the flywheel cover from the engine flywheel

housing.
P-37158
Check to see that the bolt (Item 1) [Figure 70-80-16] is
completely through the flywheel.
Place the push rods (Item 1) into the tappets (Item 2)
The engine is now fixed on Top Dead Center. [Figure 70-80-18], check to see if their ends are properly
engaged with the grooves.
NOTE: After reassembling the rocker arm, be sure to

adjust the valve clearance.

Cylinder Head Removal And Installation (Cont’d)

1
Figure 70-80-19
P100961
Make sure to note the notch (a), (b) or (c) of cylinder

P-37228A
head gasket (Item 1) [Figure 70-80-21] in advance.
Replace the same notch (a), (b) or (c) as the original

Loosen the hose clamps and remove the water return cylinder head gasket (Item 1) [Figure 70-80-21].
Select the cylinder head gasket thickness to meet with
Figure 70-80-20 the top clearance when replacing the piston, piston pin
bushing, connecting rod or crank pin bearing.
Take care handling the gasket so as not to damage it.
NOTE: When replacing the piston, piston pin
bushing, connecting rod or crank pin bearing,
select the cylinder head gasket thickness to
meet with the top clearance.
P-37266
Remove the cylinder head bolts in the order of (18) to (1)

[Figure 70-80-20], and remove the cylinder head.
Remove the cylinder head gasket.
Tightening Cylinder head 98,1 - 107 N•m

torque bolts (72.4 - 79.5 ft-lb)
The cylinder head should be free of scratches and dust.
Tighten the cylinder head bolts gradually in the order of

(1) to (18) after applying engine oil to the threads.
Be sure to adjust the valve clearance. (See Valve

Clearance Adjustment on Page 70-80-2.)

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation (Cont’d) Figure 70-80-24
Figure 70-80-22
2 1
3
5
1
4
P-37204A
P-37203
Remove the valve spring collets (Item 1) after
compressing the valve spring (Item 3) with the valve
Figure 70-80-23 spring retainer (Item 2) [Figure 70-80-24].
Remove the valve seal (Item 4) and the valve (Item 5)

1 [Figure 70-80-24].
Figure 70-80-25
3EEABAC1P026A 1
Measure the piston head’s recessing or protrusion from

the crankcase cylinder face (Item 1) [Figure 70-80-22] at 2
four spots per each piston (Item 1) [Figure 70-80-23]
P100962
using dial gauge [Figure 70-80-22] and average the four
pistons.
Install the valve spring with its small-pitch end (Item 1)
downward toward the head side (Item 2) [Figure 70-80-
25].
Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.
After installing the valve spring collets, lightly tap the

stem to assure proper fit with a plastic hammer.

CYLINDER HEAD (CONT’D) Cylinder Head Top Clearance
Cylinder Head - Servicing Figure 70-80-27
Figure 70-80-26
1 2 P-37162
P-37212
If the measurement exceeds the allowable limit, correct it
with a surface grinder.
Thoroughly clean the cylinder head surface.
Place a straightedge on the cylinder head’s four sides
Measure the clearance with a straightedge (Item 1) and a and two diagonal [Figure 70-80-27].
feeler gauge (Item 2) [Figure 70-80-26].
Cylinder Head Allowable 0,05 mm
Surface Flatness Limit 0.002 in
NOTE: Be sure to measure the valve recessing after
correcting.
Select the suitable cylinder head gasket, refer to the table below.
Notch of Cylinder Head Thickness of cylinder head gasket Piston Head’s recessing
Gasket or protrusion from the
level of crankcase
cylinder face. (average
of 4 pistons)
Before tightening After tightening
2 notches (a) 0,90 mm 0,80 mm -0,07 - +0,049 mm
(0.035 in) (0.031 in) (-0.0028 - +0.0019 in)
1 notch (b) 1,00 mm 0,90 mm +0,050 - +0,149 mm
(0.0394 in) (0.035 in) (+0.0020 - +0.0058 in)
Without notch (c) 1,05 mm 0,95 mm +0,150 - +0,20 mm
(0.0413 in) (0.037 in) (+0.0059 - +0.0078 in)

Valve Guide - Checking
The tool described below is not provided. The tool is

used for inserting and removing the valve guides.Use the
dimensions below [Figure 70-80-28] and [Figure 70-80-
29] to make this tool.
Figure 70-80-28
P-37138
Remove carbon from the valve guide section.
Measure the valve stem O.D. with an outside micrometer

[Figure 70-80-30].
Figure 70-80-31
P-37187
Figure 70-80-29
P-37139
P-37188
Measure the valve guide I.D. of the cylinder head at the
A 20 mm dia. (0.79 in dia.) most wear part as shown in [Figure 70-80-31] with a
B 11,7 - 11,9 mm dia. (0.461 - 0.468 in dia.) small hole gauge and calculate the clearance.
C 6,50 - 6,60 mm dia. (0.256 - 0.259 in dia.)
D 225 mm (8.86 in)
E 70 mm (2.8 in)
F 45 mm (1.8 in)
G 25 mm (0.98 in)
H 5 mm (0.2 in)
I 6,70 - 7,00 mm dia. (0.264 - 0.275 in dia.)
J 20 mm dia. (0.79 in dia.)
K 12,5 - 12,8 mm dia. (0.493 - 0.503 in dia.)
L 8,90 - 9,10 mm dia. (0.351 - 0.358 in dia.)
C1 Chamfer 1,0 mm (0.039 in)
C0.3 Chamfer 0,3 mm (0.01 in)

Valve Guide - Checking (Cont’d)
If the clearance exceeds the allowable limit, replace the

valves. If it still exceeds the allowable limit, replace the
valve guide. 1
2
Clearance Factory Intake 0,055 - 0,085
between spec. valve mm
valve stem (0.0022 - 3
and guide 0.0033 in)
Exhaust 0,055 - 0,085
valve mm
(0.0022 -
0.0033 in) P-76091
Allowable 0,1 mm (0.004 in)

limit Press the used valve guide out of the cylinder head (Item
1) [Figure 70-80-32] using the special driver tool.
Valve stem Factory Intake 6,960 - 6,975
O.D. spec. valve mm Put oil on the outside diameter of the new valve guide.
(0.2741 - 0.2746 Press the new valve guide into the cylinder head from the
in) top side. Use the special driver tools (Items 2 and 3)
[Figure 70-80-32], press the new guide until the tool
Exhaust 6,960 - 6,975 contacts the cylinder head.
valve mm
(0.2741 - 0.2746 Ream the valve guide to the correct specifications.
in)
Valve guide Factory Intake 7,030 - 7,045
I.D. spec. valve mm
(0.2768 - 0.2773
in)
Exhaust 7.030 - 7.045
valve mm
(0.2768 - 0.2773
in)

Reconditioning The Valve And Valve Seat 1 2

15° Exhaust
Figure 70-80-33 30° Intake
PI-9995
Inspect the seat surface and valve face (Item 1) [Figure

PI-9993 70-80-35].
(a) identical dimensions above and below the valve seat

Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-33]. If the seat surface (b) is too wide, use a 30 degree cutter
(Item 2) on the intake, and a 15 degree cutter on the
NOTE: Before correcting the valve and seat, inspect exhaust to get the correct width (Item 3) [Figure 70-80-
the valve stem and the I.D. of the valve guide 35].
section, and repair if necessary.
Valve Seat Intake 1,6 - 2,0 mm
After correcting the valve seat, be sure to Width (0.063 - 0.078 in)
measure the valve recessing [Figure 70-80-
37]. Exhaust 2,3 - 2,6 mm
(0.091 - 0.10 in)
Clean the valve seat and combustion chamber.
Valve Seat & Intake 60 degrees
Figure 70-80-34 Face Angle Exhaust 45 degrees
Correct the valve with a valve refacer.
After resurfacing the seat, inspect for even valve seating,

apply a thin film of compound between the valve face and
valve seat, and fit them with valve lapping tool.
45° Exhaust Check the valve seating with prussian blue. The valve
15° Exhaust 60° Intake seating surface should show good contact all the way
30° Intake around.
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-34].

CYLINDER HEAD (CONT’D) Valve Recessing
Reconditioning The Valve And Valve Seat (Cont’d) Figure 70-80-37
Valve Lapping
Figure 70-80-36
P-37213
Clean the cylinder head, the valve face and seat.

P-37214
Insert the valve into the valve guide.
Apply compound evenly to the valve lapping surface. Measure the valve recessing with a depth gauge [Figure
70-80-37].
Insert the valve into the valve guide. Lap the valve onto
its seat with a valve lapper [Figure 70-80-36]. If the measurement exceeds the allowable limit, replace
the valve.
After lapping the valve, wash the compound away and
apply oil, then repeat valve lapping with oil. If it still exceeds the allowable limit after replacing the
valve, correct the valve seat face of the cylinder head with
Apply prussian blue to the contact surface to check the a valve seat cutter or valve seat grinder.
percentage of the seated valve. If it is less than 70%,
repeat valve lapping again. Then, correct the cylinder head surface with a surface
grinder, or replace the cylinder head.
NOTE: When valve lapping is performed, be sure to
check the valve recessing and adjust the Valve Factory Intake 0,60 - 0,80 mm
valve clearance after assembling the valve. recessing spec. valve (0.024 - 0.031 in)
(recessing)
Exhaust 0,850 - 1,05 mm
valve (0.0335 - 0.0413
in)
(recessing)
Allowable (recessing)
limit 1,2 mm (0.047 in)

Valve Spring
Figure 70-80-38
P-37254
Measure the free length (A) with vernier calipers [Figure

P-37255 70-80-39]. If the measurement is less than the allowable
limit, replace it.
Place the valve spring on a tester and compress it to the Put the spring on a surface plate, place a square on the
same length it is actually compressed in the engine side of the spring, and check to see if the entire side is
[Figure 70-80-38]. contact with the square. Rotate the spring and measure
the maximum (B) [Figure 70-80-39]. If the measurement
Read the compression load on the gauge. exceeds the allowable limit, replace.
If the measurement is less than the allowable limit, Inspect the entire surface of the spring for scratches.
replace it. Replace spring, if any are found.
Setting Factory Intake 63,5 N / 31,5 Free length Factory Intake 35,1 - 35,6 mm
load / setting spec. valve mm (A) spec. valve (1.39 - 1.40 in)
length (14.3 lb / 1.24
Exhaust 35,1 - 35,6 mm
in)
valve (1.39 - 1.40 in)
Allowable Intake 34,6 mm
Exhaust 63,5 N / 31,5
limit valve (1.36 in)
valve mm
(14.3 lb / 1.24 Exhaust 34,6 mm
in) valve (1.36 in)
Allowable Intake 45,9 N / 31,5 Tilt (B) Allowable 1,0 mm (0.039 in)
limit valve mm limit
(10.3 lb / 1.24
in)
Exhaust 45,9 N / 31,5
valve mm
(10.3 lb / 1.24
in)

Valve Tappets
Figure 70-80-40
P-37174
Measure the tappet O.D. with an outside micrometer

P-37202 [Figure 70-80-41].
Measure the I.D. of the tappet guide bore with a cylinder

Remove the tappets (Item 1) [Figure 70-80-40] from the gauge, and calculate the oil clearance [Figure 70-80-41].
crankcase.
If the oil clearance exceeds the allowable limit or the
Before installing the tappets (Item 1) [Figure 70-80-40], tappet is damaged, replace the tappet.
apply engine oil to aid in assembly and initial start up.
Oil clearance Factory 0,020 - 0,062 mm
NOTE: Mark the cylinder number to the tappets to between tappet spec. (0.00079 - 0.0024 in)
prevent interchanging. and guide Allowable 0,07 mm
limit (0.003 in)
Tappet O.D. Factory 23,959 - 23,980 mm

spec. (0.94327 - 0.94409 in)
Tappet guide Factory 24,000 - 24,021 mm
I.D. spec. (0.94489 - 0.94570 in)

CYLINDER HEAD (CONT’D) Push Rod Alignment - Checking
Rocker Arm And Shaft - Checking Figure 70-80-43
Figure 70-80-42
P-76926
P-37173
Place the push rod on V blocks [Figure 70-80-43].
Measure the rocker arm bearing I.D. with an inside Measure the push rod alignment [Figure 70-80-43].
micrometer [Figure 70-80-42].
If the push rod exceeds the allowable limit, replace the
Measure the rocker arm shaft O.D. with an outside push rod.
micrometer, and then calculate the oil clearance [Figure
70-80-42]. Push rod Allowable 0,25 mm (0.0098 in)
alignment limit

rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace the rocker arm shaft.

or rocker arm spec. (0,00063 - 0,0017 in)
shaft and Allowable 0,15 mm
bearing limit (0.0059 in)
Rocker arm Factory 15,973 - 15,984 mm

shaft O.D. spec. (0.62886 - 0.62929 in)
Rocker arm Factory 16,000 - 16,018 mm
I.D. for shaft spec. (0.62993 - 0.63062 in)

70-80-16
T770 Service Manual
CRANKSHAFT AND PISTONS Figure 70-90-2
Piston And Connecting Rod Removal And

Installation
Remove the oil pan. (See Oil Pan Removal And

Remove the cylinder head. (See Cylinder Head Removal

1
Figure 70-90-1
1 P-37159
Align the marks (Item 1) [Figure 70-90-2] with each

other. (Face the marks toward the injection pump.)
Apply engine oil to the connecting rod bolts and lightly

thread it in by hand then tighten it to the specified torque.
If the connecting rod bolts do not thread together
smoothly, clean the threads. If the connecting rod bolt is
still hard to thread in, replace it.
P-37128
NOTE: When using the existing crank bearing, put
marks on the crank pin bearing and the
Remove the connecting rod bolts (Item 1) [Figure 70-90- connecting rod in order to keep their position.
1] from connecting rod cap.
Insert the crank pin bearing.
Remove the connecting rod caps.
Tightening Connecting 79 - 83 N•m
torque rod screw (58 - 61 ft-lb)

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-4
Piston And Connecting Rod Removal And

Installation (Cont’d) 1
Remove the top ridge from the cylinder bore with a ridge
reamer.
Turn the flywheel and set a piston to the top dead center.
Remove the piston and connecting rod.
Installation:
Before installing the piston into the cylinder, apply engine

oil to the cylinder to aid in reassembly and initial start up. P-37233A
NOTE: Do not change the combination of cylinder

and piston. Make sure of the position of each When inserting the piston into the cylinder, face the mark
piston by marking. For example, mark “1” on (Item 1) [Figure 70-90-4] on the connecting rod toward
the No. 1 position. the injection pump.
1 Top Ring Gap Oil Ring

Gap
45° (0.79 rad.)
Piston
Pin Hole
Second Ring
Gap Oil Ring Gap
P-37208 P-37209
Install the pistons using a piston ring compressor (Item 1) NOTE: When inserting the piston into the cylinder,
[Figure 70-90-3]. place the gap of the compression ring 1 on the
opposite side of the combustion chamber and
stagger the gaps of the compression ring 2
and oil ring marking a right angle from the gap
of the compression ring 1 [Figure 70-90-5].

Piston And Connecting Rod - Servicing

7
The Small End Bushing Replacing Tool can be made
using the dimensions below. One set of dimensions is for 9
8
the press out tool and one for press fit.
6 1
Figure 70-90-6
5
4 3
P-37210
1. Piston Pin
2. Piston
P-37189
3. Piston Pin Snap Ring
4. Compression Ring 1
Small End Bushing Replacing Tool
5. Compression Ring 2
Application: Use to press out and to press fit the small
end bushing in the connection rod. 6. Oil Ring
(Press out) 7. Connecting Rod
A 157 mm (6.18 in) 8. Mark (  )

B 14,5 mm (0.571 in)
C 120 mm (4.72 in) 9. Numbering Mark
D 30 mm dia. (1.181 in dia.)
E 32,95 mm dia. (1.297 in dia.) Remove the piston rings using a piston ring tool [Figure
F 20 mm (0.79 in) 70-90-7].
a 0,0000063 mm (0.00025 in)
b 0,0000063 mm (0.00025 in) Remove the piston pin (Item 1), and separate the
C1 Chamfer 1,0 mm (0.039 in) connecting rod (Item 7) from the piston (Item 2) [Figure
C2 Chamfer 2,0 mm (0.079 in) 70-90-7].
(Press fit) Installation: When installing the piston pin, immerse the
piston in 80C (176F) oil for 10 to 15 minutes and insert
A 157 mm (6.18 in) the piston pin to the piston.
B 14,5 mm (0.571 in)
C 120 mm (4.7244 in) Assemble the piston to the connecting rod with the 
D 30 mm dia. (1.181 in dia.) mark (Item 8) and the connecting rod numbering mark
E 42,000 mm dia. (1.6535 in dia.) (Item 9) [Figure 70-90-7] facing same side.
F 20 mm (0.79 in)
a 0,0000063 mm (0.00025 in) NOTE: Mark the same number on the connecting rod
b 0,0000063 mm (0.00025 in) and the piston so as not to change the
C1 Chamfer 1,0 mm (0.039 in) combination.

Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-8
P-37161
When installing the ring, assemble the rings so that the

2 manufacture’s mark (Item 1) [Figure 70-90-10] near the
P-37211A
gap faces the top of the piston.
Be sure the crank pin bearing and the connecting rod are Figure 70-90-11
same I.D. colors (Items 1 and 2) [Figure 70-90-8].
Figure 70-90-9
1
P-37253
Measure the piston pin bore I.D. in both the horizontal

P-37160
and vertical directions with a cylinder gauge [Figure 70-
90-11].
When installing the oil ring onto the piston, place the
expander joint (Item 1) on the opposite side of the oil ring If the measurement exceeds the allowable limit, replace
gap (Item 2) [Figure 70-90-9]. the piston.
Piston pin Factory 30,000 - 30,013 mm

bore I.D. spec. (1.1811 - 1.1816 in)
Allowable 30,05 mm
limit (1.183 in)

Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-12
1 2
P-37179
Press out the used bushing using a small end bushing

P-37178 replacing tool (Item 1) [Figure 70-90-13].
Figure 70-90-14
Measure the O.D. of the piston pin where it contacts the
bushing with an outside micrometer [Figure 70-90-12].
Measure the I.D. of the piston pin bushing at the

connecting rod small end with a cylinder gauge [Figure 1
70-90-12].

bushing. If it still exceeds the allowable limit, replace the
piston pin.

between piston spec. (0.00079 - 0.0015 in)
pin and small Allowable 0,15 mm (0.0059 in)
end bushing limit P-37142A
Piston pin O.D. Factory 30,006 - 30,011 mm Clean a replacement small end bushing and connecting
spec. (1.1814 - 1.1815 in) rod bore, and apply engine oil to aid in assembly.
Small end bush- Factory 30,031 - 30,046 mm
ing I.D. spec. (1.1824 - 1.1829 in) Place the bushing onto the tool and press-fit it with a
press (Item 2) [Figure 70-90-13] so that the seam (Item
1) [Figure 70-90-14] of the bushing is flush with the
connecting rod.

CRANKSHAFT AND PISTONS (CONT'D) Piston Ring Gap
Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-16
Piston Ring Groove
Figure 70-90-15
P-37180
Insert the piston ring into the lowest part of the liner
P-37215 which is the least worn.
Measure the ring gap with a feeler gauge [Figure 70-90-

Remove carbon from the ring grooves. 16].
Measure the clearance between the ring and the groove If the gap exceeds the allowable limit, replace the piston
with a feeler gauge [Figure 70-90-15]. ring.
If the clearance exceeds allowable limit, check the new Compression Factory spec. 0,30 - 0,45 mm
rings on an old piston and if it is out of spec, replace the ring 1, 2 (0.012 - 0.017 in)
piston.
Allowable 1,25 mm
limit (0.0492 in)
Factory spec. Compression 0,05 - 0,09 mm
ring 1 (0.002 - 0.003 in)
Oil Ring Factory spec. 0,25 - 0,45 mm
Compression 0,0930 - 0,120 mm
(0.0099 - 0.017 in)
ring 2 (0.00367 - 0.00472
in) Allowable 1,25 mm
limit (0.0492 in)
Oil Ring 0,020 - 0,060 mm
(0.00079 - 0.0023 in)
Allowable Compression 0,15 mm (0.0059 in)
limit ring 1
Compression 0,20 mm (0.0079 in)
ring 2
Oil ring 0,15 mm (0.0059 in)

Cylinder Bore - Checking
Figure 70-90-17
1
P-37164
When the cylinder is worn beyond the allowable limit

P-37169 (Item 1), bore and hone it to the specified dimension
(Item 2) [Figure 70-90-19].
Use a gauge to check the inside measurement of the Cylinder I.D. Oversize 100,500 - 100,522 mm
cylinder bore [Figure 70-90-17]. (Item 2) (+ 0,5 mm) (3.95670 - 3.95755 in)
Spec.
Figure 70-90-18
Maximum Allowable 100,65 mm
wear limit (3.96260 in)
1 Finishing Hone to 8 - 30 in Rz.
———
(0.2 - 0.8 m Rz.)
Replace the piston and piston rings with oversize (0,5

mm) ones.
NOTE: When the oversize cylinder is worn beyond

the allowable limit, replace the cylinder block
with a new one.
2
P-37163
Measure the six points with a cylinder gauge to find out

the maximum wear [Figure 70-90-18].
NOTE: Generally, position (1) in the (a, b) direction (at

about 20 mm (0.79 in) from the top) shows the
maximum wear [Figure 70-90-18]. Since
position (Item 2) at the lower part of the bore
will show the minimum wear.
Cylinder bore Factory 100,000 - 100,022 mm

I.D. spec. (3.93701 - 3.93787 in)
Allowable 100,150 mm
limit (3.9429 in)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Gear Removal And Installation
Connecting Rod Alignment Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-90-20 100-1.)
Remove the idler gear. (See Idler Gear And Camshaft

Figure 70-90-21
P-37181
NOTE: Since the I.D. of the connecting rod small end

bushing is the basis of this check, check the
bushing for wear beforehand.
B-3686
Install the connecting rod on the connecting rod

alignment tool. Remove the crankshaft gear with a puller [Figure 70-90-
21].
Put a gauge over the piston pin, and move it against the
face plate [Figure 70-90-20]. Remove the crankshaft key.
If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the
face plate.
If the measurement exceeds the allowable limit, replace

the connecting rod.
Connecting rod Allowable 0,05 mm

alignment limit (0.0020 in)

Crankshaft And Bearings Removal 1
Remove the flywheel housing. (See Housing Removal

3 3
Remove the oil pan. (See Oil Pan Removal And
Figure 70-90-22
2
P-37130A
NOTE: Before disassembling, check the side

clearance of crankshaft. Also check it during
reassembly. Check the crankshaft side
clearance. (See Crankshaft And Bearings -
Servicing on Page 70-90-13.)
3EEABAC1P115A Remove the eight bearing case cover mounting bolts

(Item 2) [Figure 70-90-23].
Application: Use for aligning the crankcase 1 and 2. Install the two bolts removed earlier into the bolt hole
(Item 3) [Figure 70-90-23] of bearing case cover to
A 115 mm (4.53 in)
remove it.
B 56 mm (2.2 in)
C 17 mm (0.67 in) NOTE: Install the bearing case cover / oil seal
D 20 mm (0.79 in) assembly with the casting mark labeled “UP”
E 14 mm dia. (0.55 in dia.) (Item 1) [Figure 70-90-23] at the top.
F 11 mm dia. (0.43 in dia.)
G 14 mm dia. (0.55 in dia.)
H 17,5 mm (0.6890 in)
I 17,5 mm (0.6890 in)
J 35 mm (1.4 in)
K 19 mm (0.75 in)

Crankshaft And Bearings Removal (Cont’d)
Figure 70-90-24
1
2
2
3EEABAC1P098A
Remove the fourth bearing case (Item 1) and the thrust

bearing (Item 2) [Figure 70-90-26].
P-37133
Figure 70-90-27
Remove the bolts (Item 1) that secure the crankcase 2
[Figure 70-90-24] to crankcase 1.
Remove the crankcase 2 (Item 2) [Figure 70-90-24].
Figure 70-90-25
1
2
P-37137
Remove the crankshaft [Figure 70-90-27].
3EEABAC1P099A
Remove the bolts (Item 1) and the bearing cases (Item 2)

[Figure 70-90-25] from crankcase 1.

Crankshaft And Bearings Installation
Figure 70-90-28
1
1
2
2
3EEABAC1P098A
NOTE: Install the main bearing case having the same

number as the one engraved on the
3EEABAC1P097A
crankcase, and set the casting mark “F/W
SIDE” on the main bearing case towards the
Install the thrust bearing (Item 1) [Figure 70-90-28] on flywheel side.
both sides of the fourth mainbearing case with the oil
groove facing out. Install the fourth bearing case (Item 1) and the thrust
bearing (Item 2) [Figure 70-90-30].
Install the main bearings (Item 2) [Figure 70-90-28].
Figure 70-90-31
Figure 70-90-29
3EEABAC1P099A
P-37137
NOTE: Install the main bearing case having the same

Install the crankshaft [Figure 70-90-29]. number as the one engraved on the
crankcase, and set the casting mark “F/W
SIDE” on the main bearing case towards the
flywheel side.
Apply oil to the bearing case bolts and tighten them to the
specified torque.
Tightening Main bearing 137 - 147 N•m

torque case screw (102 - 108 ft-lb)

Crankshaft And Bearings Installation (Cont’d)

2
Figure 70-90-32
3EEABAC1P096A
Match the crankcase 1 (Item 1) and crankcase 2 (Item 2)

P-37134 [Figure 70-90-33] referring to the flywheel’s contoured
face.
NOTE: Make sure the crankcase 1 and 2 are clean. Tighten the crankcase 2 mounting bolts loosely.
Apply liquid gasket (Item 1) [Figure 70-90-32] Install the jig (Item 3) [Figure 70-90-33] to the specified
to the crankcase 2 as shown. torque. This helps to minimize the level difference
between the crankcase 1 and the crankcase 2 (at the
flywheel side) Gap must be 0,05 mm (0.002 in) or
smaller.
Tightening Flywheel housing 78 - 90 N•m
torque bolt (58 - 66 ft-lb)
Figure 70-90-34
P-37133
Tighten the crankcase 2 mounting bolts (Item 1) with

even force on the diagonal line to secure the crankcase 2
[Figure 70-90-34] to crankcase 1.
Tightening Crankcase 2 mounting 49 - 55 N•m

torque bolt (37 - 41 ft-lb)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Installation (Cont’d) The following special tools are not provided, [Figure 70-
90-37], [Figure 70-90-38] and [Figure 70-90-22].
Figure 70-90-35
Figure 70-90-37
P-37131
NOTE: When replacing the oil seal, use caution

installing the seal in the bearing case cover as
not to install it tilted. The seal should be flush
with the cover. P-37114
Apply liquid gasket (Item 1) [Figure 70-90-35] to the Gearcase Oil Seal Replacing Tool
bearing case cover evenly.
Application: Use to press fit the oil seal.
Figure 70-90-36
A 148,8 mm (5.858 in)

1
B 50 mm (2.0 in)
C 18,8 mm (0.740 in)
D 13,7 - 13,9 mm (0.540 - 0.547 in)
E 11 mm (0.43 in)
F 18 mm dia. (0.71 in dia.)
G 38 mm dia. (1.5 in dia.)
H 45 mm dia. (1.8 in dia.)
I 57,90 - 58,10 mm (2.280 - 2.287 in)
J 79,5 mm dia. (3.13 in dia.)
K 87 mm (3.4 in)
L 12 mm (0.47 in)
M 40 mm (1.6 in)
P-37130A N 120 mm (4.72 in)
NOTE: Install the bearing case cover / oil seal

assembly with the casting mark labeled “UP”
(Item 1) [Figure 70-90-36] at the top.
Tighten the bearing case cover mounting bolts with even

force on the diagonal line.
Tightening Bearing Case Cover 24 - 27 N•m

torque mounting bolt (18 - 20 ft-lb)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Side Clearance
Crankshaft And Bearings - Servicing (Cont’d) Figure 70-90-39
Figure 70-90-38
3EEABAC1P105A
Set a dial indicator with its tip on the end of the

crankshaft [Figure 70-90-39].
Measure the side clearance by moving the crankshaft to

the front and rear.
Crankshaft Factory spec. 0,15 - 0,31 mm

side clearance (0.0059 - 0.012 in)
Allowable 0,50 mm
limit (0.020 in)
P-37115
If the measurement exceeds the allowable limit, replace
the thrust bearings.
Auxiliary Socket For Fixing Crankshaft Sleeve
Application: Use to fix the crankshaft sleeve of the diesel
engine.
A Rmax = 12.5 S
B 94,5 - 95,0 mm (3.72 - 3.74 in)
C 40 mm (1.6 in)
D 30 mm (1.2 in)
E 12 mm (0.47 in)
F 7,90 - 8,10 mm (0.311 - 0.318 in)
G 20 mm (0.079 in)
H 130 mm (5.12 in)
I 99,40 - 99,60 mm (3.914 - 3.921 in)
J 95,05 - 95,20 mm (3.743 - 3.748 in)
K 3 mm dia. (0.1 in dia.)
L 15 mm (0.59 in)
M 10 mm (0.39 in)
N 90 mm (3.5 in)
O 115 mm (4.53 in)
P 16,9 - 17,1 mm (0.666 - 0.673 in)

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-40
P-37182
Support the crankshaft with V block on the surface plate

P-37144 and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-90-41].
If the same size bearing can not be used because of the Rotate the crankshaft on the V block and get the
crankshaft journal wear, replace it with an oversized one misalignment (half of the measurement).
referring to the table and [Figure 70-90-40].
If the misalignment exceeds the allowable limit, replace
Oversize dimensions of crankshaft journal. the crankshaft.
Oversize 0,2 mm 0,4 mm Crankshaft Allowable 0,02 mm

(0.008 in) (0.016 in) alignment limit (0.0008 in)

Dimension A 29,20 - 29,25 mm 29,40 - 29,45 mm
(1.150 - 1.151 in) (1.158 - 1.159 in)
Dimension B 169,10 - 169,15 169,2 - 169,25
mm mm
(6.6575 - 6.6594 (6.6615 - 6.6633
in) in)
Dimension C 2,8 - 3,2 mm 2,8 - 3,2 mm
radius radius
(0.11 - 0.12 in (0.11 - 0.12 in
radius) radius)
The crankshaft journal must be fine-finished to higher

than (0.8-S)


1
Clean the crank pin and crank pin bearing.
Figure 70-90-42
P100964
NOTE: To replace it with a specific STD service part,

make sure the crank pin bearing has the same
ID color (Item 1) [Figure 70-90-43] as the
P-37145 connecting rod.
ID Connect- Crank pin bearing

Put a strip of plastigage (Item 1) [Figure 70-90-42] on Color ing rod
the center of the crank pin.
Large-end Class Center wall
NOTE: Never insert the plastigage into the crank pin inch dia. thickness
oil hole. Be sure not to move the crankshaft Blue 56,010 - L 1,496 - 1,501
while the connecting rod bolts are tightened. 56,020 mm mm
(2.2052 - (0.05890 -
Install the connecting rod cap and tighten the connecting 2.2055 in) 0.05909 in)
rod bolts to the specified torque, and remove the cap
without 56,00 - S 1,491 - 1,496
again.
Color 56,01 mm mm
(2.2048 - (0.05870 -
Measure the amount of the flattening with the scale, and
2.2051 in) 0.05889 in)
record the oil clearance.
If the oil clearance exceeds the allowable limit, replace Undersize crank pin bearing.
the crank pin bearing.
Undersize Bearing Marking
If the same size bearing can not be used because of the 0,2 mm Crank pin bearing 02 020 US
crank pin wear, replace it with an undersized one (0.008 in)
referring to the table.
0,4 mm Crank pin bearing 04 040 US
(0.016 in)
Crank pin Factory spec. 52,977 - 52,990 mm
O.D. (2.0857 - 2.0862 in)
Oil clearance Factory spec. 0,018 - 0,051 mm

between crank (0.00071 - 0.0020
pin and crank in)
pin bearing Allowable 0,20 mm
limit (0.0079 in)

Figure 70-90-44
P-37149
Clean the crankshaft journal and crankshaft bearing.

P-37146
Put a strip of plastigage on the center of the journal
[Figure 70-90-45].
Undersize dimensions of crankpin.
NOTE: Never insert the plastigage into the oil hole of
Undersize 0,2 mm 0,4 mm the journal.
(0.008 in) (0.016 in)
Dimension 2,8 - 3,2 mm 2,8 - 3,2 mm radius Install the main bearing case and tighten the bolts to the
A radius (0.11 - 0.12 in specified torque, and remove the cases again.
(0.11 - 0.12 in radius)
radius) Measure the amount of the flattening with the scale and
record the oil clearance.
Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm radius
B radius (0.040 - 0.059 in If the clearance exceeds the allowable limit, replace the
(0.040 - 0.059 in radius) crankshaft bearing.
radius)
Dimension 52,777 - 52,790 52,577 - 52,590 Crankshaft Factory spec. 74,977 - 74,990 mm
C mm mm Journal O.D. (2.9519 - 2.9523 in)
(2.0779 - 2.0783 (2.0700 - 2.0704
in) in) Oil clearance Factory spec. 0,018 - 0,062 mm
between (0.00071 - 0.0024 in)
The crank pin must be fine-finished to higher than (0.8- crankshaft Allowable 0,20 mm
S) journal and limit (0.0079 in)
crankshaft
Holes to be de-burred and edges rounded with relief. bearing
1,0 - 1,5 mm (0.040 - 0.059 in)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Sleeve
Crankshaft And Bearings - Servicing (Cont’d) Figure 70-90-47
Figure 70-90-46
2
1 4
P-37148
P-37269
Remove the used crankshaft sleeve (Item 1) [Figure 70-
90-47] using a special-use puller set.
Undersize dimensions of crankshaft journal [Figure 70-
90-46]. Set the sleeve guide (Item 4) to the crankshaft (Item 2)
[Figure 70-90-47].
Undersize 0,2 mm 0,4 mm
(0.008 in) (0.016 in) Heat a new sleeve to a temperature between 150 -
Dimension 2,8 - 3,2 mm 2,8 - 3,2 mm radius 200C (302 - 392°F), and fix the sleeve to the crankshaft.
A radius (0.11 - 0.12 in
(0.11 - 0.12 in radius) Press the sleeve onto the shaft using the auxiliary socket
radius) (Item 3) [Figure 70-90-47].
Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm radius
NOTE: Install the sleeve with the chamfered surface
B radius (0.040 - 0.059 in
facing outward.
(0.040 - 0.059 in radius)
radius)
Dimension 74,777 - 74,790 74,577 - 74,590
C mm mm
(2.9440 - 2.9444 (2.9361 - 2.9366
in) in)
Crankshaft pin must be fine-finished to higher than

(0.8-S). Holes to be de-burred and edges rounded with
1,0 - 1,5 mm (0.040 - 0.059 in) relief.

CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation
Figure 70-100-1
2 1
P100968
Confirm that the liquid gasket coating surface is free of

P-37231 water, dust and oil in order to maintain sealing effect.
Carefully apply the adhesive evenly (Item 1) [Figure 70-

Install the engine flywheel pin. 100-3].
Remove the crankshaft bolt (Item 1) [Figure 70-100-1]. NOTE: Apply a liquid gasket to the gearcase cover.
Remove the drive pulley (Item 2) [Figure 70-100-1]. NOTE: Assemble the adhesive-applied parts within
the manufactures specified cure time.
NOTE: Clean the crankshaft bolt and the drive pulley
sleeve surface thoroughly, apply engine oil to
Figure 70-100-4
the bolt threads, tighten the bolt securely to
specified torque.
Tightening Crankshaft 255,0 - 274,6 N•m

torque bolt (188.1 - 202.5 ft-lb)
Figure 70-100-2
1
2
P100967
Be careful not to damage the O-ring (Item 1) and water

1 pipe (Item 2) [Figure 70-100-4] when reassembling.
NOTE: Replace O-ring (Item 1) [Figure 70-100-4] when

P100972 reassembling.
Remove the gearcase cover (Item 1) [Figure 70-100-2].
NOTE: Use care when removing the gearcase cover

not to damage the water pipe (Item 2) [Figure
70-100-2].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation
Timing Gears Backlash - Checking Figure 70-100-6
Figure 70-100-5
3
2
1
P-76096
P100970
Remove the three bolts (Item 1) from the idler gear
[Figure 70-100-6].
Set a dial indicator (lever type) with its tip on the gear
tooth (Item 1) [Figure 70-100-5]. Remove the Idler gear (Item 2) [Figure 70-100-6].
Move the gear to measure the backlash, holding its Align the holes (Item 3) on the camshaft gear with the
mating gear. camshaft retainer plate bolts (Item 4) [Figure 70-100-6].
If the backlash exceeds the allowable limit, check the oil Remove the bolts (Item 4) [Figure 70-100-6].
clearance of the shafts and the gear.
Remove the camshaft from the engine block.
If the oil clearance is proper, replace the gear.
Installation:
Crank gear and Factory 0,049 - 0,193 mm
Idle gear spec. (0.0019 - 0.0076 in) Figure 70-100-7
Allowable 0,22 mm
limit (0.0087 in) 1
Idle gear and Factory 0,049 - 0,189 mm
Camshaft gear spec. (0.0019 - 0.0074 in)
Allowable 0,22 mm
limit (0.0087 in)
2
Idle gear and Factory 0,030 - 0,165 mm
Injection pump spec. (0.0012 - 0.0065 in)
gear 3
Allowable 0,22 mm
limit (0.0087 in)
4
P100969
Set the crankshaft at the top dead center of No. 1 and 4

cylinder and the camshaft key (Item 1) to the top position
and align the marks of idle gear (Item 2) and camshaft
gear (Item 3) and crank gear (Item 4) to assemble them
[Figure 70-100-7].

CAMSHAFT AND TIMING GEARS (CONT’D) Alignment
Camshaft - Servicing Figure 70-100-9
Side Clearance
Figure 70-100-8
P-37175
Support the camshaft with V block on the surface plate

3EEABAC1P102A and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-100-9].
Set a dial indicator with its tip on the camshaft [Figure Rotate the camshaft on the V blocks and get the
70-100-8]. misalignment (half of the measurement).
Measure the side clearance by moving the camshaft gear If the misalignment exceeds the allowable limit, replace
to the front and rear. the camshaft.
If the measurement exceeds the allowable limit, replace Camshaft Allowable 0,01 mm
the camshaft stopper. alignment limit (0.0004 in)
Side clearance Factory 0,070 - 0,22 mm

spec. (0.0028 - 0.0086 in)
Allowable 0,030 mm
limit (0.012 in)

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-12
Camshaft - Servicing (Cont’d)
Figure 70-100-10
P-37140
Measure the camshaft journal O.D. with an outside

P-37176 micrometer [Figure 70-100-12].

Measure the height of the camshaft lobe at its highest camshaft.
point with an outside micrometer [Figure 70-100-10].
If the measurement is less than the allowable limit, of camshaft spec. (0.0020 - 0.0035 in)
replace the camshaft. journal Allowable 0,15 mm
limit (0.0059 in)
Intake and Factory Intake 37,63 mm
exhaust spec. valve (1.481 in)
camshaft Camshaft Factory 45,934 - 45,950 mm
Exhaust 38,96 mm
lobe height journal O.D. spec. (1.8084 - 1.8091 in)
valve (1.534 in)
Camshaft Factory 46,000 - 46,025 mm
Allowable Intake 37,13 mm
journal I.D. spec. (1.8110 - 1.8120 in)
limit valve (1.462 in)
Exhaust 38,46 mm
valve (1.514 in)
Figure 70-100-11
3EEABAC1P103A
Measure the cylinder block bore I.D. for camshaft with an

inside micrometer [Figure 70-100-11].

CAMSHAFT AND TIMING GEARS (CONT’D) Side Clearance
Idler Gear And Shaft - Servicing Figure 70-100-14
Figure 70-100-13
3EEABAC1P101A
P-37189
Set a dial indicator with its tip on the idle gear [Figure 70-
100-14].
Bushing Replacing Tool
Measure the side clearance by moving the idle gear to
Application: Use to press out and press fit the bushing. the front and rear.
1. For idle gear bushing. If the measurement exceeds the allowable limit, replace
the idle gear collar.
A 196 mm (7.72 in)
B 37,5 mm (1.48 in) Side clearance Factory 0,15 - 0,30 mm

C 150 mm (5.91 in) spec. (0.0059 - 0.011 in)
D 44,95 mm dia.
Allowable 0,9 mm
(1.770 in dia.)
limit (0.04 in)
E 48,075 - 48,100 mm dia.
(1.8928 - 1.8937 in dia.)
F 20 mm dia (0.79 in dia)
a 0,0000063 mm (0.00025 in)
b 0,0000063 mm (0.00025 in)

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-17
Idler Gear And Shaft - Servicing (Cont’d)
Figure 70-100-15
P-37177
Using an idle gear bushing replacing tool, press out the

P100971 used bushing.
Clean a new idle gear bushing and idle gear bore, and
Measure the idle gear shaft O.D. with an outside
apply engine oil to them.
micrometer (Item 1) [Figure 70-100-15].
Using an idle gear bushing replacing tool, press in a new
Figure 70-100-16
bushing to the specified dimension [Figure 70-100-17].
P-37141
Measure the idle gear bushing I.D. with an inside

micrometer, and calculate the oil clearance [Figure 70-
100-16].
If the oil clearance exceeds the allowable limit, replace

the bushing.
Clearance Factory 0,050 - 0,091 mm

between idle spec. (0.0020 - 0.0035 in)
gear shaft Allowable 0,10 mm
and idle gear limit (0.0039 in)
bushing
Idle gear Factory 45,025 - 45,050 mm

bushing I.D. spec. (1.7727 - 1.7736 in)
Idle gear Factory 44,959 - 44,975 mm
shaft O.D. spec. (1.7701 - 1.7706 in)

TURBOCHARGER Testing
Description Remove the turbocharger. (See Removal And Installation

on Page 70-110-2.)
The turbocharger is located between the exhaust and
intake manifolds. It is driven by hot exhaust gases and Turn the compressor wheel gently with a finger and check
supplies air at more than atmospheric pressure to the for contact.
intake. Lubrication for the turbocharger is supplied with
pressurized oil from the main engine oil galley. The If the wheel does not turn smoothly, check the axial and
location of the turbocharger is between the engine and radial clearance.
the blower housing.
If the compressor / turbine wheel and housing is
Figure 70-110-1 damaged, replace the turbocharger assembly with a new
one.
Figure 70-110-2
1
P100134
The oil is delivered to the turbocharger through a tubeline

P-76099
(Item 1) and returns to the engine block through a
drainage tubeline (Item 2) [Figure 70-110-1].
Move the compressor / turbine wheel (up and down, right
The turbocharger internal components are not and left) (Item 1) [Figure 70-110-2].
serviceable.
If the compressor / turbine wheel contacts the housing,
replace the turbocharger assembly.
Inspect the oil tubelines for leaks.

TURBOCHARGER (CONT’D) Figure 70-110-4

1 2
WARNING
Turbochargers, operate at high speed and high 4
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196 3
NOTE: Engine removed for photo clarity. P100133
Figure 70-110-3
Loosen the intake hose clamp (Item 1) and remove the
intake hose (Item 2) [Figure 70-110-4].
1
2 Loosen the air cleaner hose clamp (Item 3) and remove
the air cleaner hose (Item 4) [Figure 70-110-4].
Installation: Tighten the hose clamp (Item 3) [Figure 70-

110-4] to 3,4 - 4,0 N•m (30 - 35 in-lb) torque.
3 Figure 70-110-5
1
P100134
Remove the bolt (Item 1) and tubeline (Item 2) [Figure

70-110-3].
Remove the bolts (Item 3) and tubeline (Item 4) [Figure

70-110-3].
1
NOTE: Always install new copper sealing washers on
the tubeline bolts. P100135
Remove the four exhaust tube bolts (Item 1) [Figure 70-

110-5].

TURBOCHARGER (CONT’D)
Figure 70-110-6
2
1
P100140
Remove the two EGR heat shield mounting bolts (Item 1)

and remove the shield (Item 2) [Figure 70-110-6].
Figure 70-110-7
1
3
2
4 1
1 P100138
Remove the eight turbocharger mounting bolts (Item 1)

[Figure 70-110-7].
Remove the turbocharger assembly (Item 2) [Figure 70-

110-7].
Remove the two bolts (Item 3) from the turbocharger

flange mount (Item 4) and remove flange [Figure 70-110-
7].
Installation: During installation replace all gaskets.

70-110-4
T770 Service Manual
FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-120-2
Figure 70-120-1
1
P-37365
P100238
NOTE: The lead chamfer on ring gear tooth must face
the starter.
NOTE: To avoid damage to the rpm sensor, remove
the rpm sensor before removing the flywheel. The ring gear (Item 1) [Figure 70-120-2] on the flywheel
is an interference fit. Heat the ring gear enough to
Remove the Flywheel rpm Sensor. (See FLYWHEEL expand it and hit it with a hammer to remove it evenly.
RPM SENSOR on Page 60-170-1.)
Clean the outer surface of the flywheel to give it a smooth
Remove the drive belt. (See Belt Replacement on Page fit.
30-60-2.)
Clean the new ring gear and heat it to a maximum
Remove the belt tension pulley assembly. (See Tensioner temperature of 220°C (428°F).
Pulley Removal And Installation on Page 30-60-3.)
Fit the ring gear over the flywheel. Make sure the gear is
Remove the bolts (Item 1) [Figure 70-120-1] from the seated properly.
flywheel.
Remove the flywheel from the engine crankshaft.
Installation: Apply engine oil to the bolt threads and

Installation: There are two alignment pins that are used

to install the flywheel in the proper position for timing
purposes.

FLYWHEEL AND HOUSING (CONT’D)
Figure 70-120-3
1
1
1
1
1
P100237
Remove the drive belt. (See Belt Replacement on Page

30-60-2.)
Remove the hydrostatic pump. (See Removal And

Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation on Page 30-60-3.)
Remove the starter. (See STARTER on Page 60-40-1.)
Remove the flywheel housing mounting bolts (Item 1)

[Figure 70-120-3].

Remove the flywheel housing from the engine.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
2
2
7
9
11
7 3
10 12
8
4
1
13
15
6
14
P-76942
The items listed below refer to Page 70-130-1 [Figure 70-130-1].
1. Thermo Valve 9. Cooled EGR Gas

2. Mechanical EGR Valve 10. To The Intake Manifold
3. Reed Valve 11. Fresh Air
4. Intake Manifold 12. Cooled EGR Gas Merges With Fresh Air
5. Exhaust Manifold 13. Exhaust
6. EGR Cooler 14. Coolant Inlet
7. Boost Pressure 15. Coolant Outlet
8. Coolant Temperature

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Cold Engine Coolant Temperature Test
(CONT'D)
Start the engine and run at low idle.
Testing
Start Service Analyzer and select [Monitor].
There are two tests for checking the EGR system. Both
tests will need to be performed and the coolant must be Select [Engine Temperature].
monitored through the Service Analyzer.
The Cold Engine Coolant Temperature Test will need to

be performed with the engine coolant below 55°C
WARNING
(131°F). The Hot Engine Coolant Temperature Test will
need to be performed with the engine coolant above AVOID BURNS
70°C (158°F). Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing.

WARNING W-2716-0208
AVOID INJURY OR DEATH NOTE: Verify the engine temperature is below 55°C
When the engine is running during service, the (131°F). If the engine temperature is above
steering levers or joysticks must be in neutral and 55°C (131°F), let the engine cool down and
the parking brake engaged. restart the Cold Engine Coolant temperature
W-2717-0208 Test.
NOTE: Monitor the engine coolant temperature using

the Service Analyzer.
WARNING
Figure 70-130-2
MACHINE FALLING OR MOVING CAN CAUSE

1
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208

1.)
Open the rear door.
Connect the Service PC. (See SERVICE PC (LAPTOP

COMPUTER) on Page 60-150-1.) P-76949
Measure the surface temperature of the EGR pipe (Item

WARNING 1) [Figure 70-130-1] with an Infrared Thermometer.
AVOID INJURY OR DEATH If the engine coolant temperature is below 55°C (131°F)
When an engine is running in an enclosed area, fresh and the surface temperature of the EGR pipe is 50°C
air must be added to avoid concentration of exhaust (122°F) or below, the EGR system is OK, continue with
fumes. If the engine is stationary, vent the exhaust the Hot Engine Coolant temperature Test.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. If the surface temperature of the EGR pipe reads 100°C
W-2050-0807 (212°F) or above continue this Cold Engine Coolant
Temperature Test.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Hot Engine Coolant Temperature Test
(CONT'D)
Verify the engine temperature is above 70°C (158°F), if
Testing (Cont’d) the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
Figure 70-130-3 continue with the Hot Engine Coolant Temperature Test.
Figure 70-130-5
P-76956
P-76949
Disconnect the boost hose (Item 1) [Figure 70-130-3]
from the intake.
Figure 70-130-4 1) [Figure 70-130-5] with an Infrared Thermometer.
With the engine coolant temperature above 70°C (158°F)

1 and the surface temperature of the EGR pipe 100°C

(212°F) or above, the EGR system is OK.
If the surface temperature of the EGR pipe is 50°C

(122°F) or below continue this Hot Engine Coolant
Temperature Test.
Figure 70-130-6
P-76949
1
1) [Figure 70-130-4] with an Infrared Thermometer.
If the surface temperature of the EGR pipe declines, the

thermo valve has failed.
1
If the surface temperature of the EGR pipe stays above
100°C (212°F), the EGR valve has failed. P-76956
Disconnect the two hoses (Item 1) [Figure 70-130-6].

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(CONT'D)
Testing (Cont’d)
Figure 70-130-7
P-76957
Connect a hose (Item 1) [Figure 70-130-7] directly

between the intake manifold and the EGR valve.
Figure 70-130-8
1
P-76949

1) [Figure 70-130-8] with an Infrared Thermometer.
If the surface temperature of the EGR pipe increases, the

thermo valve has failed.
If the surface temperature of the EGR pipe is 50°C

(122°F) or below, the EGR valve has failed.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-130-10
(CONT'D)
WARNING
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing. P-76952

W-2716-0208
Allow the engine to cool before working on the EGR Remove the EGR valve (Item 1) [Figure 70-130-10].
system.
Installation: When reassembling replace with new
Figure 70-130-9 gaskets.
Figure 70-130-11
1 2
3 1
4 2
5 3
P-76951A
P-76954
Remove the EGR pipe (Item 2) from the EGR valve (Item
1) [Figure 70-130-9].
Disconnect the hoses (Item 1) and (Item 2) from the
Remove the EGR cooler (Item 4), the coolant inlet pipe thermo valve (Item 3) [Figure 70-130-11].
(Item 6) and the coolant outlet pipe (Item 3) [Figure 70-
130-9]. Remove the thermo valve (Item 3) [Figure 70-130-11].
Remove the EGR flange (Item 5) [Figure 70-130-9]. Installation: Tighten the thermo valve to 30 - 39 N•m (22
- 28 ft-lb)
Installation: When reassembling replace with new
gaskets. NOTE: If the thermo valve is dropped it must be
replaced with a new one.

70-130-6
T770 Service Manual
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Compressor Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-7
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9

HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-17
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schrader® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1


AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R-134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
b-16691

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
1
Figure 80-10-1
2
P-89545
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P100384 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to

lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3688,7 kPa (36,9
P-85824 bar) (535 psi).
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
2
Figure 80-10-5 4
3
1
P101946
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P100889 10-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat and A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-7] is used to push air through the heater and
evaporator coils and into the cab.
P100878
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

Components (Cont'd)
Figure 80-10-8
1
1
2
3
4 P-89545
Pressure Switch: The pressure switch (Item 1) [Figure

P-92638 80-10-10] will disengage the compressor clutch at high
pressure readings over 2648 kPa (26,4 bar) (384 psi) on
the high side, or at very low pressure of 193 kPa (1,9 bar)
Control Panel: The panel (Item 1) [Figure 80-10-8] has (28 psi) or less on the high side, which indicates loss of
three separate components. refrigerant.
Fan Switch: This is a four position rotary switch (Item 2)

[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the key switch.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-9
P101968
Heater Valve: The heater valve (Item 1) [Figure 80-10-9]

is used to control the amount of engine coolant that flows
to the heater coil.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment WARNING

Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -6°C (21.6°F)
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-12
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
P16399
equipment, knowledge, and experience to service
refrigeration equipment.
In servicing A/C and heater systems you will be exposed W-2373-0611
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Recirculation Filter (Earlier Models)
Filters Figure 80-20-2
Fresh Air Filters
Figure 80-20-1 1
3
2
P-90490A
2
1
The recirculation filter is located behind the operator’s
seat inside the operator cab. Flip the clamps (Item 1)
holding the filter up and remove the filter (Item 2) [Figure
P-90489A P-90492A 80-20-2].
Shake the filter or use a vacuum to clean. This can be

The fresh air filters are located behind the side windows done several times before replacement is required.
outside the operator cab. (Right side shown) Remove the
retaining screw (Item 1) and filter cover (Item 2) [Figure Install the filter into the opening and flip the clamps down
80-20-1]. to hold the filter in place.
Shake the filter (Item 3) [Figure 80-20-1] or use low Recirculation Filter (Later Models)
pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter, Figure 80-20-3
filter cover and retaining screw.
1
P100755
The recirculation filter is located behind the operator’s

seat inside the operator cab. The filter cover is held in
place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-3] to remove.
Rinse the filter elements with water or use a vacuum to

clean. Do not use solvents.
Line up the clips on the filter cover with the slots provided
and push the cover into place.

REGULAR MAINTENANCE (CONT’D) Move the air conditioning compressor toward the engine
as far as it will go and remove the belt from the pulleys.
Compressor Drive Belt Adjustment
Inspect the pulleys for wear.
The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt Install new belt.
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer Figure 80-20-5
for replacement parts.
Compressor Drive Belt Replacement
Stop the engine and open the rear door. (See REAR
Figure 80-20-4
1
P100271
Insert a breaker bar (Item 1) [Figure 80-20-5] into the

1 square opening provided in the air conditioning
compressor bracket as shown. Move the breaker bar
down until the bottom air conditioning compressor
mounting bolt (Item 1) [Figure 80-20-4] can be installed.
P100070
Tighten the mounting nut and bolts (Items 1 and 2)
[Figure 80-20-4].
Condenser
The condenser should be cleaned with the oil cooler and

the radiator.
2
Air Conditioning Lubrication
Run the air conditioning for about five minutes every

week to lubricate the internal components.
P100071
NOTE: The engine is shown removed for visual

clarity.
Remove the bottom air conditioning compressor

mounting bolt (Item 1) [Figure 80-20-4].
Loosen the top air conditioning compressor mounting nut

and bolt (Item 2) [Figure 80-20-4].

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:

Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

REGULAR MAINTENANCE (CONT’D) Later Models
Evaporator / Heater Coil Raise the operator cab. (See Raising on Page 10-30-2.)
Earlier Models Figure 80-20-8
Figure 80-20-6
P100756
Unhook cover latches (Item 1) [Figure 80-20-8] and

P-90419A remove the cover.
Figure 80-20-9
Remove cover screws (Item 1) [Figure 80-20-6] and
remove the cover.
Figure 80-20-7 1
P100757
2
Use low pressure air or water to remove debris from the

P-90420A heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-9].
Use low pressure air or water to remove debris from the Install the cover and lower the operator cab. (See
heater coil (Item 1) and evaporator (Item 2) [Figure 80- Lowering on Page 10-30-3.)
20-7].
Install the cover and lower the operator cab. (See

Lowering on Page 10-30-3.)

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch malfunc- Check power into and out of the fan switch. Replace Fan Switch.
tion.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly con- Repair or adjust.
nected and seals are not damaged.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor mal- The compressor is locked up and the belt slips. Replace compressor.
function.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness compo- Test the conductance of the pressure switch, ther- Check operation / thermostat
nents. mostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 rpm are:
High pressure side pressure: 1448 - 1827 kPa (14,5 - 18,3 bar) (210 - 265 psi)
Low pressure side pressure: 103 - 229 kPa (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equal- Replace compressor.
sor. ize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostat’s tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
80-30-4
P100890
T770 Service Manual

Troubleshooting Tree (Cont’d)

80-30-5
p100892
T770 Service Manual

Troubleshooting Tree (Cont’d)
80-30-6
P-90413
T770 Service Manual

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP TEMP TEMP TEMP
kPa BAR PSIG kPa BAR PSIG
°C °F °C °F
-8,8 16 108,2 1,08 15.69 33,9 93 759,8 7,60 110.20
-7,8 18 117,5 1,17 17.04 34,4 94 773 7,73 112.10
-6,7 20 127,1 1,27 18.43 35 95 786,7 7,87 114.10
-5,6 22 137 1,37 19.87 37,8 100 857,1 8,57 124.30
-4,4 24 147,2 1,47 21.35 38,9 102 886 8,86 128.50
-3,3 26 157,8 1,58 22.88 40 104 916,3 9,16 132.90
-2,2 28 168,7 1,69 24.47 41,1 106 946,7 9,47 137.30
-1,1 30 180 1,80 26.10 42,2 108 978,4 9,78 141.90
0 32 191,6 1,92 27.79 43,3 110 1010.1 10,10 146.50
1,1 34 203,5 2,04 29.52 44,4 112 1043,2 10,43 151.30
2,2 36 216 2,16 31.32 45,6 114 1076,3 10,76 156.10
3,3 38 228,7 2,29 33.17 46,7 116 1110,7 11,11 161.10
4,4 40 241,8 2,42 35.07 47,8 118 1145,2 11,45 166.10
5,6 42 255,3 2,55 37.03 48,9 120 1181,1 11,81 171.30
6,7 44 269,3 2,69 39.05 50 122 1217,6 12,18 176.60
7,2 45 276,4 2,76 40.09 51,1 124 1254,8 12,55 182.00
10 50 313,6 3,14 45.48 52,2 126 1292,8 12,93 187.50
12,8 55 353,5 3,54 51.27 53,3 128 1331,4 13,31 193.10
15,6 60 396,3 3,96 57.47 54,4 130 1371,4 13,71 198.90

18,3 65 442 4,42 64.10 57,2 135 1473,4 14,73 213.70
21,1 70 490,8 4,91 71.19 60 140 1581,7 15,82 229.40
23,9 75 543 5,43 78.75 62,8 145 1694,7 16,95 245.80
26,7 80 598,5 5,99 86.80 65,6 150 1813,3 18,13 263.00
29,4 85 657,8 6,58 95.40 68,3 155 1938,1 19,38 281.10
32,2 90 719,8 7,20 104.40 71,1 160 2069,1 20,69 300.10
32,8 91 733 7,33 106.30 73,9 165 2207,1 22,07 320.10
33,3 92 746,1 7,46 108.20 76,7 170 2349,7 23,50 340.80

Temperature / Pressure Chart (Cont’d)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 4.5 - 5,5°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature = 90°F

90°F
+40°F
130°F condenser temperature = 200 psig
Conditions and pressures will vary from system to system.

TROUBLESHOOTING (CONT'D) Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
Poor A/C Performance 60-1.)
Start the loader, lock the park brake, and engage the A/C Check the A/C evaporator coil for dirt or mud and clean if
system with the blower fan on High. Run the loader at full necessary. (See Removal And Installation on Page 80-
RPM for approximately 15 minutes, with the loader cab 110-1.)
door closed.
Check the engine coolant to see if it is bypassing the
Figure 80-30-1 heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-17.)
P-90356
Figure 80-30-2
N-22411
Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 7,2 - 11,7°C

(45 - 53°F) depending on the amount of humidity in the
air and ambient temperature.
If louver temperature is too high. (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower for proper operation, or noise, and

replace if necessary. (See Removal And Installation on
Page 80-130-1.)

HVAC Repair And Leaks
Figure 80-30-3
P-90361
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT’D) Figure 80-30-6
Electrical System
Check to see if the compressor clutch is engaging.

1
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN OR press the
RUN Button, without starting the loader.
Figure 80-30-4
P-90357
Locate the loader harness and the compressor clutch

wire (Item 1) [Figure 80-30-6].
2
1 Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.
Figure 80-30-7
P-92638
Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON

position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
P-90358
1
With a multi meter, test the resistance to the compressor
clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor

clutch.
P100416
If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.
Open the rear door (tailgate).

Electrical System (Cont’d)
Figure 80-30-8
P-90360
1
Using a multi meter test the loader wiring harness (Item

P-90358 1) [Figure 80-30-10] for voltage.
The voltage should be battery voltage.

With a multi meter, test the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, inspect the
harness for broken wires.
The voltage reading should be battery voltage.
Figure 80-30-11
If there is no power at the clutch, inspect the wiring
If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.
Figure 80-30-9
1
P-90360
If there is voltage at the harness, test the resistance at

2
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, inspect for low refrigerant

1 P-90361 level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

Figure 80-30-12
1 P-90363
Disconnect the blower wiring connector (Item 1) [Figure

P100951 80-30-14] from the loader wiring harness.
Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
1
P-90362
2
Test the loader harness (Item 1) [Figure 80-30-15] for
1
voltage. The voltage should be battery voltage.
P-90362
If there is no voltage at the wiring harness, inspect the
Test the loader harness (Item 1) [Figure 80-30-13] for
voltage. The voltage should be battery voltage. If there is voltage at the wiring harness, test the
resistance to the blower at the blower wiring connector
(Item 2) [Figure 80-30-15].
If there is voltage at the wiring harness, test the If there is no resistance value replace the blower. (See
thermostat (Item 2) [Figure 80-30-13] for resistance. Removal And Installation on Page 80-130-1.)
The resistance value of the thermostat should be 10 ohm If there is a resistance value test the climate controls at
at 20°C (68°F). the control panel inside the loader cab.
If there is no resistance value, replace the thermostat.
If there is a resistance value, test the blower.

Figure 80-30-16 C
H
B
1 M
N-22288
If there is voltage at the wiring harness, test the blower

P-90364 switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame
[Figure 80-30-18].
Figure 80-30-17
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the

blower switch.
If the above resistance tests are good, test the A/C

P-90365 switch.
Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.
Test the loader harness for voltage. The voltage should

be battery voltage.


TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Electrical System (Cont’d) If a resistance value is found, test the potentiometer.
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does

not work, test the potentiometer.
1
Figure 80-30-21
1
P-90367
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.
Test the harness for voltage. The voltage should be

P-90366
battery voltage.
If there is no voltage at the wiring harness, inspect the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Figure 80-30-20 Test the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be battery voltage.

1
2
N-22289
If there is voltage at the wiring harness, test the A/C

switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no

resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-20].

Electrical System (Cont'd)
Figure 80-30-22
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0K
ohm.
If there is voltage at the wiring harness, test the Test the resistance between the wire terminal C and wire
potentiometer [Figure 80-30-22] for resistance. terminal B frame [Figure 80-30-24] should be around
10K ohm.
The resistance should be 10K ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
P-90368
To test the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) The tools listed will be needed to do the following
procedure:
Figure 80-30-25

Figure 80-30-27
P-90369
To test the resistance of the white wire, turn the 2 3

1
potentiometer control (Item 1) [Figure 80-30-25]
clockwise to the full Heater position.
P-90364A
Figure 80-30-26
Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1, then turn the
temperature control (Item 3) [Figure 80-30-27]

counterclockwise to the full A/C position, with the loader
key switch OFF.
A C Raise the operator cab. (See Raising on Page 10-30-2.)

B
7217666 on Page 10-61-1.)
Start the loader and run at high idle, for ten minutes.
N-22290
Test the resistance between the wire terminal A and wire

terminal B frame [Figure 80-30-26] should be around
10K ohm.

TROUBLESHOOTING (CONT’D) Heater Valve Not Opening Or Closing
Engine Coolant Bypassing The Heater Valve (Cont’d) Raise the lift arms and install an approved lift arm
Figure 80-30-28
Figure 80-30-29
2 3
1
P-90371
P-90364A
Inspect the heater hose (Item 1) [Figure 80-30-28] for

temperature. Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1 and turn the
If the hose is hot, the heater valve is leaking by, and
temperature control (Item 3) [Figure 80-30-29] to the
needs to be replaced.
High A/C position, with the loader key switch OFF.
7217666 on Page 10-61-1.)

Heater Valve Not Opening Or Closing (Cont'd)
Figure 80-30-30
P100896
NOTE: The HVAC assembly is removed for photo

clarity.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate. Place

a mark on the loader shaft.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-30-29]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-11.)
Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)

80-30-20
T770 Service Manual
SYSTEM CHARGING AND RECLAMATION Follow the steps displayed on the refrigerant identifier
screen.
Refrigerant Identification
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
WARNING and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.

If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
gas.
W-2371-0611
and properly and safely disposed of.
Figure 80-40-1
1
N-23024
NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

Connect the Refrigerant Identifier to the low pressure

hose.
Connect the Refrigerant Identifier to its power source.

SYSTEM CHARGING AND RECLAMATION (CONT'D) IMPORTANT: Only trained technicians should
perform the reclaiming and recharging.
Reclamation And Charging With Recovery / Charging
Unit

WARNING
Raise the operator cab. (See Raising on Page 10-30-2.) HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
Figure 80-40-2 blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
1
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
2 refrigeration equipment.
W-2373-0611
Use an approved recovery / charging unit [Figure 80-40-

P100895 3] to evacuate the system.
Locate the low pressure port (Item 1), and high pressure
port (Item 2) [Figure 80-40-2].
WARNING
gas.
W-2371-0611
Figure 80-40-3
N-22291

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Unit (Cont'd)
Figure 80-40-4
N-22292
Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P100385
For the correct quantity of refrigerant (See Capacities on
Page SPEC 10-5).
Figure 80-40-5
Figure 80-40-7
1
P100950
N-22381
Connect the reclaimer to the loader A/C charge ports

[Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 1) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 2) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.

80-40-4
T770 Service Manual
COMPRESSOR Remove the compressor mount bolt (Item 1) and the belt
(Item 2) [Figure 80-50-2].
Installation: Tighten the compressor mount bolt to 46
NOTE: If compressor is being removed for engine
removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor.

WARNING
Raise the operator cab. (See Raising on Page 10-30-2.) refrigerant can cause severe injuries to eyes. In
Evacuate the A/C system. (See Reclamation And gas.
Charging With Recovery / Charging Unit on Page 80-40- W-2371-0611
2.)
NOTE: Engine removed for photo clarity.
Open the rear door.
Figure 80-50-3
Figure 80-50-1
3
1
P-89543
P-90357
Remove the compressor hoses (Item 1) [Figure 80-50-3]

Disconnect the loader harness (Item 1) [Figure 80-50-1]
from the compressor.
from the compressor clutch wire.
Installation: Tighten the compressor hose (Item 2) to 30
Figure 80-50-2
Installation: Tighten the compressor hose (Item 3) to 45

Cap and plug the compressor hoses and the fittings with
1 with the proper A/C caps and plugs.
2
P100070

COMPRESSOR (CONT'D)
Figure 80-50-4
P101247
Remove the compressor mounting bolt and nut (Item 1)

[Figure 80-50-4].
Remove the compressor from the loader.

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
Oil RECLAMATION on Page 80-40-1.)
Figure 80-50-5 Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200

rpm.
Remove the compressor from the loader. (See Removal

1 And Installation on Page 80-50-1.)
P100384
The compressor (Item 1) [Figure 80-50-5] is factory filled

with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check

or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
• When ever the evaporator, condenser or receiver-

drier is replaced.
• Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 100 oil should be used, and never

mix R-12 and R-134a Oils.
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check
Figure 80-50-6
1
P100384
NOTE: After draining the oil through the drain hole

P100386 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.
Measure the drained oil in a measuring cylinder.
Inspect the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor
oil, replace the complete compressor
assembly.
Figure 80-50-9
P-16534A
Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole 1
[Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.
P100386
Add new compressor oil through the suction side

Installation: Add 150 - 170 cc's of PAG 100 oil.
NOTE: The suction port on the compressor is marked

with an SUC and is the larger port on the
compressor.

CONDENSER Figure 80-60-2

Remove the rear grille. (See Removing on Page 50-60- 1

1.)
Remove the refrigerant from the A/C system. (See

Unit on Page 80-40-2.)
P-89546
Figure 80-60-1

routes from the condenser to the receiver / dryer.
Installation: Tighten the hose (Item 1) [Figure 80-60-2]

1 to 30 N•m (22 ft-lb) torque.
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-60-3
P-85824
Remove the two brackets (Item 1) [Figure 80-60-1]. 1
WARNING
P-89548
gas.
W-2371-0611
routes from the condenser to the compressor.
Installation: Tighten the hose (Item 1) [Figure 80-60-3]

Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Remove the condenser.

80-60-2
T770 Service Manual
RECEIVER / DRIER Installation: Tighten the two A/C hoses (Item 1) [Figure
80-70-1] to 30 N•m (22 ft-lb) torque.
Receiver / Drier Removal And Installation
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
WARNING Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
NOTE: When replacing a receiver / drier in an A/C
system 30 cc of PAG 100 oil must be added to
the system when recharging.
W-2059-0598
Figure 80-70-2

1.)

WARNING
refrigerant can cause severe injuries to eyes. In P-90493

gas.
Note the flow direction on the receiver / drier (Item 1)
W-2371-0611
[Figure 80-70-2] for proper installation.
Figure 80-70-1
P-90488
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.

RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-5
Figure 80-70-3
1
N-22205
P-92665
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver /
drier (Item 2) [Figure 80-70-3]. Figure 80-70-6
Figure 80-70-4
1
N-22206
P-89521
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
Remove the two mount bolts (Item 1) [Figure 80-70-4] 3689 kPa (36,9 bar) (535 psi).
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.
The pressure relief valve is a secondary protection

device in the A/C system, with the pressure switch
shutting down the system at 2648 kPa (26,5 bar) (384
psi).
NOTE: If a pressure relief valve is found open, test

the A/C system for problems. Replace the
complete receiver / drier unit.

RECEIVER / DRIER (CONT’D) Remove the pressure switch from the loader.
Pressure Switch Removal And Installation
Figure 80-70-7
P-90361
Disconnect the loader wire harness (Item 1) [Figure 80-

70-7] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0611
Figure 80-70-8
P-90488
Remove the pressure switch (Item 1) [Figure 80-70-8]

from the A/C high pressure hose.

RECEIVER / DRIER (CONT’D)
Schrader® Valve Removal And Installation
Figure 80-70-9
N-22166
The Schrader® valve (Item 1) [Figure 80-70-9] is located

in the A/C high pressure hose and is located under the
pressure switch.

Remove the pressure switch.
With a Schrader® valve removal tool, remove the valve

from the hose.

EVAPORATOR / HEATER UNIT Figure 80-80-3


2 1 2
Evacuate the A/C system. (See Reclamation And
2.)
Figure 80-80-1
P100900
1
NOTE: Support the evaporator / heater unit before
removing the mounting hardware.

1
Figure 80-80-4
1
3
P100879 3
Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1].
1
2
Figure 80-80-2
1 P100899
1
Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Cap and plug the hoses and the expansion valve fittings
Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)

P100879 torque.

NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the Remove the two nuts (Item 3) [Figure 80-80-4].
system.
Remove evaporator / heater unit from the loader.
Remove the two hoses (Item 1) [Figure 80-80-2].

80-80-2
T770 Service Manual
THERMOSTAT The EDT has the following protection built in:
1. Over temperature
Description
2. Over current from clutch output
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil 3. Voltage (Above and below operational limits or
temperature and cycles the compressor clutch to reverse voltage)
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before start 5. Temperature sensor open and short detection
up to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 2°C (35.6°F). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor open or
temperature is below -2°C (28.4°F), the EDT will turn off short detection
the clutch and status LED.
Clutch circuit At A/C start up 2x per second
open, short or
Figure 80-90-1
over current
Compressor Continuous 3x per second
clutch short to
ground
1
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

THERMOSTAT (CONT’D) Figure 80-90-4

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P100893
Figure 80-90-2
Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-4].
2
P100889
Undo the four latches (Item 1) and remove the cover

(Item 2) [Figure 80-90-2].
Figure 80-90-3
P100894
Remove the thermostat probe (Item 1) [Figure 80-90-3]

from the A/C evaporator coil.

EXPANSION VALVE Figure 80-100-2


1
2.)
WARNING P100756
In the event of a leak, wear safety goggles. Escaping Unhook the four latches (Item 1) and remove the cover
refrigerant can cause severe injuries to eyes. In (Item 2) [Figure 80-100-2].
gas. Figure 80-100-3
W-2371-0611
Figure 80-100-1
1
1
1
P101948
P103082 NOTE: The evaporator / heater unit is removed for

photo clarity.
Remove the two A/C hoses (Item 1) [Figure 80-100-1] Remove the two evaporator fittings (Item 1) [Figure 80-
from the expansion valve. 100-3] from the expansion valve.
Installation: Tighten the two A/C hose fittings to 30 N•m Installation: Tighten the two evaporator fittings to 30
(22 ft-lb) torque. N•m (22 ft-lb) torque.
Cap and plug the hoses and the expansion valve fittings Remove the two mount bolts (Item 2) [Figure 80-100-3].
Remove the expansion valve from the loader.
Cap and plug the evaporator tubelines (Item 1) [Figure

80-100-3] and the expansion valve fittings with the proper
A/C caps and plugs.

EXPANSION VALVE (CONT'D)
Figure 80-100-4
N-22085
The expansion valve [Figure 80-100-4] is replaced as a

complete unit.

EVAPORATOR COIL Figure 80-110-2


2.)
1
WARNING P101948
In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
gas. Disconnect the two evaporator fittings (Item 1) [Figure
W-2371-0611
80-110-2] from the expansion valve.
Figure 80-110-1 Installation: Tighten the two evaporator fittings to 29,8

2
Cap and plug the evaporator tubelines (Item 1) [Figure
80-110-2] and the expansion valve fittings with the proper
A/C caps and plugs.
Figure 80-110-3
2 2
3
P100756
Unhook the four latches (Item 1) and remove the cover

(Item 2) [Figure 80-110-1]. 1
P100757
Remove the thermostat probe (Item 1) [Figure 80-110-2]

from the evaporator coil.
Remove the two retaining clips (Item 2) [Figure 80-110-

3] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil (Item 3) [Figure 80-110-2].

EVAPORATOR COIL (CONT'D)
Figure 80-110-4
P-90424
Inspect the evaporator coil [Figure 80-110-4] for leaks,

Clean with low pressure water or air.

HEATER COIL Figure 80-120-3
Remove the evaporator coil (If necessary). (See Removal

1
Remove the heater valve. (See Removal And Installation
on Page 80-140-1.)
NOTE: The evaporator / heater unit is removed for

photo clarity.
Figure 80-120-1
P101947
2
Remove the retainer clips (Item 1) [Figure 80-120-3]

from both sides.
1
Figure 80-120-4
P100756
1
Unhook the four latches (Item 1) and remove the cover
(Item 2) [Figure 80-120-1].
Figure 80-120-2
P100946
Remove the two screws (Item 1) [Figure 80-120-4].
P100944

HEATER COIL (CONT'D)
Figure 80-120-5
P100947
Remove the heater coil from the unit.
Figure 80-120-6
P100945
The heater coil [Figure 80-120-6] can be cleaned with

low pressure air or water.

BLOWER FAN Disassembly And Assembly
Remove the evaporator / heater unit. (See Removal And

Remove the heater coil. (See Removal And Installation

on Page 80-120-1.)
Figure 80-130-1
1 1
P-90458
1
1
Remove the eight screws (Item 1) [Figure 80-130-2]
2 from the blower wheel cover.
Figure 80-130-3
P100888
1
Remove the blower fan (Item 2) [Figure 80-130-1] from

the evaporator / heater unit.
2
P-90465
Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].
Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

BLOWER FAN (CONT'D) Figure 80-130-6
Figure 80-130-4
P-90463
1 Inspect the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
NOTE: Mark the wires for proper installation.
Remove the two wires (Item 1) [Figure 80-130-4] from

the blower motor.
Figure 80-130-5
1 1
P-90461
1
Remove the blower wheel outside clamp (Item 1) [Figure
80-130-7] from the blower wheel.
P100887
Remove the two screws (Item 1) [Figure 80-130-5] from

the resistor.
Remove the blower motor from the blower housing.

BLOWER FAN (CONT'D)
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-
8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.

80-130-4
T770 Service Manual
HEATER VALVE Figure 80-140-2

2
1
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly.
Remove any tie straps that hold the heater hoses.
NOTE: The evaporator / heater unit is shown

removed for photo clarity. P100948
Figure 80-140-1
with plugs to prevent coolant loss from the
system.
1
Remove the heater hose clamp (Item 1) [Figure 80-140-
2].
Remove the heater hose from the heater valve.

2].
Remove the heater hose from the heater coil.
P101961
Disconnect the loader wiring harness (Item 1) [Figure

80-140-1] from the heater valve.

HEATER VALVE (CONT’D)
Figure 80-140-3
1
2
P100949

with plugs to prevent coolant loss from the
system.

2].
Remove the heater valve (Item 3) [Figure 80-140-2] from

the evaporator / heater unit.

SPECIFICATIONS
(T770) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
SPEC-01 T770 Service Manual

SPEC-02
T770 Service Manual
(T770) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard track and 80 in. Heavy Duty Construction and Industrial
bucket and may vary with other bucket types.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
2235 mm
(88 in)
1981 mm
(78 in)
2032 mm
1532 mm (80 in)
(60.3 in)
98°
4232 mm
(166.6 in)
42°
853 mm
(33.6 in)
3353 mm
(132 in)
2065 mm
(81.3 in)
2649 mm
(104.3 in)
31.3°
31.5°
1618 mm
206 mm
(63.7 in)
(8.1 in)
2903 mm
(114.3 in)
3597 mm
(141.6 in)
NA5372
Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.
SPEC-10-1 T770 Service Manual

(T770) LOADER SPECIFICATIONS (CONT’D)
Performance
STEEL TRACK ROLLER SUSPENSION SOLID-MOUNTED

UNDERCARRIAGE UNDERCARRIAGE
Rated Operating Capacity 1361 kg (3000 lb) 1406 kg (3100 lb) 1576 kg (3475 lb)
with 200 Pound Frame
--- 1451 kg (3200 lb) 1622 kg (3575 lb)
Mounted Counterweight Kit
--- 1486 kg (3275 lb) 1656 kg (3650 lb)
--- 1520 kg (3350 lb) 1690 kg (3725 lb)
Tipping Load 3888 kg (8571 lb) 4017 kg (8857 lb) 4503 kg (9929 lb)
Operating Weight 5004 kg (11032 lb) 4938 kg (10887 lb) 4683 kg (10327 lb)
Breakout Force - Lift 2719 kg (5995 lb) 2729 kg (6017 lb) 2566 kg (5659 lb)
Breakout Force - Tilt 2741 kg (6045 lb) 2972 kg (6552 lb) 2878 kg (6346 lb)
Push Force 3229 kg (7118 lb) 3167 kg (6982 lb) 3046 kg (6715 lb)
Travel Speed
- Single Speed Loader 0 - 10,6 km/h (0 - 6.6 mph) 0 - 10,6 km/h (0 - 6.6 mph) 0 - 10,6 km/h (0 - 6.6 mph)
- Two-Speed Loader (Option)
Low Range --- 0 - 9,8 km/h (0 - 6.1 mph) 0 - 9,8 km/h (0 - 6.1 mph)
High Range --- 0 - 17,2 km/h (0 - 10.7 mph) 0 - 17,2 km/h (0 - 10.7 mph)

Engine
Make / Model Kubota / V3800-DI-TE3 Tier 3

Fuel / Cooling Diesel / Liquid
Horsepower
- ISO 9249 EEC / SAE J1349 Net 65,6 kW (88.0 hp) @ 2400 rpm
- ISO 14396 Gross 67,6 kW (90.6 hp) @ 2400 rpm
- SAE J1995 Gross 68,6 kW (92.0 hp) @ 2400 rpm
Torque
- ISO 9249 EEC / SAE J1349 Net 310,3 N•m (228.8 ft-lb) @ 1600 rpm
- SAE J1995 Gross 315,0 N•m (232.3 ft-lb) @ 1600 rpm
Low Idle rpm 1250 - 1400
High Idle rpm 2525 - 2650
Number of Cylinders 4
Displacement 3769 cm3 (230 in3)
Bore / Stroke 100 mm / 120 mm (3.94 in / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Open Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Air Intake Heater - Automatically activated as needed in RUN position.
Drive System
Main Drive Fully hydrostatic, rubber track drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic drive motors
Tracks (Tension) Grease cylinder and spring

Controls
Vehicle Steering Direction and speed controlled by two hand operated steering levers or optional
joystick(s)
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System (ACS)
or optional Selectable Joystick Controls (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control, additional foot operated speed control pedal with SJC
option; key-type start switch or optional Keyless Start Panel or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Air intake heater automatically activated as needed in RUN position
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel
Hydraulic System
Pump Type Engine driven, gear type

Pump Capacity - Standard 87,1 L/min (23.0 U.S. gpm)
Pump Capacity - High-Flow Option 138,2 L/min (36.5 U.S. gpm)
System Relief at Quick Couplers 23,8 - 24,5 MPa (238 - 245 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 76,2 mm (3.00 in)
Tilt Cylinder (2) 76,2 mm (3.00 in)
Rod Diameter: Lift Cylinder (2) 44,5 mm (1.75 in)
Stroke: Lift Cylinder (2) 664,0 mm (26.14 in)
Control Valve - Standard 3-Spool, open center, manually operated with spring detent for lift float.
Electrically controlled auxiliary spool
Control Valve - ACS and SJC 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 4.03 Seconds
Lower Lift Arms 2.86 Seconds
Bucket Dump 2.34 Seconds
Bucket Rollback 2.05 Seconds

Electrical System
Alternator Belt driven, 90 amperes, open frame

Battery 12 volt, 950 cold cranking amperes @ -18°C (0°F),
180 Minute reserve capacity @ 25 amperes
Starter 12 volt, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, General Warning.
Indicators:
BICS™ Functions, Two-Speed, 3-Point Shoulder Belt, Turn Signals, Engine
Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown,
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;
System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.
Capacities
Fuel 103,1 L (27.2 U.S. gal)

Engine Oil with Filter Change 11,4 L (12.0 qt)
Engine Cooling System
with Heater 15,1 L (4.0 U.S. gal)
without Heater 14,4 L (3.8 U.S. gal)
Hydraulic / Hydrostatic Reservoir 9,8 L (2.6 U.S. gal)
Hydraulic / Hydrostatic System 36,0 L (9.5 U.S. gal)
Hydrostatic Drive Motor (Each) 180 mL (6.1 U.S. fl oz)
Air Conditioning Refrigerant (R-134a) 0,91 kg (2.0 lb)

Tracks
Standard Rubber 450 mm (17.7 in) Rubber, C-Pattern

Optional Rubber Narrow 320 mm (12.6 in) Rubber, C-Pattern
Steel 340 mm (13.38 in) Steel, Triple Grouser
Ground Pressure
STEEL TRACK ROLLER SUSPENSION SOLID-MOUNTED

UNDERCARRIAGE UNDERCARRIAGE
Rubber track - 450 mm (17.7 in) 0,030 MPa 0,029 MPa
---
(0,30 bar) (4.4 psi) (0,29 bar) (4.2 psi)
Rubber track - 320 mm (12.6 in) 0,043 MPa 0,041 MPa
---
(0,43 bar) (6.2 psi) (0,41 bar) (5.9 psi)
Steel track 0,043 MPa
--- ---
(0,43 bar) (6.2 psi)

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
9,0 - 10,2 12,4 - 13,6
0.250
N•m (80 - 90) (110 - 120)
(in-lb) 20,3 - 22,6 24,2 - 27,1
0.3125
(180 - 200) (215 - 240)
34 - 38 47 - 54
0.375
(25 - 28) (35 - 40)
54 - 61 81 - 88
0.4375
(40 - 45) (60 - 65)
88 - 95 122 - 136
0.500
(65 - 70) (90 - 100)
122 - 136 170 - 190
0.5625
(90 - 100) (125 - 140)
170 - 190 240 - 260
0.625
(125 - 140) (175 - 190)
300 - 330 410 - 450
0.750
(220 - 245) (300 - 330)
450 - 490 645 - 710
0.875
(330 - 360) (475 - 525)
645 - 710 985 - 1085

1.000
N•m (475 - 525) (725 - 800)
(ft-lb) 880 - 975 1425 - 1600
1.125
(650 - 720) (1050 - 1175)
1200 - 1360 2000 - 2200
1.250
(900 - 1000) (1475 - 1625)
1630 - 1830 2720 - 2980
1.375
(1200 - 1350) (2000 - 2200)
2040 - 2240 3530 - 3870
1.500
(1500 - 1650) (2600 - 2850)
2720 - 2980 4680 - 5150
1.625
(2000 - 2800) (3450 - 3800)
3390 - 3730 5830 - 6500
1.750
(2500 - 2750) (4300 - 4800)
4270 - 4750 7450 - 8300
1.875
(3150 - 3500) (5500 - 6100)
5150 - 5700 8800 - 9800
2.000
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- N•m ft-lb N•m ft-lb N•m ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100
M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 2900 - 2600
NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-30-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-30-
1].
Figure SPEC-30-2
O-ring Boss
Tightening Torque
x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.
Figure SPEC-30-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
P-85926
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-30-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-30-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.

SPEC-40-2
T770 Service Manual
CONVERSIONS
U.S. To Metric Conversion Chart

Decimal And Millimeter Equivalent Chart
SPEC-50-1
T770 Service Manual
SPEC-50-2
T770 Service Manual
ALPHABETICAL INDEX
(T770) LOADER SPECIFICATIONS CONVERSIONS . . . . . . . . . . . . . . .SPEC-50-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 CRANKSHAFT AND PISTONS . . . . . .70-90-1
ACCESS PANEL (INSIDE) (SJC) . . . . 50-121-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
AIR CONDITIONING SYSTEM FLOW . 80-10-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DIAGNOSTIC SERVICE CODES . . . . .60-90-1
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-70-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-50-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 ELECTRICAL / HYDRAULIC CONTROLS
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 (ACS) . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLER (SJC) (DRIVE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLERS (GATEWAY AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 ELECTRICAL SYSTEM INFORMATION
BOBCAT INTERLOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-190-1
BOB-TACH (HAND LEVER) . . . . . . . . 10-130-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 ENGINE COOLING SYSTEM . . . . . . .70-50-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1

BOB-TACH (POWER) . . . . . . . . . . . . 10-131-1 ENGINE LUBRICATION SYSTEM . . .10-110-1
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 ENGINE SPEED CONTROL (SJC) . . .70-21-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . 40-11-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
BUCKET POSITION VALVE . . . . . . . . 20-100-1 EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1 EXHAUST GAS RECIRCULATION (EGR)
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
CAMSHAFT AND TIMING GEARS . . 70-100-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-30-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 FLYWHEEL AND HOUSING . . . . . . .70-120-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1 FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
CONTROL HANDLE / LEVER (ACS) . 50-111-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONTROL HANDLE / LEVER (SJC) . 50-112-1 FRONT AUXILIARY HYDRAULIC COUPLER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
CONTROL HANDLE / LEVER . . . . . . 50-110-1
FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-101-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CONTROL PANEL SETUP . . . . . . . . 60-180-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
CONTROL PANEL . . . . . . . . . . . . . . . 50-100-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1
CONTROL PEDALS AND LINKAGES (ACS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1 HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1
CONTROL PEDALS AND LINKAGES . 50-90-1 HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1
CONTROL SYSTEM (ACS) . . . . . . . . 60-130-1 HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1
INDEX-01 T770 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS MUFFLER . . . . . . . . . . . . . . . . . . . . . . 70-30-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 OIL COOLER . . . . . . . . . . . . . . . . . . . 20-90-1
HYDRAULIC / HYDROSTATIC FLUID OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
HYDRAULIC / HYDROSTATIC SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 OPERATOR SEAT (SUSPENSION) . . 50-30-1
HYDRAULIC CONNECTION PASSWORD SETUP (DELUXE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-30-1 INSTRUMENTATION PANEL) . . . . . . 60-190-1
HYDRAULIC CONTROL VALVE (ACS) OR PASSWORD SETUP (KEYLESS START
(SJC) (EARLY MODELS) . . . . . . . . . . .20-42-1 PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
HYDRAULIC CONTROL VALVE (ACS) OR PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-160-1
(SJC) (LATER MODELS) . . . . . . . . . . .20-43-1 REAR AUXILIARY DIVERTER VALVE
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
(EARLY MODELS) . . . . . . . . . . . . . . . .20-40-1 REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
HYDRAULIC CONTROL VALVE (STANDARD) REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
(LATER MODELS) . . . . . . . . . . . . . . . .20-41-1 RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1 REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1 REMOTE START TOOL (SERVICE TOOL) KIT
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1 - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC SYSTEM INFORMATION 20-10-1 REMOTE START TOOL KIT- MEL1563 10-60-1
HYDROSTATIC DRIVE MOTOR (TWO- RIGHT SIDE LOWER PANEL . . . . . . 50-170-1
SPEED) (S/N ANKA11001 - ANKA13449) SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21-1
SEAT BAR SENSOR . . . . . . . . . . . . 60-110-1
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1
SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-41-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-200-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-40-1
SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
HYDROSTATIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SERVICE MANUAL REVISION . . . . . . SMR-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SERVICE PC (LAPTOP COMPUTER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
LEFT SIDE LOWER PANEL . . . . . . . .50-160-1
SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1
SPARK ARRESTER MUFFLER . . . . 10-150-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1
SPEED SENSORS (SJC) . . . . . . . . . . 60-80-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1
STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFTING AND BLOCKING THE LOADER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 STEERING DRIFT COMPENSATION 60-161-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 STOPPING THE ENGINE AND LEAVING THE
LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-15
SYSTEM CHARGING AND RECLAMATION
LOADER STORAGE AND RETURN TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-170-1
THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LUBRICATING THE LOADER . . . . . .10-140-1
TORQUE SPECIFICATIONS FOR BOLTS
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
MAIN RELIEF VALVE (EARLY MODELS) TOWING THE LOADER . . . . . . . . . . . 10-50-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1
TRACK MAINTENANCE . . . . . . . . . . 40-30-1
MAIN RELIEF VALVE (LATER MODELS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-31-1 TRACK UNDERCARRIAGE COMPONENTS
(ROLLER SUSPENSION) . . . . . . . . . 40-21-1
MAINTENANCE CLOCK . . . . . . . . . .60-200-1
TRACK UNDERCARRIAGE COMPONENTS
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 (SOLID-MOUNTED) . . . . . . . . . . . . . . 40-20-1

TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
TRANSPORTING THE LOADER ON A
TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . 80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-110-1
TWO-SPEED / BRAKE VALVE (S/N
A3P811001 - A3P13174 & A3P911001 -
A3P912024) . . . . . . . . . . . . . . . . . . . . . 30-60-1
TWO-SPEED / BRAKE VALVE (S/N
A3P813175 & ABOVE AND S/N A3P912025 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . 30-61-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1

INDEX-04
T770 Service Manual
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: T770 - 1

Date: 15 January 2011
Product: Bobcat Loader
Model: T770
Manual No: 6989476 (1-11)
The follow

SM 20130101

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Service Manual

T770 Compact Track Loader

S/N A3P811001 & Above

6989476 (1-13) Printed in U.S.A. © Bobcat Company 2013

CORRECT CORRECT CORRECT

P-90216 NA1711 NA1715

WRONG WRONG WRONG

NA1714 NA1710 NA1712

NA1722 NA1725 B-6589

1-1 T770 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

1-3 T770 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-5 T770 Service Manual

3. The seat belt must be 11. Bob-Tach wedges and

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

1-7 T770 Service Manual

22. Check for any field

1-8 T770 Service Manual

IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

1-9 T770 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

1-10 T770 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrester exhaust system regularly to

Battery gas can explode and cause serious injury. Use

1-11 T770 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

1-12 T770 Service Manual

Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number (Item 1) [Figure 3] is located

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

located on the outside of the loader frame.

Module 1 - Model / Engine

Explanation of loader Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module