Professional Documents
Culture Documents
Manual
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6901828 (11-08) Printed in U.S.A. © Bobcat Company 2008
1 of 725
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-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
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
2 of 725
3 of 725
Dealer Copy -- Not for Resale
ALPHABETICAL INDEX
4 of 725
ALPHABETICAL INDEX (CONT’D)
TEMPERATURE/PRESSURE .................................80-01
THERMOSTAT.........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER.............10-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01
5 of 725
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SPECIFICATIONS
SPECIFICATIONS
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
FW SSL-1008 SM
S175, S185 Bobcat Loader
II Service Manual
7 of 725
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
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
FW SSL-1008 SM
SI SSL-1008 SM
SI SSL-1008 SM
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.
SI SSL-1008 SM
Fire Extinguishers
SI SSL-1008 SM
S175, S185 Bobcat Loader
VIII Service Manual
13 of 725
Dealer Copy -- Not for Resale
Figure 1
P10560
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
Figure 3
B-16315
SEAT BAR
REAR AUXILIARY
GRAB HANDLES QUICK COUPLERS
STEERING
LEVER
TILT CYLINDER
STABILIZER ROD
† BUCKET
FRONT AUXILIARY
QUICK COUPLERS
REAR GRILL
LIFT ARM
REAR
LIGHT
REAR DOOR
B-16604
* TIRES B-16605
Figure 10-10-1
N-18877
B-7023A
Put the floor jack under the front of the loader [Figure 10-
10-2].
Lift the front of the loader and put jackstands under the
WARNING axle tubes [Figure 10-10-2].
Procedure
WARNING P-31849
1
WARNING P-34556
P-31857
Figure 10-20-1 The lift arm support device must be tight against the
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
P-31849
1
P-31842
Figure 10-20-3
P-31856
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].
Start the engine, raise the lift arms all the way up.
Lower the lift arms all the way and stop the engine.
Level II - Protection from falling trees, rocks; for Always stop the engine before raising or lowering the
machines involved in site clearing, overhead demolition cab.
or forestry.
Stop the loader on a level surface. Lower the lift arms. If
Figure 10-30-2
P10564 P10563
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
Figure 10-30-3
Figure 10-30-6
N-20120
P-31859
P0660
Figure 10-30-5
P10563
N-18495
Push the rear window out of the rear of the operator cab.
P10564 P10563 Exit through the rear of the operator cab [Figure 10-30-
7].
Install the plates and nuts [Figure 10-30-5] (both sides).
N-20171
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
Figure 10-30-9
P-24472
Procedure
WARNING
N-19048 P-24785
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
Figure 10-40-1
1
Use the following procedure to fasten the Bobcat loader
P-31912
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
A loader with an empty bucket or no attachment must be [Figure 10-40-2].
loaded backward onto the transport vehicle [Figure 10-
40-1]. • Lower the bucket or attachment to the floor.
Be sure the transport and towing vehicles are of • Stop the engine.
adequate size and capacity (See Capacities on Page
SPEC-10-4.). • Engage the parking brake.
The rear of the trailer must be blocked or supported (Item • Install chains at the front and rear loader tie down
1)[Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
• Fasten each end of the chain to the transport vehicle.
Procedure
Figure 10-50-1
1
1
N-18409
Procedure
Figure 10-60-1
1 1
P-24653
1
1
P-24651
P-24652
Procedure (Cont'd)
WARNING
2
AVOID INJURY OR DEATH 3 1
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the P16118
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899 The traction lock switch (Item 1) [Figure 10-60-6] is used
to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
Figure 10-60-5 traction lock OVERRIDE, in this position the wheels are
able to turn.
The remote start tool (Item 1) [Figure 10-60-5] has three NOTE: With the engine running; pushing and holding
rocker switches. the pressure release switch this will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
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, 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-2003-0199
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.
▼ Replace filter element after the first 50 hours and when the transmission warning light comes ON.
1
1
P-21769 P-31836
It is important to change the air filter element only when Remove the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner icon in the right panel is ON (Item 1) remove the dust cover.
Replace the inner filter every third time the outer filter is
replaced or as indicated on Contents Page 70-01.
Figure 10-80-2
2 P-31837
1
Figure 10-80-5
P-31838
P-31837
Only replace the inner filter element under the following
conditions:
NOTE: Be sure all sealing surfaces are clean.
• Replace the inner filter element every third time the
WARNING
AVOID INJURY OR DEATH
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-24673
Check the cooling system every day to prevent over- Raise the oil cooler. Clean the top of the radiator [Figure
heating, loss of performance or engine damage. 10-90-2].
Figure 10-90-3
P-24672
P-24671 P-24672
IMPORTANT
1
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Always add a premixed solution. Adding full strength Connect a hose to the engine block drain valve (Item 1)
concentrated coolant can cause serious premature [Figure 10-90-5]. Open the drain valve and drain the
engine damage. coolant into a container.
I-2124-0497
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
Remove the cover from the coolant recovery tank. Fill the
tank until it is at the lower marker (inside the tank).
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Fuel Specifications
Contact your fuel supplier for local recommendations. Open the rear door.
Filling The Fuel Tank Remove the fuel fill cap (Item 1) [Figure 10-100-1]
Figure 10-100-2
WRONG
WARNING
B-15526
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. Use a clean, approved safety container to add fuel of the
Failure to use care around combustibles can cause correct specifications. Add fuel only in an area that has
explosion or fire. free movement of air and no open flames or sparks. NO
W-2103-0508 SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].
Fuel Filter
Figure 10-100-3
3
P-34009
1
See SERVICE SCHEDULE on Page 10-70-1, for the
service interval for removing water from, or replacing the
fuel filter.
Replacing Element Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on Squeeze the hand pump (priming bulb) (Item 2) [Figure
the seal of the new filter element. Install the fuel filter, and 10-100-4] until fuel flows from the vent with no air
hand tighten. bubbles.
Remove the air from the fuel system. (See Removing Air Close the vent (Item 1) [Figure 10-100-4] on the fuel
From The Fuel System on Page 10-100-2.)
filter housing.
Removing Air From The Fuel System
Open the vent (Item 3) [Figure 10-100-4] on the fuel
After replacing the filter element or when the fuel tank injection pump.
has run out of fuel, the air must be removed from the fuel
system before starting the engine. Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until the pump feels solid.
Checking Engine Oil See SERVICE SCHEDULE on Page 10-70-1, for the
service interval for replacing the engine oil and filter.
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-110-1
Figure 10-110-2
N-20587
2
P-34452
Install the dipstick and close the rear door. Remove the oil filter (Item 2) [Figure 10-110-2].
Figure 10-110-3
P1575
Stop the engine and check for leaks at the oil filter.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Lower the lift arms and tilt the Bob-Tach fully back.
Figure 10-120-2
P-24672
2
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
1 W-2145-0290
N-19017
N-19018
Breather Cap
Figure 10-120-6
Figure 10-130-1
P1616
P-34453
Remove the cover (Item 1) [Figure 10-130-2] which is
installed over the drain plug at the bottom rear of the
The chaincase contains the final drive sprockets and chaincase.
chains and uses the same type of oil as the hydraulic/
If oil can be reached with the tip of the your finger through 1
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole.
P1619
Install and tighten the plug.
Figure 10-140-1
N-18460
N-16043A
Move the Bob-Tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Figure 10-150-2
TS-1062
Figure 10-151-1
If the wedge does not contact the lower edge of the hole
B-15891 [Figure 10-151-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
Figure 10-151-2
B-17460
Procedure
Figure 10-160-1
3
2
1
N-18506
P-18506
N-18505
Access
Lubricate the loader as specified in the SERVICE Hole
SCHEDULE, Contents Page 10-01, for the best
Always use a good quality lithium based multi-purpose 2. Stabilizer Rod - Rear (Both Sides) [Figure 10-160-2]
grease when you lubricate the loader. Apply lubricant
until extra grease shows. 3. Lift Cylinder Rod End (Both Sides) [Figure 10-160-2].
Lubricate the following locations on the loader: 4. Lift Cylinder Base End (Both Sides) [Figure 10-160-
2].
1. Stabilizer Rod - Front (Both Sides) [Figure 10-160-1].
Figure 10-160-3
N-18510
Procedure (Cont’d)
Figure 10-160-4
10
6 7
N-18508
Figure 10-160-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-160-
9 7].
P16045
Procedure (Cont’d)
Figure 10-160-8
12
P1533
Rotating WARNING
Check the tires regularly for wear, damage and pressure.
AVOID INJURY OR DEATH
Inflate tires to the maximum pressure shown on the
Do not inflate tires above specified pressure. Failure
sidewall of the tire.
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
Figure 10-170-2 W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
Cleaning Procedure
Figure 10-180-1
WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
Start the engine and run for about ten seconds while a
second person, wearing safety glasses, holds a piece of
1 wood over the outlet of the muffler.
P-31840
Stop the engine.
Stop the engine. Open the rear door and rear grill. WARNING
Remove the plug (Item 1) [Figure 10-180-1] from the Never use machine in atmosphere with explosive
bottom of the muffler. dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
V-0156legend
LEGEND
1 RESERVOIR: 14 LOAD CHECK VALVE 27 PILOT ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 24 Qts. (23 L) CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
2 SPRING LOADED FILTER BY-PASS 15 LIFT CYLINDER SPOOL - MADE TO AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) RESTRICT FLOW DURING BOOM ("D2" and "P2")
DOWN BUT NOT DURING BOOM UP 41 CHECK VALVE - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 28 FILTER - DIVERTER VALVE (SCREEN)
36-44 PSI (250-300 kPa) 16 SOLENOID ACTIVATED DIRECTIONAL 42 PRESSURE COMPENSATED FLOW
INTEGRATED IN SOLENOID
Normally Closed CONTROL VALVE - BICS CONTROL CONTROL
29 SOLENOID ACTIVATED DIRECTIONAL
4 DRIVE MOTOR SHUTTLE VALVE 43 RELIEF VALVE - PORT:
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - TILT CONTROL 3500 PSI (24132 kPa)
5 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1")
PRESSURE: 5000 PSI (34475 kPa) 18 PILOTED ACTIVATED DIRECTIONAL 44 RELIEF/ANTICAVITATION VALVE -
30 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL PORT (TILT BASE END)
6 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - FOR REAR
3500 PSI (24132 kPa)
185-195 PSI (1276-1345 kPa) 19 PULL BUTTON ACTIVATED AUXILIARY - NORMALLY CLOSED
at 16.7 GPM (63. 2 L/min.) Dealer Copy -- Not ("P1"
DIRECTIONAL CONTROL VALVE - LIFT and "F1")
for Resale 45 PILOT ACTIVATED DIRECTIONAL
at 3000 RPM ARM BY-PASS CONTROL VALVE - HYDRAULIC
31 FILTER - HYDRAULIC (CANISTER)
With 120 degrees F. (49 degrees C.) Fluid POWERED BOB-TACH
20 PILOTED ACTIVATED DIRECTIONAL
7 FRONT AUXILIARY MANUAL CONTROL VALVE - UNLOADING 46 TWO-STAGE RELIEF
32 FILTER - CASE DRAIN (SINTERED
PRESSURE SPOOL BRONZE) 1000/2000 PSI (6895/13790 kPa)
8 BLEED-OFFPUMP
HYDRAULIC VALVE . . . . . . . Gear Type 21 PILOTED ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
16.7 GPM (63.2 L/min.) at 3000 RPM CONTROL VALVE - FLOW CONTROL 33 FILTER - BICS CONTROL VALVE CONTROL VALVE (TWO COIL)
at 1150 PSI (7929 kPa) SPOOL (SCREEN)
48 RELIEF VALVE - 1200 PSI (8268 kPa)
9 RELIEF VALVE - MAIN: 22 FLOW DIVIDER ADJUSTMENT VALVE 34 CHECK VALVE - BUCKET POSITION
3300 PSI (22754 kPa)
VALVE 49 RESTRICTION - 0.015 inch (0.381 mm)
at Front Quick Couplers
23 SOLENOID ACTIVATED DIRECTIONAL 35 RESTRICTION
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - BLEED OFF REAR
3500 PSI (24132 kPa) AUXILIARY ("SV2") 36 VARIABLE CAPACITY DISPLACEMENT
11 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
24 LOAD SHUTTLE VALVE - BLEED OFF
37 SHUTTLE RELIEF VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 25 PILOT ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set)
CONTROL VALVE - AUXILIARY CONTROL VALVE - FOR REAR 65 PSI (448 kPa)
AUXILIARY - NORMALLY CLOSED
13 RELIEF VALVE - PORT: . . . . . (Optional) 38 FIXED CAPACITY DISPLACEMENT
("P2" and "F2")
3500 PSI (24132 kPa) BIDIRECTIONAL HYDROSTATIC
26 PILOT ACTIVATED DIRECTIONAL MOTOR
CONTROL VALVE - FOR REAR
39 ONE WAY RESTRICTOR VALVE NOTE: Unless otherwise specified
AUXILIARY - NORMALLY OPEN
("D1" and "P1") springs have NO significant
pressure value.
7 (FRONT AUXILIARY
MALE
24 7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
(REAR QUICK
1 COUPLERS)
MALE
23 25 27
MALE
F2 D2
4 37
DRAIN P1 P2
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
HYDRAULIC
AUXILIARY
POWERED
SPOOL
BOB-TACH
(OPTIONAL)
36 39
44 TILT CYLINDERS
BICS CONTROL VALVE
5 8 5
INLET OUTLET
D C
48
47
A B 17
43 TILT
46 CYLINDER
SPOOL
42
11
DRIVE MOTOR 14
DR 49
10 LIFT CYLINDERS
38
P1 P2 18
45
A B
LIFT
CYLINDER
PP SPOOL 35
15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
73 of 725
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S175 (S/N 517625001 AND ABOVE)
(S/N 518115001 AND ABOVE)
S185 (S/N 519028001 AND ABOVE)
(S/N 519215001 AND ABOVE)
(PRINTED MAY 2002) Printable Version Click Here
V-0157legend
LEGEND
1 RESERVOIR: 14 LOAD CHECK VALVE 30 LOAD SHUTTLE VALVE 40 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 24 Qts. (23 L) CONTROL VALVE - BUCKET POSITION
SPRING LOADED FILTER BY-PASS 15 LIFT CYLINDER SPOOL - MADE TO 31 FILTER - HYDRAULIC (CANISTER) VALVE (ON/OFF)
2
VALVE: 45-55 PSI (311-379 kPa) RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 41 CHECK VALVE - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 32 FILTER - CASE DRAIN (SINTERED
36-44 PSI (250-300 kPa) 16 SOLENOID ACTIVATED DIRECTIONAL BRONZE) 42 PRESSURE COMPENSATED FLOW
Normally Closed CONTROL VALVE - BICS CONTROL CONTROL
33 FILTER - BICS CONTROL VALVE
4 DRIVE MOTOR SHUTTLE VALVE 43 RELIEF VALVE - PORT:
17 PILOTED ACTIVATED DIRECTIONAL (SCREEN)
CONTROL VALVE - TILT CONTROL 3500 PSI (24132 kPa)
5 RELIEF/REPLENISHING VALVE - HIGH 34 CHECK VALVE - BUCKET POSITION
PRESSURE: 5000 PSI (34475 kPa) 18 PILOTED ACTIVATED DIRECTIONAL 44 RELIEF/ANTICAVITATION VALVE -
VALVE
CONTROL VALVE - LIFT CONTROL PORT (TILT BASE END)
6 RELIEF VALVE - CHARGE INLET: Dealer Copy --35NotRESTRICTION
for Resale 3500 PSI (24132 kPa)
185-195 PSI (1276-1345 kPa) 19 PULL BUTTON ACTIVATED
at 16.7 GPM (63. 2 L/min.) DIRECTIONAL CONTROL VALVE - LIFT 45 PILOT ACTIVATED DIRECTIONAL
36 VARIABLE CAPACITY DISPLACEMENT
at 3000 RPM ARM BY-PASS CONTROL VALVE - HYDRAULIC
BIDIRECTIONAL HYDROSTATIC PUMP
With 120 degrees F. (49 degrees C.) Fluid POWERED BOB-TACH
20 PILOTED ACTIVATED DIRECTIONAL
37 SHUTTLE RELIEF VALVE 46
7 FRONT AUXILIARY MANUAL CONTROL VALVE - UNLOADING TWO-STAGE RELIEF
(Not Adjustable - Factory Set) 1000/2000 PSI (6895/13790 kPa)
PRESSURE SPOOL
65 PSI (448 kPa)
BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 38 FIXED CAPACITY DISPLACEMENT CONTROL VALVE (TWO COIL)
8 HYDRAULIC PUMP . . . . . . . Gear Type BIDIRECTIONAL HYDROSTATIC
SPOOL
16.7 GPM (63.2 L/min.) at 3000 RPM MOTOR 48 RELIEF VALVE - 1200 PSI (8268 kPa)
at 1150 PSI (7929 kPa) 22 FLOW DIVIDER ADJUSTMENT VALVE
39 ONE WAY RESTRICTOR VALVE
9 RELIEF VALVE - MAIN: 49 RESTRICTION - 0.015 inch (0.381 mm)
23 CHECK VALVE
3300 PSI (22754 kPa)
at Front Quick Couplers 50 AUXILIARY HYDRAULIC PUMP:
24 SOLENOID ACTIVATED DIRECTIONAL
PUMP CAPACITY:
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - HIGH FLOW
10 GPM (37,8 L/min.) at 3000 RPM
3500 PSI (24132 kPa) 25 SOLENOID ACTIVATED DIRECTIONAL
51 SELECT VALVE RESTRICTOR
CONTROL VALVE - DIVERTER
11 ANTICAVITATION VALVE
26 RELIEF VALVE - MAIN (HIGH FLOW)
12 SOLENOID ACTIVATED DIRECTIONAL 3300 PSI (22754 kPa)
CONTROL VALVE - AUXILIARY 27 SOLENOID ACTIVATED DIRECTIONAL
13 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE (TWO COIL)
3500 PSI (24132 kPa) NOTE: Unless otherwise specified
28 PILOT TO OPEN CHECK VALVE springs have NO significant
29 pressure value.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
Printed in U.S.A. V-0157legend (5-7-02)
74 of 725
HYDRAULIC/HYDROSTATIC SCHEMATICS MALE
FEMALE
FEMALE
MALE
MALE
S185 (S/N 519028001 AND ABOVE) 30
28 28
(S/N 519215001 AND ABOVE) 1
(REAR QUICK COUPLERS)
(PRINTED MAY 2002) Printable Version Click Here OPTIONAL
V-0157
51 51
23 INTEGRATED QUICK
DRIVE MOTOR 27
COUPLER BLOCK
P
B FEMALE
PRESS
25 7 (FRONT AUXILIARY
MALE
4 7 LEFT SIDE LIFT ARM)
37
26 24
MALE
T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
48
47
A B 17
43 TILT
46 CYLINDER
D C SPOOL
42
11
DRIVE MOTOR 14
DR 49
10 LIFT CYLINDERS
38
P1 P2 18
45
A B
LIFT
CYLINDER
PP SPOOL 35
15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
75 of 725
HYDRAULIC SYSTEM INFORMATION
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3,
Checking
WARNING 2
1
AVOID INJURY OR DEATH
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 N-18786
from a physician familiar with this injury.
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Figure 20-20-1
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the
N-18785
WARNING
Lower the lift arms. Stop the engine. Pull up on the lift AVOID INJURY OR DEATH
arm by-pass control and move the lift pedal to release the Always clean up spilled fuel or oil. Keep heat, flames,
hydraulic pressure. Raise the seat bar. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Check only one cylinder at a time. Open the rear door. explosion or fire.
W-2103-0508
Disconnect the negative ground cable to the battery.
1
1
N-18785
P-34048
Disconnect the hose (Item 1) [Figure 20-20-3] from the Figure 20-20-6
lift cylinder base end port.
Figure 20-20-4 1
P-34049
Use a slide hammer, remove the lift cylinder rod end pivot
pin (Item 1) [Figure 20-20-6].
N-18806
Figure 20-20-7
P-34047
N-18782
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-8].
Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring
7 8
14
1 13
2 12
3
11
10
B-13593
Disassembly
3
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1 2
Spanner Wrench
Figure 20-20-10
N-20610
Figure 20-20-13
Figure 20-20-11
N-20611
2 1
3 Remove the wiper seal (Item 1) [Figure 20-20-13], and
4 rod seal (Item 2) [Figure 20-20-13], the back up washer
(Item 3) [Figure 20-20-13] the thin O-ring (Item 4)
[Figure 20-20-13] and the thick o-ring (Item 5) [Figure
20-20-13] from the head.
N-20552
Remove the head and the rod assembly from the cylinder
[Figure 20-20-11]. Put the rod end in a vise.
Assembly
Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) [Figure 20-20-15] and
installation. seal (Item 2) [Figure 20-20-15] on the piston (Item 3)
[Figure 20-20-15].
Figure 20-20-14
NOTE: The piston center hole (Item 4) [Figure 20-20-
15] has a bevel on one end. The bevel goes
Figure 20-20-16
P7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-14].
N-20612
Install the rod seal on the rod seal tool [Figure 20-20-16].
Assembly (Cont’d)
Figure 20-20-17
1
2
3
P7422
Figure 20-20-20
3 4
2
1
P7425
N-20552
Install the rod seal in the head [Figure 20-20-18].
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-20-20], and spacer
the head. (Item 2) [Figure 20-20-20].
Assembly (Cont’d)
Figure 20-20-21
P7429
Checking
WARNING 1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 P-34137
Figure 20-21-1 1
N-18802
1
Install a cap (Item 1) [Figure 20-21-3] on the fitting and
tighten.
1 3
P-34137
Installation: If the bolt and nut are 1/2 in. tighten to 65-70
Remove the attachment. Roll the Bob-Tach forward. Stop ft.-lb. (88-95 N•m) torque. If the bolt and nut are 5/8 in.
the engine. Raise the seat bar. tighten to 125-140 ft.-lb. (170-190 N•m) torque.
Figure 20-21-5
N-18545
Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-5].
Figure 20-21-7
1
1
N-18556
P-34228
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Removal And Installation on Page 20-21-2.)
Disconnect the hose (Item 1) [Figure 20-21-7] from the
cylinder. Use a seal pick to remove the seals (Item 1) [Figure 20-
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
N-18555
Rod End Pivot Pin Bushing And Seal Replacement Figure 20-21-11
(Cont’d)
Figure 20-21-10
P-34051
Reverse the removal procedure to install the pivot pin Loosen the retainer bolt (Item 1) [Figure 20-21-11] from
Identification
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal
8. O-ring 16. Rod
3
MC-1688A
11
5
6 12
7 13
9 14
15 16 15
MC-1688C 10
TS-1233A
Figure 20-21-12
N-20609
Figure 20-21-15
N-20615
5
3
4
Put the base end of the cylinder in a vise.
3 1
N-20611
N-20554
Assembly
3
Use the following tools to assembly the cylinder:
Lubricate all O-rings and seals with hydraulic oil during Install the O-ring (Item 1) [Figure 20-21-17] and seal
installation. (Item 2) [Figure 20-21-17] on the piston (Item 3) [Figure
20-21-17].
Figure 20-21-16
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Figure 20-21-18
P7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-16].
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 20-21-18].
Assembly (Cont’d)
Figure 20-21-19
1
2
3
P7422
Figure 20-21-22
2
3
1
P7425
N-20554
Install the rod seal in the head [Figure 20-21-20].
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-21-22], and the
the head. piston (Item 2) [Figure 20-21-22]. The small diameter of
the piston goes into the cylinder tube first.
Assembly (Cont’d)
Figure 20-21-23
P7429
Checking
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508 1
P16330
Figure 20-22-1
1 P16332
Engage the parking brake. Lower the seat bar. Start the
engine.
Figure 20-22-4
1 1
N-21401
Figure 20-22-5
N-21400
Identification
1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
7
8 9
10
11
12
13
B-16276
Disassembly
3
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench
Figure 20-22-6
P16295
Figure 20-22-9
Figure 20-22-7
N-20611
3 2
1 Remove the wiper seal (Item 1) [Figure 20-22-9], and
rod seal (Item 2) [Figure 20-22-9], the back up washer
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
P16294
Assembly
3
Use the following tools to assembly the cylinder: 2 1
Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) [Figure 20-22-11] and
installation. seal (Item 2) [Figure 20-22-11] on the piston (Item 3)
[Figure 20-22-11].
Figure 20-22-10
NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
Figure 20-22-12
P7424
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].
Assembly (Cont’d)
Figure 20-22-13
2
3
P7422
Figure 20-22-16
1 3
2 4
P7425
P16294
Install the rod seal in the head [Figure 20-22-14].
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-22-16], and spacer
the head. (Item 2) [Figure 20-22-16].
Assembly (Cont’d)
Figure 20-22-17
P16293
Checking
IMPORTANT 2
The hydraulic tester must be in the fully open 1
position before you start the engine.
I-2024-0284
P-34480
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
steering levers must be in neutral and the parking the loader.
brake engaged. Failure to do so can cause injury or
death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-0284 hydraulic tester to the top (male) quick coupler on the
Figure 20-30-2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 20-30-3
Right
Steering
Lever O-ring
Control
Back-up
B-6764
1
P-31833
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [Figure 20-30-4].
• Push the front switch (Item 1) [Figure 20-30-3] to give
the front quick couplers a constant flow of fluid. Turn the adjusting screw in or out until the pressure is
The free flow should be approximately 16.7 GPM (63,2 L/ Figure 20-30-5
min.). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the
main relief is approximately 3300 PSI (22752,7 kPa).
P-34004
Figure 20-30-6
N-19238
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-40-1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
P-34004
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. Remove the right rear tire.
W-2059-0598
Figure 20-40-2
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device (See Installing Lift Arm Support Device on Page P-31998
10-20-1.)
Raise the operator cab. (See Raising The Operator Cab Mark all tubelines and hoses for correct installation.
on Page 10-30-1.)
The fixed end main valve hose assembly (Item 1) [Figure
Clean the area around the control valve. 20-40-2] is connected to a fixed end fitting on the control
valve. The hose is routed to the back upright where the
Drain the hydraulic reservoir. (See Fluid Removal on hose is connected to a tee fitting that feeds the base end
Page 20-80-1.) of both lift cylinders. The hose must be removed at the
back tee fitting, located in the right side upright.
Remove the control panel. (See Removal and Installation
on Page 50-100-1.) NOTE: Remember the hose routing for ease of
control valve installation.
2
1
1
P-34388
5 4 3
1
1 2
2 P-34389
P-34387
Disconnect the drive motor case drain hose (Item 1)
[Figure 20-40-6].
Disconnect the tubeline (Item 1) [Figure 20-40-4] from
the lift arm by pass valve. Disconnect the Power Bob-Tach drain hose (Item 2)
[Figure 20-40-6] if so equipped.
Remove the drain tubeline (Item 2) [Figure 20-40-4] from
the lift arm by-pass valve and the control valve. Disconnect the drain to reservoir hose (Item 3) [Figure
20-40-6].
Remove the bolts (Item 3) [Figure 20-40-4] from the lift
arm by-pass control valve. Disconnect the auxiliary tubeline (Item 4) [Figure 20-40-
6] and (Item 5) [Figure 20-40-6].
Installation: Tighten the bolts to 180-200 in.-lb. (21-23
N•m) torque.
Figure 20-40-7
1
2
P-34005
3
Figure 20-40-8
P-34391
P-31997
Figure 20-40-11
1 1
1 1
1
1 1
N-18679
Figure 20-40-12
N-18695
P-34391 Remove the BICS™ valve assembly from the top of the
control valve [Figure 20-40-14].
N-18697
Figure 20-40-16
6
3
1 2
5 4
N-18679
Figure 20-40-17
N-18687
1
Figure 20-40-19
N-18686
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-18] & [Figure 20-40-
19].
Figure 20-40-20 1
P-8956
1
Figure 20-40-21
2
1
N-18684
Figure 20-40-26
1
1
1
N-18682
2
2 2
N-18690
Figure 20-40-24
N-18688
Figure 20-40-25
N-18689
N-18692
Figure 20-40-28
N-18693
Figure 20-40-30
3
2
P9175
1
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
IMPORTANT 1
Figure 20-40-33 Mark each valve section, spool and related parts so that
they will be returned to its original valve section during
assembly.
1 1 Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
Figure 20-40-35
N-18697
3
2 N-18699
Figure 20-40-36
1
N-19031
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-39].
N-18923
Figure 20-40-40
N-18977
Figure 20-40-41 4
1 1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
N-18923 Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-43].
Figure 20-40-44
1
N-18843
Figure 20-40-45
1
1
N-18923
Figure 20-40-48
1 N-18923
E-01509
1. Anti-Cavitation Valve
2. O-ring 2
1
3. Backup Washer
4. O-ring
N-18924
N-18839
Figure 20-40-52
N-18926
2
1
Remove the block [Figure 20-40-54].
N-18923 NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Figure 20-40-53
Figure 20-40-55
2
2 1
N-18925
1
Remove the lock solenoids (Item 1) [Figure 20-40-52] &
[Figure 20-40-53] from the lock block.
2
Remove the rubber boot (Item 2) [Figure 20-40-52] &
1
[Figure 20-40-53]. (See “Identification Chart” on page
20-40- 11.)
N-18923
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
55] from the control valve. (See Lift And Tilt Lock Block
Removal And Installation on Page 20-40-17.)
Figure 20-40-56
1 2 2
N-18971
2
1
1
N-18972
Remove the end cap (Item 1) [Figure 20-40-57]. Remove the detent bonnet (Item 2) [Figure 20-40-59].
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-60
N-18975
Figure 20-40-61
2
3
1
N-18930
N-18974
Figure 20-40-64
1
2
N-18916
1
1
N-18915A
N-19004
Figure 20-40-68
N-18918
Remove the stud from the end of the spool [Figure 20-
40-70].
N-19009
Figure 20-40-71
Remove spring tool (Item 1) [Figure 20-40-68] from the
spring assembly.
1
2
3
N-18920
N-18919A Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
Inspect the adapter (Item 1) [Figure 20-40-69], collar tap drill.
(Item 2) [Figure 20-40-69], spring (Item 3) [Figure 20-
40-69], and washer (Item 4) [Figure 20-40-69]. Turn a 6-32 tap (Item 1) [Figure 20-40-71] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Figure 20-40-72
2
Plastic
1 Plug
.06 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.60 inch (15,2 mm) from the spool [Figure
N-18961 20-40-74].
Figure 20-40-75
Install the O-ring (Item 1) [Figure 20-40-72] over the
nipple on the plastic plug (Item 2) [Figure 20-40-72].
N-18967
Install the plastic plug and O-ring in the spool [Figure 20-
40-73].
Figure 20-40-76
1 N-19004
3
2
Install the spring tool (Item 1) [Figure 20-40-78] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-79
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-76].
Figure 20-40-77
N-18917
N-18968
Figure 20-40-80
N-19007
Figure 20-40-81
N-19008
CD-15051
Figure 20-40-84
N-18976
1
Install the end cap (Item 1) [Figure 20-40-86].
2
N-18972 Figure 20-40-87
Figure 20-40-85
N-18930
N-18971
Figure 20-40-88
1 2
1
N-18923
N-18927 Remove the lift and tilt lock block (Item 1) [Figure 20-40-
90] from the control valve. (See Lift And Tilt Lock Block
Removal And Installation on Page 20-40-17.)
Install the spacer (Item 1) [Figure 20-40-88] and O-ring
(Item 2) [Figure 20-40-88] on the linkage end of the lift
Figure 20-40-89
2
1
1
N-18928
Install the lift and tilt lock block (Item 1) [Figure 20-40-
89]. (See Lift And Tilt Lock Block Removal And
Installation on Page 20-40-17.)
N-18942
N-18942
Put the linkage end of the spool in the vice [Figure 20-
40-94].
N-18686
Install the spool tool (Item 1) [Figure 20-40-94] over the
centering spring.
Remove the screws (Item 1) [Figure 20-40-92] from the
end cap.
Figure 20-40-93 1
N-19014
Figure 20-40-96
2 1
3
4
1
N-18976
1
1
N-18990
N-18930 N-18943
Figure 20-40-100
1
2
N-18823
N-18992
Figure 20-40-104
2
1
1
N-18800
Figure 20-40-107
Figure 20-40-105
N-18843
N-18993
Check that the load check valve seats are not worn.
P-34004
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
P-31998
damage the system.
I-2003-0888
1
P-31992
3 1
2
1
2
P-31993
P-34054
Label and disconnect the actuator electrical connectors
(Item 1) [Figure 20-41-6].
Disconnect the tubeline (Item 1) [Figure 20-41-4] from
the lift arm by-pass valve. Remove the bolt (Item 2) [Figure 20-41-6] from the wire
harness clamp.
Disconnect the drain hose (Item 2) [Figure 20-41-4] from
the control valve. Installation: Tighten the bolt to 180-200 in.-lb. (21-23
N•m) torque.
Remove the bolts (Item 3) [Figure 20-41-4] from the lift
arm by-pass control valve.
Figure 20-41-7 4
2
6
1 2 3 5
P-31996
1
2 2
P-31995
P-31997
If loader is equipped with rear auxiliaries remove the Disconnect the BICS valve electrical connector (Item 1)
drain tubeline (Item 1) [Figure 20-41-8] from the control [Figure 20-41-10].
valve and the rear auxiliary valve.
Figure 20-41-11
P-34006
P-34007
P-34008
Figure 20-41-15
1 1
1
1
2
1 1
N-18697
1
1 Remove the four large O-rings (Item 1) [Figure 20-41-
17] and the small O-ring (Item 2) [Figure 20-41-17] from
N-18679 the top of the control valve.
Figure 20-41-16
N-18695
Figure 20-41-18
3 6
1 2
5 4
N-18679
Figure 20-41-19
N-18685
1
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-41-20] & [Figure 20-41-
21].
N-18686
Orifice size is 0.078 inch.
Remove the fitting (Item 1) [Figure 20-41-19] from the
Figure 20-41-22
N-18687
N-18683
Figure 20-41-23
2
1
N-18684
Figure 20-41-24
P-8956
N-18682
Figure 20-41-26
N-18688
Figure 20-41-27
N-18689
Figure 20-41-28
1
1
1
2
2 N-18693
2
N-18690
Remove the O-rings (Item 1) [Figure 20-41-30] from
both ends of the solenoid.
Remove the O-rings (Item 1) [Figure 20-41-28] and
Figure 20-41-29
1
N-18692
N-18691
Figure 20-41-32
3
2
P9175
1
Use an Ohm meter to measure coil resistance [Figure
N-18694 20-41-33].
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Figure 20-41-34
3
2
1
1 N-19114
2 1
Remove the actuator (Item 1) [Figure 20-41-36].
Figure 20-41-35
N-18940
1
Figure 20-41-41
N-21159
1
Remove the BICS™ valve assembly from the controll
valve. (See BICS™ Valve Removal And Installation on
N-19099
Figure 20-41-42
1 1
N-19034
3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-44].
Figure 20-41-45
Remove the load check plugs (Item 1) [Figure 20-41-42].
Figure 20-41-43
1
1
N-19035
2 N-19102
Figure 20-41-46
1
2
3 4 5
B-06764
Figure 20-41-47
N-18981
N-19000
Figure 20-41-50
4 1
2
1
1. O-ring N-18980
2. Backup Washer
3. O-ring
Remove the anti-cavitation/port relief valve (Item 1) from
4. Relief Valve
the control valve for the tilt section.[Figure 20-41-52]
N-18844
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-41-50].
Figure 20-41-51
N-18843
Figure 20-41-54
1 E-1509A
1. Anti-Catitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
N-19036
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-41- Remove the actuator (Item 1) [Figure 20-41-57] from the
54] & [Figure 20-41-55] from the control valve. control valve. (See Actuator Removal And Installation on
Page 20-41-12.)
Figure 20-41-58
1
1
N-19112
Figure 20-41-59
1
1
1 N-19003
Figure 20-41-62 1
N-19014
4
1
N-18944A
Put the linkage end of the spool in the vice [Figure 20-
41-63].
2
1
2
1
N-18987
1
1
N-18988
Figure 20-41-70
3
2
1 N-18992
Figure 20-41-71
2
1
1
N-18795
Remove the end plate (Item 1) [Figure 20-41-71] and Installation: Always use new O-rings and apply oil to the
housing (Item 2) [Figure 20-41-71]. O-rings prior to installation.
Port-Auxiliary Section
Figure 20-41-74
3 2
N-18843
1
Install jack stands under the rear corners of the loader. Remove the rubber washer (Item 4) [Figure 20-50-1].
Start the engine. Raise the lift arms and install an Figure 20-50-2
approved lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)
1
WARNING P-34045
Never work on a machine with the lift arms up unless Disconnect the base end lift tubeline (Item 1) [Figure 20-
the lift arms are secured by an approved lift arm 50-2] from the Lift Arm By-Pass valve.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the drain tubeline (Item 2) [Figure 20-50-2]
to fall and cause injury or death. from the Lift Arm By-Pass valve.
W-2059-0598
Remove the two mounting bolt/nuts (Item 3) [Figure 20-
50-2].
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Installation: Tighten the mounting bolts to 180-200 in. lb.
(21-23 N•m) torque.
Figure 20-50-1
Remove the lift arm by-pass control valve.
4
3
1
P-31990
Figure 20-50-3
P-26065
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
1
P-26071
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-60-2] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Raise the operator cab. (See Raising The Operator Cab 20-60-2] from the tester to the hose (Item 1) [Figure 20-
on Page 10-30-1.) 60-1] which was disconnected from the pump.
Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
1 2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-26682
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-60-5] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-60-4]
on the top of the Power Bob-Tach block. Connect the
Raise the operator cab. (See Raising The Operator Cab OUTLET hose (Item 2) [Figure 20-60-5] from the tester
on Page 10-30-1.) to the hose (Item 1) [Figure 20-60-4] which was
disconnected from the Power Bob-Tach block.
Open the rear door of the loader.
Figure 20-60-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
Figure 20-60-8
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
P-26068
support device can allow the lift arms or attachment
to fall and cause injury or death.
2
1
P-26071
P-26069
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Remove the two mounting bolts (Item 1) [Figure 20-60-
10-20-1.) 9] from the hydraulic pump.
Stop the engine. Raise the seat bar. Installation: Tighten the mounting bolts to 27-37 ft.-lb.
(37-50 N•m) torque.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.) Remove the hydraulic pump (Item 2) [Figure 20-60-9]
Raise the operator cab. (See Raising The Operator Cab from the hydrostatic pump.
on Page 10-30-1.)
Figure 20-60-10
P-26347
1 2
P-26347
Identification
15
8
7
6
14
12
11 13
10
B-16050A
P-26352
2
2
P-26353
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-60-13 1
P-26358
2
Figure 20-60-16
P-26354
1
Figure 20-60-14
1
P-26359
Figure 20-60-17
1
P-26391
Figure 20-60-20
P-26389
Figure 20-60-18
P-26362
1
1
P-26362
Figure 20-60-21
P-26394
Remove the drive gear (Item 1) [Figure 20-60-21] from Figure 20-60-24
the pump end section.
1 P-26395
P-26393
Figure 20-60-25
P-26398
P-26397
P-26374
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
1
P-26753
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-61-2] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-61-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Raise the operator cab. (See Raising The Operator Cab 20-61-2] from the tester to the hose (Item 1) [Figure 20-
on Page 10-30-1.) 61-1] which was disconnected from the pump.
Figure 20-61-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-26754
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-61-5] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-61-4]
on the top of the Power Bob-Tach block. Connect the
Raise the operator cab. (See Raising The Operator Cab OUTLET hose (Item 2) [Figure 20-61-5] from the tester
on Page 10-30-1.) to the hose (Item 1) [Figure 20-61-4] which was
disconnected from the Power Bob-Tach block.
Open the rear door of the loader.
Figure 20-61-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
Figure 20-61-8
WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm P-26739
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
2
P-26741
P-26740
Raise the lift arms and install an approved lift arm support
Remove the two mounting bolts (Item 1) [Figure 20-61-
device. (See Installing Lift Arm Support Device on Page
9] from the hydraulic pump.
10-20-1.)
Stop the engine. Raise the seat bar. Installation: Tighten the mounting bolts to 27-37 in.-lb.
(37-50 N•m) torque.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.) Remove the hydraulic pump (Item 2) [Figure 20-61-9]
Raise the operator cab. (See Raising The Operator Cab from the hydrostatic pump.
on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See Fluid
Removal on Page 20-80-1.)
Open the rear door of the loader.
Figure 20-61-10
P-26684
1 2
P-26684
Identification
26
22 23
19
27
24 25
23
21
18
16 17 20 7 8
15
14
2
13
B-16051a
Figure 20-61-11
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888
P-26622
Figure 20-61-12
2
2 1
1 P-26622
Installation: Tighten the four smaller bolts (Item 1) Remove the pump end section (Item 1) [Figure 20-61-
[Figure 20-61-11] to 30 ft.-lb. (40,7 N•m) torque. Tighten 12].
the four larger bolts (Item 2) [Figure 20-61-11] to 54 ft.-
lb. (73,2 N•m) torque.
Figure 20-61-13
1 1
P-26627
2 Figure 20-61-16
P-26625
Figure 20-61-14
1
3
1 P-26628
Figure 20-61-17
P-26631
Figure 20-61-20
P-26629
P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-19] &
[Figure 20-61-20].
P-26636
1
1
P-26635
2
Remove the load seal (Item 1) [Figure 20-61-23].
P-26633
Figure 20-61-24
Figure 20-61-22
1
P-26637
P-26634
Remove the pre-load seal (Item 1) [Figure 20-61-24].
Figure 20-61-25
2
P-26657
Remove the pump center section (Item 1) [Figure 20-61- NOTE: Inspect the pump center section (Item 3)
25] from the pump sections. [Figure 20-61-27] and bushings (Item 4)
Figure 20-61-28
1
2
P-26655
Figure 20-61-29
P-26662
Figure 20-61-30
P-26661
Figure 20-61-32
P-26666
1
P-26665
1
1
P-26664
P-26670A
P-26669
2
Remove the load seal (Item 1) [Figure 20-61-38].
P-26667
Figure 20-61-39
Figure 20-61-37
1
P-26671
P-26668
Remove the pre-load seal (Item 1) [Figure 20-61-39].
Figure 20-61-40
P-26673
1
3
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,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-26756
P-26755
Fluid Removal
Figure 20-80-1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888
Lift and block the loader. (See LIFTING AND BLOCKING Figure 20-80-2
THE LOADER on Page 10-10-1.)
1
P-34113
WARNING Remove the left rear tire assembly (Item 1) [Figure 20-
80-2].
Never work on a machine with the lift arms up unless Remove the two access panels (Item 2) [Figure 20-80-
the lift arms are secured by an approved lift arm 2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 20-80-3
1
1
2
3
2
P-34040
2
1
1
2
P-34038N-
19059
P-34039
Figure 20-80-7
2
P-34044
Figure 20-80-8
1
2
P-34053
Remove the bolt and nut (Item 1) [Figure 20-80-8]. NOTE: Standard loaders without rear auxiliaries and
all high flow loaders will have a one-piece
Loosen the bolt and nut (Item 2) [Figure 20-80-8] to auxiliary tubeline from the control valve to the
allow the hydraulic reservoir mount to drop down. rear upright hoses. Disconnect the tubeline
(Item 1) [Figure 20-80-10] from the control
valve and loosen the fitting in the left rear
upright to allow movement of the tubeline for
the hydraulic reservoir removal.
Figure 20-80-11
P-34052
Figure 20-90-1
1
2
2
N-18191
Figure 20-90-2
P-9175
Replace the test meter with 12 volt power. You can see
Remove the solenoid stem (Item 1) [Figure 20-90-2] and hear the spool shift.
from the bucket positioning valve.
2
2
1
1
P-34166
Never work on a machine with the lift arms up unless Remove the four steering linkage mounting bolts (Item 2)
the lift arms are secured by an approved lift arm [Figure 20-90-5].
Figure 20-90-6
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 2
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-34024
Figure 20-90-7
1
2
3
P-34027
Figure 20-90-10
Remove the tilt tubeline (Item 1) [Figure 20-90-7] from
the C port.
Figure 20-90-8
P-34029
P-34028
Figure 20-90-11
1
N-19072
Figure 20-90-12
1
1 N-19041
N-19070
Remove the plug (Item 1) [Figure 20-90-14].
Figure 20-90-15
1
N-19045
Figure 20-90-16 3
N-19046
1
Remove the plug (Item 1) [Figure 20-90-18], spring (Item
2 2) [Figure 20-90-18] and unloading spool (Item 3)
[Figure 20-90-18].
3
Check all parts and replace as needed. Install a new O-
N-19042 ring on the plug before installing.
Figure 20-100-1
2
2
1
P-28726
1
Figure 20-100-3
3 1
1
3
2 2 P09174 P16342
Figure 20-100-5
B-15551
Start the engine and run at low idle RPM. Push the flow
switch (Item 1) [Figure 20-100-3] once (on the
Figure 20-100-6
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. 11
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
WARNING 2
2
Figure 20-100-8 3
1
2
1 3
P-26414
Figure 20-100-11
1
2
P-34298
P-34295
Disconnect the rear auxiliary tubelines (Item 1) [Figure
20-100-9] (If so equipped).
Disconnect the outlet hose from the gear pump (Item 1)
Disconnect the right side (secondary) auxiliary tubelines [Figure 20-100-11].
(Item 2) [Figure 20-100-9] (If so equipped).
Figure 20-100-12
3 2
1
1
P-34299
Figure 20-100-15
2 4
1 1
N-18181 N-18175
P-34296
NOTE: The sta-strap colors are listed below for
identification during select valve installation.
Remove the select valve (Item 1) [Figure 20-100-15]
Second Aux. Rear Rod (Male coupler) (Item 1) [Figure through the right side access panel.
20-100-13] Brown.
Second Aux. Rear Base (Female coupler) (Item 2)
[Figure 20-100-13] White.
Second Aux. Rear Aux. (Pressure relief) (Item 3) [Figure
20-100-13] Green.
High Flow (Item 4) [Figure 20-100-13] Blue.
Diverter (Item 5) [Figure 20-100-13] Yellow.
3 1
4
1 5
NOTE: The controls wiring harness colors are listed Inspect O-rings (Item 1) [Figure 20-100-18] and back-up
below for identification during select valve washer (Item 2) [Figure 20-100-18] on the secondary
Rear Rod male coupler (Item 1) [Figure 20-100-16] Installation: Put oil on O-rings and back-up washer.
Brown Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
Rear Base female coupler (Item 2) [Figure 20-100-16]
White Figure 20-100-19
Rear Aux. pressure relief (Item 3) [Figure 20-100-16]
Green
High Flow (Item 4) [Figure 20-100-16] Blue
Diverter (Item 5) [Figure 20-100-16] Yellow
Figure 20-100-17
1
2
P-26864
P13829
Inspect the O-rings (Item 1) [Figure 20-100-20] and Installation: Put oil on O-rings and back-up washers.
back-up washer (Item 2) [Figure 20-100-20] on the hi- Install and tighten to 20 ft.-lb. (27,1 N•m) torque.
Figure 20-100-21
2
3
P-26866
Figure 20-100-26
P13830
P-26913
Assembly: The coils largest opening must be positioned
on the valve shoulder (Item 1) [Figure 20-100-24]. Install
Figure 20-100-25
2 1
P-26868
1 N-18182
Remove the load shuttle (Item 1) [Figure 20-100-27]
from the select valve.
Remove the two plugs (Item 1) [Figure 20-100-25] from
the select valve.
Figure 20-100-28
P-26870
2
1
P-26873
1
Remove the solenoids (Item 1) [Figure 20-100-31] from
P-26869 the solenoid stems.
Figure 20-100-32
1
P-26872
2
Figure 20-100-33
P-26871
Figure 20-100-38
1
P-26875
Figure 20-100-36
Replace the test meter with 12 volt power. You can see
1 and hear the spool shift.
P-26877
Figure 20-100-37
P-26914
Removal And Installation Drain the hydraulic fluid from the reservoir. (See Fluid
Removal on Page 20-80-1.)
Put jackstands under the front axles and rear corners Figure 20-110-1
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 11
Figure 20-110-2
WARNING
2
Never work on a machine with the lift arms up unless 2
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
1
to fall and cause injury or death. 1
W-2059-0598
P-34166
IMPORTANT Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-110-2] which are connected to the
steering shaft on the control panel.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Remove the four steering linkage mounting bolts (Item 2)
parts clean. Always use caps and plugs on hoses, [Figure 20-110-2].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Align the marks on the steering linkage
I-2003-0888 bars. Tighten the steering linkage mounting bolts to 25-
28 ft.-lb. (34-38 N•m) torque.
1
2
P-34167
3
1
2
P-34168
4
Figure 20-110-7
P-34170
P-34169
Figure 20-110-12
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-110-10
P16315
1
P16312
Figure 20-110-11
P16314
P16313
Figure 20-110-14
P16319
1
Remove the nuts (Item 1) [Figure 20-110-16] & [Figure
1 20-110-17] from the solenoid valve.
P16316
Installation: Tighten the nuts to 50-55 in.-lb. (5,6-6,2
N•m) torque.
Figure 20-110-15
3
2
2
1
1
2 2
P16317 1
P16321
Figure 20-110-18
P16322
Figure 20-110-21
P16323
Figure 20-110-19 1
P16325
Figure 20-110-22
P9137
1 Inspection
P16327
WARNING P-26414
Never work on a machine with the lift arms up unless Remove the nut from the speed control linkage (Item 1)
the lift arms are secured by an approved lift arm [Figure 20-120-1].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Unplug the rear lights electrical connector (Item 2)
to fall and cause injury or death. [Figure 20-120-1].
W-2059-0598
Figure 20-120-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page P-34141
10-20-1.)
Raise the operator cab. (See Raising The Operator Cab Disconnect the wire harness connectors (Item 1) [Figure
on Page 10-30-1.) 20-120-2].
Figure 20-120-3
3
1
2
1
P-34140
Figure 20-120-4
1
2
P-26100
P-34139
Clean the block (Item 1) [Figure 20-120-6] to remove dirt
before disassembly. Block ports are labeled for correct
Disconnect the hose (Item 1) [Figure 20-120-4] from the assembly.
“BASE” port on the Power Bob-tach block.
Remove the plug (Item 2) [Figure 20-120-6].
Disconnect the hose (Item 2) [Figure 20-120-4] from the
“ROD” port on the Power Bob-tach block. Installation: Tighten the plug to 46 ft.-lb. (62,4 N•m)
torque.
Disassembly And Assembly (Cont'd) Installation: Tighten the plug to 120 in.-lb. (13,6 N•m)
torque.
Figure 20-120-9
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2
Figure 20-120-7 1
3
P-26107
3
P-26103
Figure 20-120-8
1
P-26109
P-26105
Figure 20-120-11
P-26208
3 2 1
2 P-26114
1
Figure 20-120-12
P-26116
1
Remove the nut (Item 1) [Figure 20-120-14] & [Figure
P-26113 20-120-15].
4
3
2
2
1
P-26122
Figure 20-120-16
P-26120
Figure 20-120-18
P-26125
Figure 20-120-21
1 P-26123
Figure 20-120-19
3 P-26127
2
1
Remove the plug (Item 1) [Figure 20-120-20] & [Figure
3 20-120-21].
P-26309
Figure 20-120-22
P-26130
Figure 20-120-25
P-26128
Figure 20-120-23
3
P-26132
1
Figure 20-120-26
3
2
1
4 P-26136
1 P-26134
Figure 20-120-29
P-26140
1
Figure 20-120-32
P-26137
Figure 20-120-30
2
1
P-26141
Figure 20-120-33
P-26141A
Figure 20-120-34
2
1
3
P-26143
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses, 4
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 3
I-2003-0888
Figure 20-130-1
P-34661
Figure 20-130-3
P-34360
1
2
P-34665
Figure 20-130-7
Check the O-ring (Item 1) [Figure 20-130-4] for damage
and replace as needed.
P-34664
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9, 10, 11
Service code HP2 appears. (Warnings, low charge pressure.) 8, 11, 12, 13
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 30-10-8
CHARGE OIL
B-2804
Figure 30-20-2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. 1
W-2059-0598
P-34004
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Lift and block the loader. (See LIFTING AND BLOCKING
Figure 30-20-3
1
1
1 N-19240
Figure 30-20-4
P-4141
Parts Identification
3
10
11
9
8
13
3 16
5
14
6
15
21 7
6
22
20
17
19
18
19
17 20
1
26
25
12 24 2
23
D-3431
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 30-20-5
N-00623
Figure 30-20-8
1
N-00621
2
Seal all open ports and clean the motor with solvent.
Figure 30-20-6
N-00624
1
Turn the mounting flange over and remove the O-ring
(Item 1) [Figure 30-20-8] and back-up ring (Item 2)
[Figure 30-20-8].
N-00622
Disassembly (Cont’d)
1
Figure 30-20-9
N-00627
Figure 30-20-12
Turn the mounting flange backover and remove the seal
(Item 1) [Figure 30-20-9] from the mounting flange.
N-00628
Disassembly (Cont’d)
Figure 30-20-13
N-00631
Figure 30-20-16
Remove the square cut seal (Item 1) [Figure 30-20-13]
from the gerolor.
1
N-00632
Disassembly (Cont’d)
1
Figure 30-20-17
N-00635
Figure 30-20-20
Remove the square cut seal (Item 1) [Figure 30-20-17]
and small O-ring (Item 2) [Figure 30-20-17] from the end
Figure 30-20-18
N-00636
Turn the end cover over and remove the shuttle valve
plug from the end cover [Figure 30-20-20].
N-00634
Disassembly (Cont’d)
3
Figure 30-20-21
2
1
1
2
3
N-00640
Remove the spring seat (Item 1) [Figure 30-20-21], NOTE: The relief pressure is factory set and must not
spring (Item 2) [Figure 30-20-21] and poppet (Item 3) be changed. Shims may or may not have been
Figure 30-20-24
2
1
N-00639
N-00641
Remove the low pressure relief valve plug from the side
of the end cover [Figure 30-20-22].
The low pressure relief valve is made up of the poppet
(Item 1) [Figure 30-20-24], the spring (Item 2) [Figure
30-20-24] and the plug assembly (Item 3)[Figure 30-20-
24].
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-00643
Prior to assembly:
Install the new O-ring on the plug and tighten to 300 in.-
Clean all parts with solvent and dry with compressed air. lb. (34 N•m) torque [Figure 30-20-26].
1
1
N-00644
Install the poppet (Item 1) [Figure 30-20-25] and spring NOTE: The tapered end of the poppet must face
(Item 2) [Figure 30-20-25] in the low pressure relief port towards the shuttle valve.
in the end cover.
Assembly (Cont’d)
Figure 30-20-28 1
N-00648
Figure 30-20-31
Install a new O-ring on the plug [Figure 30-20-28] and
tighten to 260 in.-lb. (41 N•m) torque.
Figure 30-20-29
4
2
3 1 N-00649
N-00647
Assembly (Cont’d)
Figure 30-20-32
N-00652
Figure 30-20-35
Align the case drain ports in the valve plate with the case
drain port in the end cover [Figure 30-20-32].
1
N-00653
Assembly (Cont’d) 1
Figure 30-20-36
N-00656
N-00655 N-00657
Install the two check balls (Item 1) [Figure 30-20-37] in Mark the case drain hole on the outer ring of the gerolor
their bores in the gerolor. (as shown) [Figure 30-20-39].
Assembly (Cont’d)
1
Figure 30-20-40
2
3
4
5
N-00660
N-00661
N-00659
Assembly (Cont’d)
Figure 30-20-44
N-00664
Install the nine bolts into the motor. Make sure all the
N-00662 parts are in correct alignment [Figure 30-20-46].
Figure 30-20-47
Align the case drain port (Item 1) [Figure 30-20-44] in
the mounting flange with the case drain port in the
Figure 30-20-45
MC-2230
Figure 30-20-48
1
P-4456
Figure 30-20-50
The tool listed is necessary for the following procedure:
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
P-4455
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running. Use a slide hammer to remove the seal from the motor
• Tools are being used. carrier shaft [Figure 30-20-50].
W-2019-0907
Figure 30-20-51
P-4149
P-4150
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-20-52].
WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-4152
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-20-
54]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See LIFTING AND BLOCKING 1.)
THE LOADER on Page 10-10-1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising The [Figure 30-20-54] from the inside of the chaincase.
Figure 30-20-56
P-4165
Figure 30-20-57
P-4168
4
3
6 7
MC-1937A
Carrier Disassembly
Figure 30-20-58
7.000’’
Length
(177,8 mm) P-4176
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-20-60].
procedure. Refer to photo [Figure 30-20-58] for the
2
1
1
P-4372
P-4365
Figure 30-20-62
P-4369
P-4373
Put the motor carrier housing in the press as shown
[Figure 30-20-64].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30- Use 4-5/16 inch driver tool and press the new inner
Figure 30-20-63
P-4368
P-4370
Turn the motor carrier housing over as shown [Figure
30-20-65].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-20-63]. Use 4-5/16 inch driver tool and press the new outer
bearing race into the motor carrier housing [Figure 30-
Use a 3-7/8 inch driver tool and press the outer bearing 20-65].
race from the housing.
Press the bearing race in until it is fully seated in the
Check all parts for wear and damage. Replace the carrier housing.
bearing race when new bearings are to be installed.
Figure 30-20-66
P-4366
Put the motor carrier housing (Item 1) [Figure 30-20-67]
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) [Figure 30-20-66]
and 3.0 inch driver tool, install the new inner bearing Put the outer bearing over the end of the sprocket shaft
(Item 2) [Figure 30-20-66] on the sprocket shaft as and press the bearing on with the press tool and driver
shown. tool [Figure 30-20-67].
Remove the press and drive tools from the sprocket Remove the press and driver tools from the sprocket
shaft. shaft.
Figure 30-20-68
1
1
P-4374
Put the snap ring (Item 1) [Figure 30-20-68] over the end
P-4375
of the sprocket shaft.
Using the press and driver tools, press the snap ring Hit the tool with a hammer until the seal is fully seated on
(Item 1) [Figure 30-20-68] over the sprocket. the carrier shaft [Figure 30-20-70].
Press the snap ring on until it snaps into the groove on See Carrier Shaft Seal Replacement on Page 30-20-15
the shaft. for complete shaft seal installation procedure.
P-4376 N-15088
Put a new shaft seal (Item 1) [Figure 30-20-69] on the Check the end play of the motor carrier as follows:
sprocket shaft.
Use a rubber mallet [Figure 30-20-71], tap down on the
cluster shaft.
Figure 30-20-72
The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).
Figure 30-30-1
WARNING
1
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
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 30-30-2 Remove the charge pressure sender (Item 2) [Figure 30-
30-2] from the fitting.
P-28590
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-19567
2
1
3
N-19566
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 30-40-8
P-4235
P-4238
2
Figure 30-40-12
P-28850
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
5 4
8 3
7
6
2
9 1
13 14
10 15
11
12 17
19
21 16
23 18
22
29 24
26
28
38
30 33
36
34 32
31
37
35 46
47 48
40
42 45
39 44
49
41
43
D-2427
4
17 6
16
11 8
1
14 2
13 10 3
5
12
7
9
15
22
23
18
19 21
20 24
28
33
35
47
37
46
39 45
44
48 43
49 42
50 40
51
52 58
41
53
53 52 57
59
55
56
54
D-2428B
Figure 30-40-13
1
2 1
1 1
N-19569
N-21967
Remove the four mounting bolts (Item 1) [Figure 30-40-
15].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-13] (both sides). Figure 30-40-16
Figure 30-40-14
2 N-19570
1
N-21969
Figure 30-40-17
3 1
1
N-19551
2 3
Disassembly
Figure 30-40-18
1 1
N-17193
N-19550
Disassembly (Cont’d)
1
Figure 30-40-21
2
1
N-17198
N-17199
Disassembly (Cont’d)
Figure 30-40-25
1
3 3
2
2 1
3 3
3
N-17481
Figure 30-40-26
N-17239
N-17201
Disassembly (Cont’d)
Figure 30-40-29 1
1
N-17242
Figure 30-40-32
Remove the snap ring (Item 1) [Figure 30-40-29] from
the pump housing and remove the driveshaft and bearing
Figure 30-40-30
1 1
N-17243
1
Disassembly (Cont’d)
Figure 30-40-33
2
2
1
1
1 N-17246
Figure 30-40-34
1
1
2 N-17247
Disassembly (Cont’d)
Figure 30-40-37
1 N-17249
Inspect the seal (Item 1) [Figure 30-40-37] in the upper Figure 30-40-40
trunnion cover and replace if needed.
1
N-17251
2
N-17248 Slide the swashplate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-40-40] from
the swashplate shaft.
Remove the O-ring (Item 1) [Figure 30-40-38] and
bearing race (Item 2) [Figure 30-40-38] from the pump
housing.
Disassembly (Cont’d)
Figure 30-40-41
N-17252
Figure 30-40-44
Tilt the swashplate (Item 1) [Figure 30-40-41] and
remove the swashplate and lower bearing from the pump
Assembly
Figure 30-40-42
1
1 2
N-17249
N-17253
Assembly (Cont’d)
Figure 30-40-45
N-17246
Figure 30-40-46
N-17247
Assembly (Cont’d)
Figure 30-40-48
2
N-17243
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-40-48] and O-
ring (Item 2) [Figure 30-40-48] at the lower trunnion as
shown in [Figure 30-40-49]. Install the snap ring (Item 1) [Figure 30-40-51] on the
pump shaft.
Assembly (Cont’d)
1
1
Figure 30-40-52
1
1 2 3
1
N-17200
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-53]. 30-40-55] onto the slipper holddown pins.
Assembly (Cont’d)
1
2
Figure 30-40-56
N-17194
Assemble the piston assemblies into the slipper guide Figure 30-40-59
[Figure 30-40-56]. Lubricate the pistons and cylinder
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. 2
1
Figure 30-40-57
N-17196
Assembly (Cont’d)
1 1
Figure 30-40-60
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-62] to 35-45 ft.-
lb. (47-61 N•m) torque.
Coat the backside of the valve plate with petroleum jelly Figure 30-40-63
to hold it in position and install the valve plate onto the
Figure 30-40-61 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-40-63].
Assembly (Cont’d)
Figure 30-40-64
N-19570
1
N-19569
Figure 30-50-1
P-34358
P-34359
To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
Remove the three drive belt shield fasteners (Item 1)
[Figure 30-50-1]. Stop the engine. Open the rear door.
P-34358
Adjusting (Cont’d)
Figure 30-50-4
1
1
P-8761
P-8762
Figure 30-50-7
P-4064
Remove the drive belt from the pump pulley and flywheel.
P-34358 Remove the drive belt from the loader [Figure 30-50-9].
Remove the belt shield fasteners. Remove the belt shield Tensioner Pulley Removal And Installation
[Figure 30-50-7].
Figure 30-50-10
Figure 30-50-8
1
2
P-34359
P-8760
The belt tensioner is located between the flywheel and Remove the belt shield.
pump pulley. Loosen and remove the bolt (Item 2)
[Figure 30-50-8] from the belt tensioner.
Figure 30-50-11
P-8760
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring
8 16
17
9
18
10
19
20
E-2296
Figure 30-50-12
3
1
1 4
P-8861
Remove the grease cover (Item 1) [Figure 30-50-12]. Remove the bracket assembly (Item 3) [Figure 30-50-
14] by tapping on the shaft (Item 4) [Figure 30-50-14]
Figure 30-50-15
5
2 3
2
1
1
4
P-8859
P-8862
Remove the bolt (Item 1) [Figure 30-50-13], the flat
washer (Item 2) [Figure 30-50-13], the retainer washer
(Item 3) [Figure 30-50-13], the spring washer (Item 4) Remove the spring (Item 1) [Figure 30-50-15] from the
[Figure 30-50-13] and the second retainer washer (Item bracket (Item 2) [Figure 30-50-15].
3) [Figure 30-50-13] from the pulley assembly (Item 5)
[Figure 30-50-13].
Figure 30-50-16
1
1
2 P-8873
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-50-18] into the hub.
Figure 30-50-19
Install the spring (Item 1) [Figure 30-50-16] on the pulley
(Item 2) [Figure 30-50-16] as shown.
3 2 P-8874
Figure 30-50-20
2
1
1
P-8877
Install the first retainer washer (Item 1) [Figure 30-50-20] NOTE: When pressing the grease cap onto the pulley
and spring washer (Item 2) [Figure 30-50-20] over the assembly, do not press down on the arrow
2
1
P-8876
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-19540
Figure 30-60-1
Figure 30-60-4
N-19216
N-19346
Lift up the oil cooler and remove the cooler from the
loader.
N-19345
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . 40-10-2 SAFETY &
MAINTENANCE
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . 40-30-3
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-4
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
DRIVE
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle Sprocket And Bearings Removal And Installation . . . 40-20-3
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-20-8
ENGINE
SERVICE
SPECIFICATIONS
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
N-19105
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Inspect the traction lock guides (Item 1) [Figure 40-10-2]
and the brake disc for damage or wear and replace as
Raise the loader operator cab. (See Raising The necessary.
Operator Cab on Page 10-30-1.)
See Inspecting on Page 60-110-2 for the Traction Lock
Disconnect and remove the engine speed control. (See inspection procedure.
Figure 40-10-1
N-19081
Figure 40-10-3
2 1
P-21944
N-19082
The parking brake switch in the front panel (Item 1)
[Figure 40-10-5] replaced the pedal parking brake. (See
Figure 40-10-4 INSTRUMENT PANEL on Page 60-50-1.)
N-19083
2
2
2 1
P-4157 P-4159
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
P-4161 the following procedure:
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
1
Reverse removal procedure to install the axle hub and
wheel assembly.
P-4181
Figure 40-20-6
P-34255
Figure 40-20-8
P-4170
1
P-4158
A bearing puller (Item 1) [Figure 40-20-10] is needed for
the following procedure:
Install the MEL1242 power ram (Item 1) [Figure 40-20-8]
Figure 40-20-9
2 P-4171
1
P-4162 Be sure the bearing puller makes good contact with the
inner race of the bearing and press the bearing off the
mounting surface of the axle.
Remove the drive chain from the sprocket (Item 1)
[Figure 40-20-9] and remove the sprocket from the Be sure to hold onto the axle during removal as it will
chaincase. slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts
Remove the inner bearing (Item 2) [Figure 40-20-9] and the spline on the shaft.
remove the axle from the axle tube. (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20- Press the splined end of the axle free from the bearing
3.) [Figure 40-20-11].
Figure 40-20-12
4
3
P-4175
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
P-4180
P-4172
Use the slide hammer and remove the bearing cup from
Use the tools provided in the MEL1202B Axle Bearing the axle tube [Figure 40-20-16].
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-14].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].
Figure 40-20-15
2
1
P-4179
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
Figure 40-20-19
P-4174
Figure 40-20-18
P-4173
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-4152
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 40-20-
20]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See LIFTING AND BLOCKING 1.)
THE LOADER on Page 10-10-1.)
Remove the six carrier mounting bolts (Item 2) [Figure
Raise the loader operator cab. (See Raising The 40-20-20] from inside the chaincase.
Figure 40-20-22
B-13504
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22]. Tighten the
threaded rod of the chain link tool to 130 ft.-lb. (176 N•m)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307
Figure 40-30-1
P1616
P-34453
To check the chaincase oil level, use the following Figure 40-30-3
procedure:
If oil can be reached with the tip of the your finger through
the hole the oil level is correct. 1
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
P1619
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
2
P-34255
Figure 40-30-6
2
1
Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
Figure 40-30-5 2
3
Remove the ten chaincase cover mounting bolts (Item 1)
[Figure 40-30-6].
2 1
Installation: Tighten the cover mounting bolts to 25-28
ft.-lb. (34-38 N•m) torque.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
2
P-34259
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-40-3 SAFETY &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 MAINTENANCE
Figure 50-10-1
P10564 P10563
Figure 50-10-4
N-18463
Lower the seat bar. Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].
Figure 50-10-5
4 6
5
7
1
2 9 8
10
1
N-19383
N-18572
Figure 50-10-8
N-19219
1 Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Reverse the above procedure to install the seat bar into Installation: Tighten the mounting bolt (Item 2) [Figure
the operator cab. 50-10-7] & [Figure 50-10-8] to 50-70 in.-lb. (5,6-7,9 N•m)
torque.
Figure 50-10-9
5
4 6
2 7
1
N-19340
Figure 50-10-10
7
1
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Figure 50-10-11
6 7
5
4 6
N-19222
3
2
1 Turn the bolt (Item 1) [Figure 50-10-12] & [Figure 50-10-
N-19384 11] out of the clevis.
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
WARNING 1
Figure 50-20-1
P1518 P1528
N-19165
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-31965
Figure 50-20-4
N-19184
1
Install a strap (Item 1) [Figure 50-20-4] from the operator
cab to the loader main frame to prevent the cab from
tipping forward when the gas cylinder(s) are removed.
Figure 50-20-5
2
1 N-19171
Figure 50-20-8
2
1
P1008
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
P1006
W-2245-0796
Apply a small amount of LOCTITE on the threads of the Use the hoist connected to the operator cab grab handles
cylinder rod [Figure 50-20-9]. to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.
Figure 50-20-11
1
N-19231
Figure 50-20-14
Remove bolt (Item 1) [Figure 50-20-11] from the cab
ground.
Figure 50-20-12
P-31966
N-19185
Figure 50-20-15
2 1
1
N-19202
N-19165
1
P-31967
Figure 50-30-1
1 1
1 2
N-20729
N-20729
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Item
Figure 50-30-2
2
N-20655
Figure 50-31-1
1 2
N-20974
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
Figure 50-31-2
N-20973
P10564 P10563
1 1
2 2
1
1 N-18582
Figure 50-31-8
N-18587
Figure 50-31-6
N-18579
Figure 50-31-9
1 1
N-18578
Figure 50-31-10
N-18583
1
1
2
N-18586
1
N-18585
Figure 50-40-3
N-18544
N-18547
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 inches) under each side of the
Figure 50-40-2 1
2
P13099
Remove the pivot pin (Item 1) [Figure 50-40-2] from the Remove the Bob-Tach from the lift arms.
tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Figure 50-40-5
1
1
N-18560
Use the following procedure to remove and install the Figure 50-40-8
Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
Figure 50-40-6
1
3
2
1
N-18561
Use a punch and hammer, remove the roll pin (Item 1) Installation: Tighten the nut to 25-28 ft.-lb. (34-38 N•m)
[Figure 50-40-6] from the Bob-Tach Wedge and spring torque.
clevis.
Figure 50-40-9
2 4 2 1
3
N-18557
N-20625
Remove the Bob-Tach. (See Removal And Installation on
Page 50-40- 1.)
If the bolt (Item 1) [Figure 50-40-9], handle pivot (Item 2)
[Figure 50-40-9], spring (Item 3) [Figure 50-40-9], or Use a seal pick to remove seal (Item 1) [Figure 50-40-
Figure 50-40-10
N-18563
Figure 50-41-1 1
2 3
1
N-18545
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 inches) under each side of the
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
N-18547
Figure 50-41-4
1
N-18559
Use a punch to drive the pivot pin and cap (Item 1) Figure 50-41-7
[Figure 50-41-4] out of the Bob-Tach frame.
N-18560
N-21401
Figure 50-41-8
4
1
2 1
3
3 2
4
N-20625
5
If the bolt (Item 1) [Figure 50-41-9], handle pivot (Item 2)
N-21401 [Figure 50-41-9], spring (Item 3) [Figure 50-41-9], or
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
Remove the washers and bolts (Item 1) [Figure 50-41-
8]. Remove the bolt and replace the damaged parts as
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
N-18563
Figure 50-41-11
2 1
N-18557
Figure 50-50-1
N-18850
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.
Figure 50-50-2
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-4].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Figure 50-50-5
1
P-34136
Figure 50-50-8
N-18793
N-18851
Remove the tilt port block mounting bolt (Item 1) [Figure
50-50-6] under the step.
Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-8].
Figure 50-50-9
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
N-18806 pin (Item 1) [Figure 50-50-11] (both sides).
Use a drift pin and hammer remove the lift arm pivot pin
(Item 2) [Figure 50-50-9] (both sides).
Figure 50-50-10
P-31972
Figure 50-50-14
P-31971
Figure 50-50-13
N-18806
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 50-50-14] (both sides).
P-31970
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. 1
• Engine is running.
• Tools are being used.
W-2019-1285
P-31975
Figure 50-50-15
Open the rear door.
Use a drift pin and hammer, remove the lift arm pivot pin
P-31969
N-18851
P-31968
1
Figure 50-60-1
N-19336 N-19337
N-19207
N-19216
N-19218
N-19215
P-34606
1
Remove the top and bottom door hinge mounting bolts
P-24792 (Item 1) [Figure 50-70-3] and nuts.
P-34588
Figure 50-70-4
WARNING
AVOID INJURY OR DEATH
1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of the mounting
holes.
Figure 50-70-7
1
P-31128
Figure 50-70-8
1
P-31127
P-28143
Installation: Tighten the cover mounting bolts to 190-240 Installation: Tighten the battery holder mounting bolts to
in.-lb. (21,5-27 N•m) torque. 190-240 in.-lb. (21,5-27 N•m) torque.
Figure 50-80-4
1 1
P1619
Drain the fuel from the tank through the fuel drain (Item 1)
P-28144
[Figure 50-80-2].
2
1
P13876
P13874
Lift the fuel tank up and remove the tank from the loader
[Figure 50-80-5].
1 P13875
P13870
Turn the fuel level sender out and remove it from the fuel
tank. Check the fuel level sender for damage and replace
if necessary.
Figure 50-80-9
P13873
1
P13872
Figure 50-90-1 1
P-34375
WARNING P-34260
Never work on a machine with the lift arms up unless Remove the hairpin clip and cross-pin (Item 1) [Figure
the lift arms are secured by an approved lift arm 50-90-4] from the control valve lift spool.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the crossbar from the control valve.
to fall and cause injury or death.
W-2059-0598 Figure 50-90-5
Figure 50-90-3
2
1
1
P-34376
P-34257
Figure 50-90-6
1 1
P-34258
P-34257
Remove the hairpin clip and cross-pin (Item 1) [Figure
50-90-8] from the control valve tilt spool.
Remove the bolt and nut (Item 1) [Figure 50-90-6] to
disconnect the lift foot pedal linkage from the crossbar Figure 50-90-9
Figure 50-90-7
P-26008
Remove the bolt and nut (Item 1) [Figure 50-90-7] to Installation: Tighten the bolt and nut to 21-25 ft.-lb. (28-
disconnect the lift foot pedal. 34 N•m) torque.
Figure 50-91-1
2 1
P-21936
P-21927
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6
Figure 50-91-7
P-21931
Figure 50-91-8
2
3
1
P-21932
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 50-100-2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 2 2
1 1
2
1 3 P-34166
Figure 50-100-3
1
2 1
1
1
P-34363
Figure 50-100-6
P-26323
Figure 50-100-4
N-19390
Remove the fuse/relay block [Figure 50-100-4]. Reverse the removal procedure to install the control
panel.
Figure 50-100-7
1 3
3 2
1
P-4146
Remove the mounting nut (Item 1) [Figure 50-100-7] Remove the steering shaft pivot bolt (Item 2) [Figure 50-
from the end of the shock connected to the steering 100-8] from both sides of the control panel.
Installation: Tighten the mounting bolts to 25-28 ft.-lb. Shaft Disassembly And Assembly
(34-38 N•m) torque.
Figure 50-100-9
Shaft Removal And Installation
P-4154
1
1
2
3 2
1 P-3736
P-26331
Figure 50-100-11
2 1
P-3729
Figure 50-100-15
5
6
4
1 2
1
3 2 2
2 N-15310 1
Figure 50-100-14
1
2
N-15312
Figure 50-100-16
3
2 1
1
P-34365
Figure 50-100-17 The torsion bushings can now be removed from the
steering bell cranks.
P-3734
Linkage Adjustment
2
WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm
2
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment 1
to fall and cause injury or death.
W-2059-0598 3
P-34365
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.) Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 50-100-20
1
3
P-3723
2
3
4 Move the right side steering lever forward and install a
P-3726 15/16 inch (24 mm) thick spacer (Item 1) [Figure 50-100-
22] between the center plate (Item 2) [Figure 50-100-22]
and the mounting plate (Item 3) [Figure 50-100-22].
Loosen the nut (Item 1) [Figure 50-100-20] 3 to 4 turns,
then loosen the bolt (Item 2) [Figure 50-100-20]. The bolt This will allow the pintle arms to move freely while
4
2
1
3
3 4
1 2
P-3724 P-3730
Move the right side steering lever to the rear and install a Before adjusting the linkage, check that the pintle arm
3/8 inch (10 mm) thick spacer (Item 1) [Figure 50-100- mounting bolt (Item 1) [Figure 50-100-23] is tight, 25-28
21] between the pintle arm cam (Item 2) [Figure 50-100- ft.-lb. (34-38 N•m) torque and that there is no play
21] and the centering block (Item 3) [Figure 50-100-21]. between the pintle arm (Item 2) [Figure 50-100-23] and
the square pump shaft (Item 3) [Figure 50-100-23]. Also
check that the cam mounting bolts (Item 4) [Figure 50-
100-23] are tight, 45-50 ft.-lb. (62-68 N•m) torque.
1
1
P-3727 P-3723
Loosen the two bolts and nuts (Item 1) [Figure 50-100- Remove the spacer (Item 1) [Figure 50-100-26].
24] on each steering linkage bar.
P-3728
WARNING P-3731
2
3
4
P-3726
P-3725
Loosen the nut (Item 1) [Figure 50-100-27] a couple of
turns, then loosen the bolt (Item 2) [Figure 50-100-27].
The bolt (Item 2) [Figure 50-100-27] is threaded into the Adjust the left centering block first [Figure 50-100-29].
linkage bars (Items 3 & 4) [Figure 50-100-27].
Figure 50-100-30
P-3732
NOTE: If the centering blocks are worn, they can be Stop the engine.
removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.
Figure 50-100-32
2
3
4
P-3726
Figure 50-100-33
P-34365
Figure 50-110-1
2 2
N-18884
1
P-34362
To replace the rubber boot (Item 1) [Figure 50-110-2] on
the control panel, remove the control lever (See above
Disconnect the electrical connectors from the control procedure).
lever [Figure 50-110-1].
Components Identification
Figure 50-111-1 1
P-24909
P16572
Figure 50-111-3
1
2
P-24910
1
Figure 50-111-6
To remove the handle sensor, slide the rubber handle
Figure 50-111-4
2
1
2
1
P-24911
Figure 50-111-7
1 1
P-24913
Figure 50-111-10
Using an allen wrench, remove one of the two mounting
Figure 50-111-8
P-21880
2
Remove one of the two mounting screws (Item 1) [Figure
50-111-10] from the handle sensor.
1
Installation: Tighten bolt to 32-38 in.-lb. (3,6-4,3 N•m)
torque.
P-24915
Figure 50-111-11
3 1
1
3
4
3 P-24909
2
Remove the handle sensor (Item 1) [Figure 50-111-13].
P-24918 (See Handle Sensor Removal And Installation on Page
50-111- 2.)
Remove the handle sensor (Item 1) [Figure 50-111-11]
1
P16534
P-24909
Figure 50-111-15
2
1
N-17394
2 2
N-22796
N-17385
Figure 50-111-19
18.25”
1
1
1
B-16618
1
N-22658
Figure 50-111-22
2
2
1
1
N-22659
Components Identification
Figure 50-112-1
1
1
P-21879
P16572
Figure 50-112-3
P-21836
1
Figure 50-112-4
P-21861
1
Remove the handle sensor connector (Item 1) [Figure
50-112-6] from the clip.
NOTE: Pry out with a small screw driver and push the
P-21837 connector down.
Figure 50-112-7
P-21863
1
Remove the top mounting bolt (Item 1) [Figure 50-112-9]
P-21860 from the handle sensor.
1
7
3
5 1
2
4
8
4
3 3
5 6
1 2
P-21791
P-21862
Figure 50-112-11 3
2
P-21878
1
Figure 50-112-14
P-21880
Figure 50-112-12
4 1
3 8
1 P-21799
N-17384
1
Remove the rubber handle cover (Item 1) [Figure 50-
112-17] from the handle.
2 2
N-17385
N-22667
2
1
Disconnect the electrical connectors (Item 1) [Figure 50-
N-17394 112-21] from the control lever switch handle.
Figure 50-112-20
N-22796
Figure 50-112-22
2
1
1
P13734
Figure 50-112-25
18.25”
B-16618
1
nuts.
To replace the rubber boot (Item 1) [Figure 50-112-25]
Installation: Tighten the u-bolts so the lever can not be
on the control panel, remove the control lever. (See
moved either right or left when seated in the operator
Control Lever Removal And Installation on Page 50-110-
seat. Control lever end (Item 2) [Figure 50-112-22]
1.)
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Drill out the four rivets (Item 2) [Figure 50-112-25]
raising the cab. The distance between handles should be
located on the flange of the rubber boot and remove the
18.25 inches [Figure 50-112-23].
old boot.
Remove the control lever from the cross shaft and control
Install the new boot and reinstall the control lever. (See
panel.
Control Lever Removal And Installation on Page 50-110-
1.)
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
2910 G GROUND
C414
(Without ACS Option)
B A A B 4440 A A 7.5 ohm
9110 H SYSTEM Tx
12V
WHITE TIE STRAP 2440 B B
2750
6110
6120
2760
9210 K SYSTEM Rx TILT SPOOL LOCK
H H (NOT Used With AHC or ACS)
SEE FUSE/RELAY 9300 A CLOCK/LATCH
C421
S175 (S/N 517625001 - 517625419)
C407
CENTER
J J A A 4370 DIVERTER
9310 B DATA
C416
7.7 ohm
RED = RED (EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
WIRES CONNECT BY
(S/N 518115001 - 518115246) RNG = ORANGE
BLK = BLACK LETTER ACROSS
LIGHTING)
THIS PAGE
2900 M M 2900
9330
9320
J
C
START
BUZZER LIFT SPOOL LOCK
YELLOW TIE STRAP 2450 B B 12V
C422
DBL = DARK BLUE 9200 D D 9200 A A 4380 FRONT AUX RELIEF
7.7 ohm
LGN = LIGHT GREEN 9320 +
(S/N 519215001 - 519215072)
C424
B A 9100 E E 9100 BUZZER PWM B B 2380 4490 A A
DGN = DARK GREEN
- 11 ohm
C408
SEE CONTROL 2930
12V
YEL = YELLOW B 4500 F F 4500 1930 RIGHT PANEL 2490 B B
SOME CONNECTOR
(PRINTED JUNE 2002) PNK = PINK
WHT = WHITE BODIES NOT SHOWN
MODULE J4
THIS PAGE 2740 S S 2740 2770
BRAKE
SWITCH BICS HYDRAULIC
9330 J START
FOR DRAWING CLARITY
V-0167 BRN = BROWN
TAN = TAN
1900 P P 1900
9310 B DATA
LOCK REAR AUX RELIEF
C417
C420
PUR = PURPLE 1200 R R 1200 9.7 ohm A A 4410 4480 A A 9.8 ohm
9300 A CLOCK/LATCH GREEN TIE STRAP
BATTERY FEED 1000-1999 RED, RED/WHT, RNG B SEAT BAR 9120 H SYSTEM Tx
2530 GROUND 2000-2999 BLK 3920 G G 3920 FRONT ROD HIGH FLOW / 900 LOAD SENSE
GROUNDS SENSOR 1920 F COMPUTER POWER
C418
C415
MONITORING 3000-3999 LBL 3910 K K A A A 4330 4460 A A
2480 3910 3.3 ohm 7.5 ohm
HYDRAULIC 4000-4999 LGN 1220 E PROTECTED POWER PWM 12V
2460 ATTACHMENT CONTROLS 5000-5999 YEL N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
LIGHTS 6000-6999 PNK
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 ACCESSORIES 7000-7999 WHT 2930
MAIN 2920 G GROUND
2440 2400 ENGINE 8000-8999 TAN 2770 CAB 2000 FRONT BASE
COMMUNICATION 9000-9999 PUR FRAME C OPEN
2750 2740
C419
2430 2760 3.3 ohm A A 4340
B3
D3
D2
D1
A1
A2
A3
C3
C2
C1
B2
B1
E3
E1
E2
F2
F3
F1
2330
C441
2520 4350 A FOR
J2 WHITE FUTURE
C406
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2350 B USE
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITIONING
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM Rx OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
C405
WHITE
2 2
HIGH FLOW /
A A 3700 3700 E2 K2
REAR AUX
DIVERTER
2420 B B
RELIEF
4460
2380 2390
4470
AIR FILTER 9350 9200 3910
3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
OPEN
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN
GROUND
F3 4360
2370 D C
F3 E3 B3 A3
3 3 G2 4430
TWO SPEED
+
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
A 2900 9340 3920
4350
4420
4410
3910
H3
H2
H1
A A 3400 3400 C1 G1 4440
C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450
REAR BASE
REAR ROD
0.5 - 7.5 V B
4200
4430
4440
B B 3410 D3 J3
RESERVED
G3
G2
G1
4470
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
(hall)
F3
F2
F1
2800
HYDRAULIC
CONTROL MODULE J1 4460
C112 C108
TEMPERATURE
FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3
FILTER SIGNAL
4350
HYD CHARGE
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
SENDER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
3430
E3
E2
E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
ENG OIL
ENG OIL
A
J4
A E3
3520
3430 3430 3430
OPEN
3500
C2 4830
D3
D2
D1
HYDRAULIC OIL FILTER
J1 BLACK
2110 (DIFFERENTIAL) SWITCH B B SEE LEFT B2 4820
PWM SIGNAL
HANDLE
PWM +
4300
DIFFERENTIAL SWITCH HARNESS 6728626
PWM -
C A3
4310
4640
4320
A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
D1
RH SKI UP
ENGINE OIL 3500 3500
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A A A3 4500 B
C107
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 PRESSURE THIS PAGE
C3
C2
C1
C 3520 3520 D2 SEE
SENDER - C C D1 4940
2710 B CONTROL
0.5-7.5 V B 3510 C1
RH SKI DOWN
4930
LH SKI DOWN
B
FUEL SENDER
EHC INPUT
HYDRAULIC
2350 SPARE ACCESSORY UNSWITCHED
MODULE
9400
3300
3100
SIGNAL
4830
4930
3200
C3
C2
C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
B1 4920
J1 THIS
C106
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
SPEED A A 3600 3600 E1 A1 4910 PAGE
8800 1110
LH AUX LEFT
9500 8000 8250 8210
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
SENSOR
HANDLE
B B
4640
ATTACHMENT BRAKE PULL
SPARE
SPARE
REAR WKLT BRAKE PULL UNSWITCHED
3610
FLOAT
4820
4920
1400
OUT
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
C
J3
C3 K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
ENGINE HARNESS 6729973
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
A3
A2
A1
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104
C113
4220
COOLANT A A 3200 B B 3200 3200 B2 D3 9410
180
SENDER BLAC
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
A A
4930
B B 3210 1800 G3 4200
500-3000 ohm 0
K
H3
H1
D3
D1
C1
C3
C2
B2
B3
D2
A3
A2
A1
H2
K1
K2
K3
G1
G2
G3
B1
E3
E1
E2
F3
F2
F1
J1
J2
J3
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110
B B E H J A F G B C K D
4730
4110
FUEL B D C G F E K J H A
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
A A 1800 SHUTOFF
B
EXCITATION
WHT/LGN
YEL/RED
YEL/LGN
WHT/RED
HOLD
WHT/BLK
A A 8800
DBL
2010 10.9 ohm
C101
DGN
WHT
RNG
Dealer Copy -- Not for Resale
YEL
RNG
LGN
WHT
1010 C C 2800
STARTER
PULL
9410
9400
(ACCESSORY E 6400
CONNECTOR) A HOLD 10.9 ohm
C425
6500 4200 A
D
6600 SEE CAB GLOW PLUGS 2200 C C
RNG/WHT
G B A
RNG/DBL
CONNECTOR
C404
0.4 ohm B
BRN
DGN
4100
YEL
C 7100 A TO OPTIONS THIS PAGE
B PULL 0.3 ohm
B (BACKUP C473
ALARM SWITCH) C407 B A
HR
A
J 2730 ACS E B A D D B A
9420
9420
P JUMPER
8500
6600
C411 C412
6000
M 6500
TO OPTIONS TO OPTIONS
L 6400 (ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
D 4235
N 6300
C488
TO OPTIONS C 4275
(ACCESSORY E 4550
CONNECTOR)
S 1700
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11
25A
8000
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
4275
B 2720 SWITCHED MARKER REAR GLOW FUEL TRACTION
LIGHT LIGHT PLUG STARTER PULL P
(COMPUTER)
A 1720 1720 POWER LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A N
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1710
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D
C492
(HEATER R
) 1 FUSE 2 120 (ACS CONNECTOR)
FUSE FUSE 3 FUSE 6 FUSE 5 S
15A 15A 30A 30A OHM
25A
RESISTOR
J
MAINFRAME HARNESS 6729974 1140
9520 C
1150 1160 G
1070 2240 H
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12 1740 B
ARE CONNECTED IN SERIES 25A 25A
1080
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040
30A 15A 25A
FUSE 7 FUSE 3 FUSE 11
REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR
Printed in U.S.A.
1040 V-0167 (5-29-02)
BATTERY 1080
406 of 725
LEFT RIGHT LEFT PANEL REAR ROD
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
2910 G GROUND
12V
BROWN TIE STRAP 2430 B B
9340 D HEADLIGHTS
B A A B
C414
B A A B 4440 A A 7.5 ohm
9110 H SYSTEM Tx
12V
RED = RED
WHITE TIE STRAP 2440 B B
2750
6110
6120
(With ACS Option)
2760
WIRES CONNECT BY 9210 K SYSTEM Rx TILT SPOOL LOCK
RNG = ORANGE H H (NOT Used With AHC or ACS)
BLK = BLACK LETTER ACROSS SEE FUSE/RELAY 9300 A CLOCK/LATCH
C421
C407
LBL = LIGHT BLUE CONNECTORS CENTER
J J A A 4370 DIVERTER
9310 B DATA
C416
A B 7.7 ohm
DBL = DARK BLUE (EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
S175 (S/N 517625001 - 517625419) LGN = LIGHT GREEN
DGN = DARK GREEN
B A LIGHTING)
THIS PAGE
2900 M M 2900
9330
9320
J
C
START
BUZZER LIFT SPOOL LOCK
YELLOW TIE STRAP 2450 B B 12V
C422
WHT = WHITE BODIES NOT SHOWN 9200 D D 9200 7.7 ohm A A 4380 FRONT AUX RELIEF
9320
S185 (S/N 519028001 - 519029062) +
C424
BRN = BROWN FOR DRAWING CLARITY 9100 E E 9100 BUZZER PWM B B 2380 4490 A A
- 11 ohm
C408
TAN = TAN SEE CONTROL 2930
12V
B 4500 F F 4500 1930 RIGHT PANEL 2490 B B
(S/N 519215001 - 519215072) PUR = PURPLE
GRY = GRAY
MODULE J4
THIS PAGE 2740 S S 2740 2770
BRAKE
SWITCH 9330 J START BICS HYDRAULIC
Printable Version Click Here (PRINTED JUNE 2002) BATTERY FEED 1000-1999 RED, RED/WHT, RNG
1900 P P 1900
9310 B DATA
LOCK REAR AUX RELIEF
C417
C420
GROUND 2000-2999 BLK 1200 R R 1200 9.7 ohm A A 4410 4480 A A 9.8 ohm
V-0177 MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
9350 B B 9350
9300
9220
A
K
CLOCK/LATCH
SYSTEM Rx
12V B B 2410
GREEN TIE STRAP
2480 B B 12V
3900 C
ATTACHMENT CONTROLS 5000-5999 YEL L L 3900
LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx
2530 3920 G G 3920 FRONT ROD HIGH FLOW / 900 LOAD SENSE
GROUNDS ACCESSORIES 7000-7999 WHT SENSOR 1920 F COMPUTER POWER
C418
C415
ENGINE 8000-8999 TAN 3910 K K A A A 4330 4460 A A
2480 3910 3.3 ohm 7.5 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM 12V
2460 N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
2750 2740
C419
2430 2760 3.3 ohm A A 4340
B3
D3
D2
D1
A1
A2
A3
C3
C2
C1
B2
B1
E3
E1
E2
F2
F3
F1
2330
C441
2520 4350 A FOR
J2 WHITE FUTURE
C406
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2350 B USE
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITIONING
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM Rx OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
C405
WHITE
2 2
HIGH FLOW /
A A 3700 3700 E2 K2
REAR AUX
DIVERTER
2420 B B
RELIEF
4460
2380 2390
4470
AIR FILTER 9350 9200 3910
3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
OPEN
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN
GROUND
F3 4360
2370 D C
F3 E3 B3 A3
3 3 G2 4430
TWO SPEED
+
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
A 2900 9340 3920
4350
4420
4410
3910
H3
H2
H1
A A 3400 3400 C1 G1 4440
C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450
REAR BASE
REAR ROD
0.5 - 7.5 V B
4200
4430
4440
B B 3410 D3 J3
RESERVED
G3
G2
G1
4470
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
(hall)
F3
F2
F1
2800
HYDRAULIC
CONTROL MODULE J1 4460
C112 C108
TEMPERATURE
FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3
FILTER SIGNAL
4350
HYD CHARGE
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
SENDER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
3430
E3
E2
E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
ENG OIL
ENG OIL
A
J4
A E3
3520
3430 3430 3430
OPEN
3500
C2 4830
D3
D2
D1
HYDRAULIC OIL FILTER
J1 BLACK
2110 (DIFFERENTIAL) SWITCH B B SEE LEFT B2 4820
PWM SIGNAL
HANDLE
PWM +
4300
DIFFERENTIAL SWITCH HARNESS 6728626
PWM -
C A3
4310
4640
4320
A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
D1
RH SKI UP
ENGINE OIL 3500 3500
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A A A3 4500 B
C107
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 PRESSURE THIS PAGE
C3
C2
C1
C 3520 3520 D2 SEE
SENDER - C C D1 4940
2710 B CONTROL
0.5-7.5 V B 3510 C1
RH SKI DOWN
4930
LH SKI DOWN
B
FUEL SENDER
EHC INPUT
HYDRAULIC
2350 SPARE ACCESSORY UNSWITCHED
MODULE
9400
3300
3100
SIGNAL
4830
4930
3200
C3
C2
C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
B1 4920
J1 THIS
C106
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
SPEED A A 3600 3600 E1 A1 4910 PAGE
8800 1110
LH AUX LEFT
9500 8000 8250 8210
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
SENSOR
HANDLE
B B
4640
ATTACHMENT BRAKE PULL
SPARE
SPARE
REAR WKLT BRAKE PULL UNSWITCHED
3610
FLOAT
4820
4920
1400
OUT
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
C
J3
C3 K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
ENGINE HARNESS 6729973
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
A3
A2
A1
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104
C113
4220
COOLANT A A 3200 B B 3200 3200 B2 D3 9410
180
SENDER BLAC
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
A A
4930
B B 3210 1800 G3 4200
500-3000 ohm 0
K
H3
H1
D3
D1
C1
C3
C2
B2
B3
D2
A3
A2
A1
H2
K1
K2
K3
G1
G2
G3
B1
E3
E1
E2
F3
F2
F1
J1
J2
J3
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110
B B E H J A F G B C K D
4730
4110
FUEL
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
B D C F E J H A G K
A A 1800 SHUTOFF
B
EXCITATION
WHT/LGN
RNG/BLK
RNG/BLK
YEL/RED
HOLD
WHT/RED
WHT/BLK
YEL/RED
10.9 ohm A A 8800
PNK
TAN
DBL
2010
C101
DGN
WHT
RNG
Dealer Copy -- Not for Resale
PUR
RNG
LGN
YEL
WHT
1010 C C 2800
STARTER
PULL
8250 B B 8250
BATTERY CABLE
S PWM C466 C465
B 8200 A A 8200 RIGHT 1 3 2 2 1 3
SKI SIDE
ROCKER SKI FLOAT
UP DETENTCTRL SHIFT CTRL
FLOW
HANDLE HANDLE
F RIGHT HANDLE LOCK LOCK LEFT HANDLE
B 2600 AHC LIFT
AHC TILT TURN HORN
H 6200 HALL HALL SIGNAL
C103
SENSOR SENSOR
TO OPTIONS A 6310 TRACTION LOCK
9410
9400
(ACCESSORY E 6400
CONNECTOR) HOLD 10.9 ohm
RED/WHT
PUR/WHT
RED/WHT
PUR/WHT
A
C425
4200
BLK/WHT
BLK/WHT
DD 6500 A
G 6600 SEE CAB GLOW PLUGS 2200 C C
G B A
CONNECTOR
C404
0.4 ohm
BRN
DGN
YEL
CC 7100 A TO OPTIONS 4100 B B PULL 0.3 ohm
THIS PAGE
C473
RED
(BACKUP
BLK
B
ALARM SWITCH) C407 B A 1 3 2 1 3 2
HR C450 C449
A
2730 J J 2730 1 3 2 1 3 2 E B A D D B A
ACS
9420
9420
6600 P P JUMPER
8500
6600
C411 C412
6000
6500 M M 6500 A C B A C B
TO OPTIONS TO OPTIONS
6400 L L 6400 C469 C472 (ACCESSORY (ACCESSORY
4730 F F 4730 A C B A C B CONNECTOR) CONNECTOR)
hand 4
4235 4235 D D 4235
1510
4650
2650
1610
4750
2750
6300 N N 6300 13 ohm 13 ohm
at 12V at 12V
5
C488
4270
2500
K
4280
2510
K (ALTERNATOR
DGN
DGN
RED
RED
RED
RED
& KITS)
BLK
BLK
BLK
BLK
1800
FUSE 11
25A
8000
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
(COMPUTER)
A 1720 1720 POWER LOCK
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A N N
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
4790
4780
1630
4770
2770
4690
4680
1530
4670
2670
CONNECTOR) 25A 9720 E E
1710
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D D
C492
(HEATER R R
) 1 FUSE 2 120
FUSE FUSE 3 FUSE 6 FUSE 5 S S
15A 15A 30A 30A OHM
25A
RESISTOR
J J
MAINFRAME HARNESS 6729974 1140
9520 C C
2270
2260
4260
4220
4780
4690
4680
1190
4790
1180
1150 1160 G G
1070 2240 H H
RELAY GROUNDS 2000-2060 FUSE 9 C B G E J K A H D F
FUSE 12 1740 B B
ARE CONNECTED IN SERIES 25A 25A
1080
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040 2240 2280 H
30A 15A 25A 1740 B
FUSE 7 FUSE 3 FUSE 11
J2
1500 A
REAR LT ALT & KITS
ACS HARNESS - BLACK
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER 6726925 OR A G B K C J D F H E
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300 F E D A B C G 6733292 (6726925 Shown,
1060
See Schematic - S/N & Above
100A
1010 1030
C426 TO OPTIONS
(ATTACHMENT
for 6733292)
ACD & REMOTE CONTROL)
2760
2660
4760
1620
4660
1520
1310 START CONNECTOR TILT LIFT
PEDAL PEDAL
1040
Printed in U.S.A. 2 2 1 1
C470
C471
BATTERY 1080
3 3 3 3
V-0177 (5-29-02)
1 1 2 2
407 of 725
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
B B 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
PWM
WIRING SCHEMATIC
6733137 REAR BASE 2380 2 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
A A 4440
G
C
D
E
B
A
K
E
F
J
7.5 ohm
C415
12V
C420
7.5 ohm A A A A 4460 B B 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B 2 2
S175 (S/N 517625420 AND ABOVE) ACROSS CONNECTORS
2420 2330 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
(S/N 518115247 AND ABOVE) B A
2340 2 2 PWM
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(S/N 519215073 AND ABOVE)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY HYDRAULIC
Printable Version Click Here (PRINTED JUNE 2002) 3300 A A TEMPERATURE
SWITCH
SENDER
BRAKE
FRONT AUX RELIEF 3310 B B
V-0175
1930
RED = RED 500-3000 ohm
2000
C424
RNG = ORANGE 4490 A A 11 ohm
BLK = BLACK GREEN TIE 12V
C435
2490 B B
RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG REAR AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND REAR SPARE SYSTEM LH AUX SPARE AIR FILTER RH FRONT
3010 23
SERIAL IN BASE ANALOG 2 POWER Rx LEFT DIGITAL 1 SIGNAL
PWM - DETENT
9400 F See C492
B B 3410 23
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
2410 REAR STATUS LH SKI FUEL PWM RH SKI
SEE J2 FRONT COMPUTER SEAT BAR
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
BASE ROD IN DOWN SENDER DOWN
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 3 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
2240 4420 9350 3910 4840 2110
8
4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 6729973 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm A A 8800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
2520
4240
1010
STARTER 0.3 ohm
C
B
C
B
2800
8100
Dealer Copy -- Not for Resale
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B PULL 0.3 ohm
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 6731977 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040
G
-
D
C
E
A
B
1300
F
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE
1310 START CONNECTOR V-0175 (5-23-02)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
408 of 725
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
B B 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
WIRING SCHEMATIC
6733137 REAR BASE 2380 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
A A 4440
G
C
D
E
A
K
E
F
7.5 ohm
C415
12V
C420
7.5 ohm A A A A 4460 B B 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B 2 2
S175 (S/N 517625420 AND ABOVE) ACROSS CONNECTORS
2420 2330 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
(S/N 518115247 AND ABOVE) B A
2340 2 2 PWM
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(S/N 519215073 AND ABOVE)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY HYDRAULIC
SWITCH
SENDER
BRAKE
FRONT AUX RELIEF 3310 B B
V-0176
1930
RED = RED 500-3000 ohm
2000
C424
RNG = ORANGE 4490 A A 11 ohm
BLK = BLACK GREEN TIE 12V
C435
2490 B B
RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG REAR AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
2410 REAR STATUS LH SKI FUEL PWM RH SKI
SEE J2 FRONT COMPUTER SEAT BAR
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
BASE ROD IN DOWN SENDER DOWN
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 3 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
2240 4420 9350 3910 4840 2110
8
4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 6729973 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm A A 8800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
2520
4240
1010
STARTER 0.3 ohm
C
B
C
B
2800
8100
Dealer Copy -- Not for Resale
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
TO OPTIONS C465 C466
GLOW PLUGS 4100 B B PULL 0.3 ohm
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
C 7100 A TO OPTIONS C450
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
2730 J J 2730
C411
B
C
C412
A
6600 P P 6600 C469
6000
6500 M M 6500 C472
A
C
B
TO OPTIONS TO OPTIONS
C
B
A
6400 L L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
4730 F F 4730 CONNECTOR) CONNECTOR)
1510
4650
hand 4
2650
4235 4235 D D 4235
C488
BLK
1150
DGN
1700 1150 H H
RED
f A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
2 4550 R R
C467 C468
1 B B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
K (ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
FUSE 1 FUSE 3 FUSE 6
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
MAINFRAME HARNESS 6731977 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0176 (5-28-02)
BATTERY
409 of 725
WIRING SCHEMATIC
OPTIONS TO ENGINE OR MAINFRAME AIR CONDITIONER SWITCH
THERMOSTAT
S175 (S/N 517625001 AND ABOVE) 7100 C 3100 A A
C630
2650 F
(S/N 518115001 AND ABOVE)
C612
OFF A 7010 B B
C103
6600 G
S185 (S/N 519028001 AND ABOVE) LOW
2100
B 2310 2205 C C
6400 E MEDIUM
(S/N 519215001 AND ABOVE) BACK-UP
ALARM 6310 A
TO OPTIONS (AC)
HIGH
(PRINTED JUNE 2002) 6500 D
V-0168 6200 H HERE OR TO OPTIONS
(HVAC JUMPER) HEATER VALVE
2600 B
DBL A A 3200 1300 A A RED 10
C613
Printable Version Click Here WHT B B 7200 D D WHT 8 M
6340
C614
2620
7000
2610
6610
6320
6620
6330
2640
C BLK C C 2110 2130 C C BLK 7
1110
POTENTIOMETER B B
B E E
2630 6210 1000
E F C A B D F E D C B A F F 7 pin Octal ACD/Remote
C604 C605 Start connector Left Side
E F C A B D F E D C B A
REGISTRATION
LAMP
LEFT WORK RIGHT WORK L 5000 3 3 YEL BLOWER MOTOR engine compartment
SSL 7-PIN
C426 To Mainframe
Kit DL Attach
Control -
M Harness
1200 2 2 RED CAN CONNECTOR D F C E A B G 6719431
C611
H 1010 1 1 RNG M
Controller
2200 4 4 BLK
DELUXE EUROPEAN BLOWER SWITCH POWER RELAY
DLX ACD W/Mag.
9800
1160
9700
1710
9500
9600
2710
TO OPTIONS 667549
5 5
(DELUXE ACCESSORY) 6675493
TAILLIGHT HARNESS - 6718198 6 6
1740
85 86
2210
LEFT TAILLIGHT RIGHT TAILLIGHT 87 A
C705
C617
30 KEY "RUN" D 9800 J1 - 8-PIN
87A 1190 B Instl DL Atch
UNSW POWER F 1160 2720 H GROUND
HVAC HARNESS - 6725933 2740 C
CAN SHIELD C 9710 9710 F CAN SHIELD
Control 6719450
9800
1160
9700
1710
9500
9600
2710
PNK/
C432
C450
A 1 1 RED BOOM-MOUNTED
TILT N
To C 3 3 PNK/DGN ACD CONNECTORS
CONTROL
KEY "RUN" D 9800 C705 J1 - 8-PIN
Mainframe
B 2 2 PNK/BLK
SW POWER K 1740
C409
C666 ATTACHMENT
CONNECTOR G OPEN To
F WHT/LGN SPEED A OUTPUT A 5250 5250 F A OUTPUT Compartment
M OUTPUT M 5200 5200 E B OUTPUT
J Mainframe G
BOOM-MOUNTED DETENT ID (K TO L) L 5910 5000 A J OUTPUT
N E DGN 12
ACD CONNECTORS ID (K TO P) P 5510 5450 K K OUTPUT
SW POWER K 1740 K 11
GROUND B 2740 C703 J2 - 10-PIN BLACK J YEL
SKI
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
E OUTPUT E 5100 5100 C E OUTPUT H LGN CONTROL
Connector CONNECTOR
on Loader 5900 J ID #1
F OUTPUT F 5350 5350 H F OUTPUT A RNG
Boom 5500 A ID #2
G OUTPUT G 5400 5400 J G OUTPUT
B ID #3 ACD
H OUTPUT H 5050 5050 B H OUTPUT
D PUR FLOAT C ID #4 Input
C OUTPUT C 5300 5300 G C OUTPUT SIGNAL Connector to
J D ID #0
D OUTPUT D 5150 5150 D D OUTPUT Engine
A OUTPUT A 5250 5250 F A OUTPUT
A RNG DELUXE ATTACHMENT E OPEN
Compartment
C WHT SKI F OPEN
M OUTPUT M 5200 5200 E B OUTPUT
CONTROL HARNESS -
C410
B DBL CONTROL G OPEN
ID (K TO L) L 5910 5000 A J OUTPUT To
ID (K TO P) P 5510 5450 K K OUTPUT
Mainframe G
F
PNK
TAN
PADDLE
MOMENTARY
6732730 H OPEN
K OPEN
Rev. none
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
K
CONNECTOR E
5900 J ID #1
H
5500 A ID #2
B ID #3
B BRN
C
C412
F OPEN 2750 B
E 1730 A
G OPEN HORN RELAY
30
7200
C433
A 1 RED/WHT
C490
E 85 86 2740 B
2780 6415
To 3
LIFT
87
C 3 PUR/WHT
CONTROL D 6410 6410 1740 A
Mainframe 30
C411
B 2 2 BLK/WHT 87A 6020 10
C
LEFT HANDLE B 6000
TO 9 TO AWS TO MAINFRAME
C401or
A 6510 B C A
C402
MAINFRAME CONTROLS
RIGHT BLINKER
C489
POWER BOB-TACH C404 2720 B
B RELAY
TO OPTIONS
SOLENOID
7100 A ADVANCED HAND CONTROL 85 86
C497
1720 A
2790 6515
C606
A A
A
D
7000
2760 B B BACK-UP ALARM
(WITH PUSH BUTTON FLOAT) - 6510
87
30
6010
C601
87A
C
SWITCHES
7110
RIGHT STEERING LEVER - 6675742 and
TO
C607
B B B
7010 POWER BOB-TACH
SOLENOID MAINFRAME LEFT STEERING LEVER 6675750 AWS HORN/BLINKER HARNESS - 6726662
C402
C631
C612
B B 2310 2300 B
J
A A 7030 A
N
P
AIR CONDITIONER DIODE
M TO OLDER
FRONT WIPER CLUTCH SOLENOID MODEL ATTACHMENTS
M BOTTLE AND TANK A
C506
D WHT S
REAR LIGHT HARNESS 6716419 TO MAINFRAME C BRN LT
C623
F DOME LIGHT E BLK TM
7020
7010
TO OPTIONS SWITCH
RIGHT
2620 6200 2600 B F DBL CENTER
C608
WORKLIGHT A RED
6210 6200 H G RED GD
LEFT B BLK
2630 6210 6310 A H YEL RT
WORKLIGHT C622 FRONT WIPER
RIGHT
2610 6320
E
L X MOTOR DOME LIGHT B A L RNG
BACKUP
(DELUXE ACCESSORY)
C 7310
6707303
ALARM
B 2735 2755 B B
HARNESS -
C610
C667
STROBE OR
7 pin Octal ACD/Remote BEACON
Start connector Left Side
engine compartment SSL 7-PIN
CAN CONNECTOR LEFT RIGHT ADDITIONAL POWER CONNECTOR
C490
FLASHER FLASHER 1740 A
KEY "RUN" D 9800 D LIGHT LIGHT
2 1
2740 B
UNSW POWER 2 1160 F C609
CAN SHIELD C 9700 C 2 1 TO
1 To Mainframe STROBE/BEACON TO MAINFRAME
SW POWER 1710 E
Harness TO OPTIONS TO OPTIONS (ACCESSORY CONNECTOR)
CAN LOW B 9600 A
2790
2795
C402
6700 E
C668 OR C670
6440 1 A 2720 B
C669
C412
2730 B RNG = ORANGE
CONTROL HARNESS - 6718426 3 6540 B
7200 A
BLK = BLACK LETTER ACROSS
HARNESS - 6718873 LBL = LIGHT BLUE CONNECTORS
EXTERIOR CAB HARNESS - FRONT HORN HARNESS - DBL = DARK BLUE
LGN = LIGHT GREEN
A
B
B
A BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
6718872 6727498
DGN = DARK GREEN
YEL = YELLOW
SOME CONNECTOR
MONITORING 3000-3999 LBL
PNK = PINK HYDRAULIC 4000-4999 LGN
WHT = WHITE BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL
BRN = BROWN FOR DRAWING CLARITY LIGHTS 6000-6999 PNK
TAN = TAN ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
PUR = PURPLE
COMMUNICATION 9000-9999 PUR
GRY = GRAY
V-0168 (5-29-02)
410 of 725
WIRING SCHEMATIC
OPTIONS
S175 (S/N 517625001 AND ABOVE) TO OPTIONS
6676732-6674585 (POWER BOB-TACH)
(S/N 518115001 AND ABOVE) 6557904 POWER BOB-TACH 2770 E
S185 (S/N 519028001 AND ABOVE) FLASHER SWITCH
2760 D
C601
(S/N 519215001 AND ABOVE) 6668816-6665317 1
7000 A
BEACON SWITCH 2
(PRINTED JUNE 2002) C
6 6665316-6668815
V-0169 5 HAZARD SWITCH 3
7010 B
4
2 1
Printable Version Click Here TO LIGHT
3
1130
X L
6010 6430 5
4
CONNECTOR 1180 3
RED = RED TO OPTIONS 1 2
WIRES CONNECT BY 4
6530
6
RNG = ORANGE (EXTERIOR CAB)
LETTER ACROSS 5 2750
BLK = BLACK 6 6676537 (AHC/AFC) TO MAINFRAME
CONNECTORS E 6700
LBL = LIGHT BLUE ACS SWITCH
2755
DBL = DARK BLUE A B D 2780 1
C670
LGN = LIGHT GREEN 4550 E
B A B 6540 2
DGN = DARK GREEN 3 R
YEL = YELLOW F 6440 2745
SOME CONNECTOR 4
PNK = PINK A 2755 4235 D
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
C 6
BRN = BROWN FOR DRAWING CLARITY K
C488
TAN = TAN
PUR = PURPLE G
GRY = GRAY B
2730 J
TO TO
1700 S
MAINFRAME MAINFRAME
6400 L
DIVERTER
C416
C416
YELLOW A YEL A
6500 M TIE
BATTERY FEED 1000-1999 RED, RED/WHT, RNG STRAP B BLK B
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
1150 H
N
RELIEF
HYDRAULIC 4000-4999 LGN P HARNESS -
C417
C417
ATTACHMENT CONTROLS 5000-5999 YEL GREEN A DGN/YEL A
LIGHTS 6000-6999 PNK F TIE
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
A 6710870 STRAP B BLK B
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH 2770 E
BEACON SWITCH V
2745
1
6420
SWITCH Dealer CopyD -- Not for
2760 M Resale
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 4 7220
3 5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670
7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
(FRONT WIPER)
PLUG
6000 B C
C F
E
C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G
B
C488
2730 J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S
V-0169 (5-29-02)
Printed in U.S.A.
411 of 725
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
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
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Description
Figure 60-10-1
P-26323
Figure 60-10-2 The fuse panel cover (Item 1) [Figure 60-10-3] & [Figure
60-10-5] has a decal inside to show the location and amp
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
1
P-13848A
F5 F1 E D C B F9
P-28903
WARNING 1
2
1
P-3873
Installation
Figure 60-20-4
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Figure 60-20-6
P9588
P9590
When installing the battery in the loader, do not touch any Clean the terminals and cable ends as shown in figure
metal parts with the battery terminal posts. [Figure 60-20-4] and [Figure 60-20-5].
Connect and tighten the battery cables. Connect the Check the electrolyte level in the battery. Add distilled
negative (-) cable last to prevent sparks. water as needed.
Install the battery holddown clamp. Put battery saver or grease on the battery terminals and
cable ends to prevent corrosion.
P-31861
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and 3 1
rubber gloves to keep acid off body.
If electrolyte is taken internally drink large quantities Connect the end of the first cable (Item 1) [Figure 60-20-
of water or milk! DO NOT induce vomiting. Get 7] to the positive (+) terminal of the booster battery.
prompt medical attention. Connect the other end of the same cable (Item 2) [Figure
W-2065-0807
60-20-7] to the positive terminal on the loader starter.
WARNING Connect the other end of the same cable (Item 4) [Figure
60-20-7] to the engine.
AVOID INJURY OR DEATH Keep cables away from moving parts. Start the engine.
Keep arcs, sparks flames and lighted tobacco away (See Procedure on Page 10-60-1.)
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-7] first.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before Remove the cable from the positive terminal (Item 2)
connecting to a charger. Unplug charger before [Figure 60-20-7].
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-30-1
2 2
P-24416
1
4
1
3 P-24417
1
P-24543
Figure 60-30-3
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lb. (66 1 1
N•m) of force. 1
2 P-24542
Tighten the adjustment bolt and mounting bolt.
Lower the operator cab. (See Lowering The Operator The black cover has been removed to show alternator
Cab on Page 10-30-3.) rectifier/regulator assembly. The alternator contains field
coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] &
[Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] &
[Figure 60-30-3], and four pair of large power diodes
(Item 1) [Figure 60-30-3] on the underside of the rectifier.
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P-24547
Check the electrolyte level in the battery. Add distilled Turn the engine on with the remote start tool and run at
water as needed. (Does not apply to maintenance free idle. With a voltmeter, check the voltage between the B+
batteries.) terminal and ground at the starter [Figure 60-30-5].
Verify the charge of the battery. Make sure battery is fully The voltage must be higher than 13.5 volts but lower than
charged. 14.7 volts at 70°F (Alternator Temperature).
Disconnect the battery cables (negative first, then If the voltage is higher that 14.7 volts, proceed to the
positive). Inspect the cable clamps and battery posts for following high voltage test.
corrosion. Remove acid or corrosion from the battery
and cables with a sodium bicarbonate and water If the voltage is lower than 13.5 volts, run the engine at
solution. Put grease on the cable ends and battery high idle and recheck voltage. If voltage is still below 13.5
terminals to prevent corrosion. Reconnect the cable to volts, proceed with the following low voltage test.
the positive terminal.
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Below.)
Figure 60-30-6 1
P-24568
1
P-34679 P-34678
P-24547
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] off the alternator. Check the continuity between the "S" terminal (Item
P-34677
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables 2
disconnected.
• Battery cables are connected when using a fast
3
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are P-24543
connected wrong.
I-2023-1285
Remove the adjustment bolt (Item 1) [Figure 60-30-10]
from the mounting bracket.
Figure 60-30-9
Remove the alternator belt (Item 2) [Figure 60-30-10]
from the alternator pulley.
Figure 60-30-11
1
3
2
P-24547
Raise the lift arms and install an approved lift arm support 1
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Figure 60-30-12
1
1
P-24558
1 2
P-24527
1
Touch the probes to the terminals (Item 1) [Figure 60-30-
13] of each diode and read the meter.
P-24533
4 7 13 14
1
12 5
2
11
10
9
P-24535 8
Figure 60-30-18
P-24524
P-24537
Touch the probes to the slip rings [Figure 60-30-20].
Use an ohmmeter to test the stator. The ohmmeter should read between 3.0-4.0 ohms.
Touch the probes to two of the bare stator wires [Figure
Move one of the probes to the third wire. Rotor Ground Test
Figure 60-30-19
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-21].
Assembly
Figure 60-30-22
P-24557
Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-30-22]. Tighten to 72 + 14.5 ft.-lb. (98
+ 20 N•m) torque.
Checking
Figure 60-40-1
2
1
Bat
S
M
Cranking
Motor
P-34673
If the starter turns but does not turn the engine, the
starter drive has a defect. 2
Figure 60-40-2 1
P-34675
1
Bat
S
M
Cranking
P-34674
Motor
Figure 60-40-5
4
2
1
P-34385
Parts Identification
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
32 7*
21
15
14 37
14
6
29
1 4
3
28
2
27
35 25. Holder
26. Bracket
27. Ring
22 26 28. Bolt
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
24 36. Bracket
37. Bearing
Figure 60-40-6
1 2
1
2
1
P-34596
P-34594
Remove the bolts (Item 1) [Figure 60-40-8] from the
brush cover (Item 2) [Figure 60-40-8].
Remove the cable (Item 1) [Figure 60-40-6] from the
magnetic switch. Remove the cover (Item 2) [Figure 60-40-8].
1 2
4
1
3
3
N-00980
NOTE: When separating the parts there will be a steel Remove the brush holder (Item 3) [Figure 60-40-9] from
ball (Item 3) [Figure 60-40-7] located at the end the end of the armature.
of the armature shaft (Item 4) [Figure 60-40-7].
2 P-34600
Figure 60-40-11
3 2
1
1
P-34601
P-34599
Figure 60-40-14
1
3
2
2 2 4
P-34604
Figure 60-40-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Figure 60-40-17
N-00997
Figure 60-40-18
B-14458
Figure 60-40-21
N-00999
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-23
N-15005
S
M.T.
Starter B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a vise. Using a 12 volt battery and
Left Panel 2
1 3
The left instrument panel is the same for both Standard
and the Deluxe Instrument Panels [Figure 60-50-1]. 4 5
4 6 7 8
REF.
NO Description Function / Operation
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER- Records operating hours of loader. CODE DISPLAY- Displays
GLOW PLUG COUNTDOWN numeric SERVICE CODES* relating to the loader monitoring system.
COUNTDOWN- Glow Plug time remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
29
B-15552B
OPT. OR ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
STD. LIGHT
System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
Std. FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure Std. FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range
25 Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature Std. FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature Std. FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter Std. FLASHING 3 Beeps * WARNING Air filter switch not connected.
Figure 60-50-3
1 3
B-16656
4
The first screen you will see on your new loader will be as
6 5 B-15553 shown in [Figure 60-50-4].
Figure 60-50-5
B-16655
Press
ADJUST CONTRAST
Press
UP OR DOWN
Arrow to
change contrast.
Press EXIT to
return to
previous level
menu.
B-16163/B16164/B-16161/B-16166/B-16167
Right Panel Setup Display Options (Deluxe) (Cont’d) TOOL/SETUP [Figure 60-50-8]
Languages
LOADER FEATURES.
TOOL/SETUP
Press MODIFY OWNER DISPLAY OPTIONS
or
MODIFY USER LANGUAGES
TOOL/SETUP
LOADER FEATURES.
VITALS
Press SELECTION ARROW to select METRIC or
ENGLISH (M/E) readouts
B-16163/B16164/B-16171/B-16172/B-16173/B-16174
More EXAMPLES:
3 4 5
POWER
2 6
FRONT
WIPER
WIPER
PLUG
USED
USED
REAR
USED
NOT
NOT
1
NOT
SIDE
CONSOLE
FRONT 12
CENTER 9
11
PANEL POWER TURN SIGNAL
BOB-TACH INDICATORS ROTATING
13 10 BEACON
8
PARKING HAZARD
NOT USED BRAKE LIGHTS
Side Console
Ref.
No. Description Function / Operation
1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED ---
3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for
wiper fluid). Press the bottom of the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of
the switch to provide washer fluid to clean the rear window.
5 NOT USED ---
6 NOT USED ---
Front Center Panel
7 ADVANCED CONTROL
Press the top to select Hand Controls; bottom to select Foot Controls.
SYSTEM (ACS)
8 NOT USED ---
9 TURN SIGNAL
Indicates left or right TURN SIGNALS are ON.
INDICATORS
10 HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn
OFF.
11 ROTATING BEACON Press the left side to turn the ROTATING BEACON ON; right side to
turn OFF.
12 POWER BOB-TACH Press and hold the top side to disengage the Bob-Tach wedges.
Press and hold the down side to engage the wedges into the
mounting frame holes.
13 PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
14 NOT USED ---
Figure 60-50-9
RIGHT N-19353
1
Figure 60-50-12
RIGHT P-21769A
Figure 60-50-10
1
LEFT
N-19351
Remove the front light. (See Front Removal And Remove the panel.
Installation on Page 60-60-1.)
Reverse the removal procedure to install the instrument
Remove the three mounting bolts (Item 1) [Figure 60-50- panel.
9] or [Figure 60-50-10].
Figure 60-50-13
1 1
P-21944
Figure 60-50-14
P-21945
Figure 60-60-1
1 1
N-19351
P-34372
Figure 60-60-5
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
Identification Chart (S/N 517625419 & Below, S/N 519029062 & Below)
TS-01941
Identification Chart (S/N 517625420 & Above, S/N 519029063 & Above)
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller
41 50 41 50
31
J1 40 31 J2 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-172
Identification Chart (S/N 517625420 & Above, S/N 519029063 & Above) (Cont’d)
41 50
J1
1400 8000 X 9800 X X 3420 7200 3520 X
1 2 3 4 5 6 7 8 9 10
V-172
1
1
1
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. S/N 517625419 & Below
W-2059-0598
S/N 519029062 & Below
N-19391
Figure 60-70-1
N-19390
1
1
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Lift and block the rear of the loader. (See LIFTING AND S/N 517625420 & Above
BLOCKING THE LOADER on Page 10-10-1.) S/N 519029063 & Above
P-34842
Figure 60-70-4
P-34843
Service Codes
Figure 60-80-1
B-15551B
Display (Cont'd)
05-09 Hydraulic charge pressure low 18-05 Spool lock solenoid short to battery
11-05 Seat bar sensor short to battery 27-02 Front rod solenoid error ON
11-06 Seat bar sensor short to ground 27-03 Front rod solenoid error OFF
12-21 Front auxiliary PWM switch out of range high 28-02 Diverter solenoid error ON
12-22 Front auxiliary PWM switch out of range low 28-03 Diverter solenoid error OFF
12-23 Front auxiliary PWM switch not calibrated
Display (Cont'd)
34-04 Deluxe not downgraded error 90-02 Service tool output ‘C’ error ON
90-03 Service tool output ‘C’ error ON
36-48 ACD multiple controllers present
91-02 Service tool output ‘D’ error ON
37-02 Two-speed secondary error ON 91-03 Service tool output ‘D’ error OFF
37-03 Two-speed secondary error OFF
92-02 Service tool output ‘E’ error ON
39-04 Left smart grip in error 92-03 Service tool output ‘E’ error OFF
40-04 Right smart grip in error 93-02 Service tool output ‘F’ error ON
93-03 Service tool output ‘F’ error OFF
Inspecting The BICS™ Controller (Engine STOPPED - NOTE: Record what lights are blinking (if any) and
Key ON) number of light flashes. See Troubleshooting
Guide on Page 60-90-4.
Figure 60-90-1
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
N-18409 5. Start the engine and operate at low idle. Press the
PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
AVOID INJURY OR DEATH NOTE: * The TRACTION light on the left instrument
The Bobcat Interlock Control System (BICS) must panel will remain OFF until the engine is
deactivate the lift, tilt and traction drive functions. If it started, the PRESS TO OPERATE LOADER
does not, contact your dealer for service. DO NOT Button is pressed and the parking brake is
modify the system. disengaged.
W-2151-0394
Inspecting The Lift Arm By-Pass Control
1. Sit in the operator's seat. Turn key ON (Standard
Panel), press RUN / ENTER Button (Deluxe Panel, 8. Raise the lift arms 6 feet (2 meters) off the ground.
lower the Seat Bar and disengage the parking brake Stop the engine.
pedal. Press the PRESS TO OPERATE LOADER
Button. Three BICS™ lights (Items 1, 2, & 3) [Figure Turn the lift arm by-pass control knob clockwise 1/4 turn.
60-90-1] [PRESS TO OPERATE LOADER, SEAT Pull up and hold the lift arm by-pass control knob until the
BAR, and LIFT & TILT VALVE] on left instrument lift arms slowly lower.
panel should be ON [Figure 60-90-1].
2. Raise the Seat Bar fully. All four BICS™ lights (Items
1, 2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
LOADER, SEAT BAR, LIFT & TILT VALVE and
TRACTION*] on left instrument panel should be OFF
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.
Troubleshooting Chart
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting guide.(See Troubleshooting Guide on Page 60-90-
4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into
Troubleshooting Guide
2 Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.
3 Control valve Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
can be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.
4 Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward & be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
SEAT BAR 2 LIFT & TILT VALVE 3 TRACTION4 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL1567 to check
sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
Test
Figure 60-100-1
1
P-4698
Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adatper (MEL1567) for the following procedure:
Figure 60-100-2
P-4699
1
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-100-4] should go off.
If the above test fails, there is a problem with the seat bar
N-19558 sensor.
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See BICS™ Circuit Test on Page 60-100-4.)
Figure 60-100-7
1 2
1
3
N-19224
N-19383
Remove the seat bar (Item 1) [Figure 60-100-5] from the
loader. (See Removal And Installation on Page 50-10-1.)
IMPORTANT
3
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
1
Installation: Be sure the tabs on the pivot bushing are
positioned in the slotted hole (Item 1) [Figure 60-100-7]
of the seat bar.
N-19219
Figure 60-100-8 NOTE: The sensor test light (Item 3) [Figure 60-100-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Figure 60-100-10
N-18463
1
Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
1
2
P-4699
P-4703
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of traction lock. 8, 9, 10,
2
P-4712
P-34256
WARNING
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat
Company parts if repair is necessary.
W-2165-0100
Figure 60-110-2
N-19079
Figure 60-110-5
Remove the bracket (Item 1) [Figure 60-110-2] from the
chaincase cover.
1
Figure 60-110-3
P7926
1
Remove and inspect the compression spring (Item 1)
[Figure 60-110-5] and spring cap washer (Item 2)
[Figure 60-110-5] for wear or damage. Replace if
necessary. The spring may also stay with the shaft when
the electric solenoid and bracket are removed from the
chaincase.
Figure 60-110-6
2
3
P-7964
IMPORTANT
Failure to use Loctite® may allow the traction lock
assembly to loosen up which can cause damage to
the traction lock system.
I-2090-1095
Guide Removal
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
WARNING N-19079
Never work on a machine with the lift arms up unless Remove the center chaincase cover [Figure 60-110-7]
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Figure 60-110-8
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 60-110-9
1 P11333
P11330
Apply a bead of polyurethane (P/N 6633583) on the
traction lock guides and bolts [Figure 60-110-11].
To remove the traction lock guides remove the four bolts
(Item 1) [Figure 60-110-9]. Figure 60-110-12
1
3
2
4 4
P11334
2
P11332
Install the electric solenoid/bracket assembly (Item 1)
[Figure 60-110-12] to the center chaincase cover (Item
Thoroughly clean the polyurethane from the chaincase 2) [Figure 60-110-12].
cover (Item 1) [Figure 60-110-10], bolts (Item 2) [Figure
60-110-10] and traction lock guides (Item 3) [Figure 60- NOTE: Bolt (Item 3) [Figure 60-110-12] & [Figure 60-
110-10] and dry. 110-13] represents the rear of the chaincase
cover.
Figure 60-110-13 2
1
INCORRECT CORRECT
1
3
2
P11334
1
Remove the two bolts (Item 1) [Figure 60-110-15] and
N-19106A N-19105A remove the electric solenoid (Item 2) [Figure 60-110-15]
from the center chaincase cover.
Install the traction lock guides (Item 1) [Figure 60-110- Figure 60-110-16
13] to the chaincase cover (Item 2) [Figure 60-110-13]
Figure 60-110-14
1 2
2 N-19079
1
2
N-19109
Figure 60-110-18
1
2
P11341
Components Identification
Figure 60-120-1
11
2 1
P-21767
P-24909
P-21769
Troubleshooting Guide
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature
To see what error occurred, check the service code on the left instrument panel. (See DIAGNOSTICS on Page 60-80-1.)
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
Figure 60-120-5
1
P-24924A
P-21843
Figure 60-120-8
1
2 3
1
1
P13733
11
P13725 P13732
Figure 60-120-11
3 1
2
1
2 1
P13735
1
P13725 P13732
P13725 P13732
Figure 60-120-15 1 2 3 4
1
3
2 N-17772
Figure 60-120-18
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-120-15] and pull the wire from the connector.
1
2 2
N-22783
2
Figure 60-120-19
N-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 The switch handle comes with a 6 inch piece of heat
1) [Figure 60-120-19] from the control lever.
Figure 60-120-20
P-24234
Switch Handle Installation (Cont'd) Install the wires into the connectors as listed below:
Three-Pin Connector
P-21700 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
Figure 60-120-24
1
1
3
2
P13735
N-17779 Left and Right Control Lever Switch Handle [Figure 60-
120-26]
Figure 60-120-25 1-Terminal - Red/White
1
3
N-17772 2
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
Figure 60-120-28
N-18940
Figure 60-120-29
N-18912
Figure 60-120-31
N-17742 N-17741
Figure 60-121-3
1
11
2
P-16536 P-21879
Figure 60-121-2
P-21767
1
Figure 60-121-5
P-21769
Troubleshooting Guide
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature
To see what error occurred, check the service code on the left instrument panel. (See DIAGNOSTICS on Page 60-80-1.)
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
Figure 60-121-6
P-21840
P-21843
Figure 60-121-9
2
3
1
1 P13733
1
1
P13725 P13732
Figure 60-121-12
1
3
2
P13735
1
2
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-121-14] and pull the wire from the connector.
P-21879
Figure 60-121-15
NOTE: Switch handle can be removed and installed
while in loader.
P13725 P13732
P13725 P13732
Figure 60-121-16 1 2
3 4
3 1
2 N-17772
Figure 60-121-19
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-121-16] and pull the wire from the connector.
2 2
N-22783
2
Roll the pistol grip handle cover (Item 1) [Figure 60-121-
N-17779 19] down.
Figure 60-121-20
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 The switch handle comes with a 6 inch piece of heat
1) [Figure 60-121-20] from the control lever.
Figure 60-121-21
P-24234
Switch Handle Installation (Cont'd) Install the wires into the connectors as listed below:
Ten-Pin Connecter
1 A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
P-21700A A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.
2 Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
inches of heat shrink tube (Item 1) [Figure 60-121-24]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
Figure 60-121-25
3 1
2
P13735
3 1
N-17772
2
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
Figure 60-121-29
N-18940
Figure 60-121-30
N-18912
Figure 60-121-32
1
N-17742 N-17741
Figure 60-121-33
P-21878A
1
P-21836 Remove solenoid (Item 1) [Figure 60-121-35] from the
solenoid mount (Item 2) [Figure 60-121-35].
Disconnect the harness connector (Item 1) [Figure 60- Installation: Apply a drop of oil to the solenoid threads
121-33] from the handle sensor connector.
P-21789
1
P-21832
Check the O-ring (Item 1) [Figure 60-121-36] for
damage. Replace as necessary.
Remove the two screws (Item 1) [Figure 60-121-34]
holding the handle lock solenoid to the handle.
Figure 60-121-37
1 3
2
P-21802
1 1
P-21801
Figure 60-121-40
1
B-16627
1
With the seat bar down, turn the ignition key on (keyless
panel choose RUN/ENTER) [Figure 60-121-41] and
P-24182 push the PRESS TO OPERATE button (Item 1) [Figure
60-121-42] to unlock the hand controls.
The new controller uses a calibration sequence to NOTE: Do not start the engine.
optimize the control system. The optimizing ensures full
or
Press RUN/ENTER
B-16626
Figure 60-121-44 NOTE: During the calibration cycle, the system will
beep three times. The calibration process
generates two codes 32-35 (tilt handle not
calibrated) and 32-40 (lift handle not
calibrated). Ignore these two codes, this is
normal during the calibration procedure.
Then Turn Key On
Release the control handles.
or
NOTE: After pushing the PRESS TO OPERATE
button, the handle position does not affect the
Press RUN/ENTER
calibration process.
Calibration is complete.
Turn the ignition key on (keyless panel choose RUN/
1 B-16628
B-16627
With the seat bar down and the ignition key off (keyless
panel power off), fully stroke both control handles in
Push the PRESS TO OPERATE button (Item 1) [Figure
toward the center of the cab and hold the handles there
60-121-45] to begin the calibration.
[Figure 60-121-46].
B-16627
Figure 60-121-49
1
P-24271
1
P-24269 The wire connector (Item 1) [Figure 60-121-51] can be
removed from the sensor wires, using the following
procedure:
Remove the two bolts (Item 1) [Figure 60-121-49] from
the end of the foot sensor.
1
1
4 P-24272 P-24273
P-24273
3
2
Remove the wedge (Item 1) [Figure 60-121-52] from the
connector.
1
P-24270
1 2
1 3
2
P-21939
Figure 60-121-54 2
P-21790
1
P-21938
Figure 60-121-57 1 3
2
P-21802
2 - Terminal - Open
Remove the wedge (Item 1) [Figure 60-121-57] from the
connector. 3 - Terminal - Black
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
The ACD (Attachment Control Device), automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab
flashes, check for diagnostic service codes. See the Electrical System Service Manual for the proper
procedure.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 4 on the Standard Flow (diverter
valve) or solenoid 9 on the High Flow Loader (select valve). It will also shut down the loader, and bleed
the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so equipped.)
The high flow button in the left side instrument panel must be pushed ON to activate solenoid number 8
on the select valve.
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Chart (Cont’d)
WARNING P-4072
Never work on a machine with the lift arms up unless Pull the speed control away from the loader frame and
the lift arms are secured by an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device. Failure to use an approved lift arm 2] from the control.
support device can allow the lift arms or attachment
to fall and cause injury or death. Installation: Be sure to install the control rod in the
W-2059-0598 bottom hole of the speed control.
1
1 1
2
N-18878 P-34156
Raise the lift arms and install an approved lift arm device. Installation: Install the stop bracket (Item 1) [Figure 70-
(See Installing Lift Arm Support Device on Page 10-20- 20-3] in the same location. It is necessary for the front
1.) and rear stop on the bracket to be located correctly.
Raise the operator cab. (See Raising The Operator Cab Reverse the removal procedure to install the engine
on Page 10-30-1.) speed control.
Figure 70-30-1
1
3
2 P-34448
1
Remove the right side mounting bolt (Item 1) [Figure 70-
P-34447 30-2] from the muffler.
Figure 70-40-1
1
1
2
P-28915
2
Remove the lower mounting bolt (Item 1) [Figure 70-40-
P-34449 3] and engine harness mounting bracket (Item 2) [Figure
70-40-3] from the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Installation: Tighten the three mounting bolts to 25-28
70-40-1] from the air cleaner sensor on the air cleaner. ft.-lb. (34-38 N•m) torque.
2
1
P-34450
Figure 70-50-3
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot. 1
You can be seriously burned.
W-2070-1203
Figure 70-50-1
N-19211
1
Figure 70-50-4
P-3971
Figure 70-50-2 2
1
N-19212
P-24674
Figure 70-50-5
1
2
P-34449
Figure 70-50-8
Remove the hose clamp (Item 1) [Figure 70-50-5] from
the inlet hose.
2 1
N-19213
Remove the hose clamp (Item 1) [Figure 70-50-6] from Reverse the above procedure to install the radiator.
the outlet hose.
Figure 70-60-1
1
P0581
4
1 3
2
5 1
N-00303
N-19188
Figure 70-60-5
1
1 Oil Level
N-19375
Remove the left gas cylinder mounting bracket (Item 1) Remove the fan drive belt (Item 2) [Figure 70-60-7] from
[Figure 70-60-5]. (See Gas Cylinder Removal And the pulley on the blower fan.
Installation on Page 50-20-1.)
NOTE: When checking the fan gearbox oil level, be
sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use a
light colored 90W gear lube if the level is low.
S175, S185 Bobcat Loader
70-60-2 Service Manual
529 of 725
COOLING FAN (CONT’D) Figure 70-60-10
Figure 70-60-8
1
4
P13920
3 1 Lower the blower fan from the housing until it rests on the
steering linkage plate [Figure 70-60-10].
N-19376
Figure 70-60-11
Figure 70-60-9
N-19378
P-4301
Remove the strip of sealant along the top of the blower
housing [Figure 70-60-11].
Remove the two mounting bolts (Item 1) [Figure 70-60-
8] and the two spacer tubes (Item 2) [Figure 70-60-8] Installation: Use R.T.V. sealant to reseal the blower
from the blower fan. housing.
Remove the rear mounting bolt (Item 3) [Figure 70-60- Loosen the electrical harnesses from the frame of the
8]. loader.
Remove the front mounting bolt (Item 4) [Figure 70-60- Slide the blower fan and housing forward and remove
8]. both from the loader.
Figure 70-60-12
1
P3006
CD-9952
Figure 70-60-15
CD-8954
1
1
CD-9954
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
11. Nut 1
12. Gear
13. Washer
14. Screw 18
15. Square Shim
*16. Short Housing 1 2
17. Bolt 6
3 4
18. Snap Ring (Large) 7
19. Cap 5 4
4
12
13
14
9
21
10 *16
11
15
20 17
12
4
13
14
18
19
Gearbox Disassembly
Figure 70-60-18
3 Part Number
Tag
P2983
2
Remove the four mounting bolts and the part number tag
P3005 [Figure 70-60-19].
Long Housing
P2999
Loosen the set bolts (Item 1) [Figure 70-60-18] and
remove the pulley (Item 2) [Figure 70-60-18].
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
Remove the long key (Item 3) [Figure 70-60-18]. hammer tool to remove the seal [Figure 70-60-20].
Figure 70-60-21
P2966
Figure 70-60-24
Remove the small snap ring [Figure 70-60-21].
P3004
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-24].
Remove the small shims [Figure 70-60-22]. NOTE: The gear and the other bearing (pulley end) will
be removed with the shaft.
Figure 70-60-25
P2996
P3298
WARNING
Support the bearing and press the shaft from the bearing
[Figure 70-60-25]. AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
Figure 70-60-28
P2997
Short Housing
Remove the large snap ring from the flange end of the
housing [Figure 70-60-28].
Figure 70-60-29
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-31].
Figure 70-60-32
Remove the large shims from the housing [Figure 70-60-
29].
Figure 70-60-30
1
P2998
Figure 70-60-33
P2972
Press the bearing from the tapered end of the shaft Figure 70-60-36
[Figure 70-60-33].
P2961
Long Housing
Press a bearing on the short keyed end of the long shaft
[Figure 70-60-36].
S175, S185 Bobcat Loader
70-60-11 Service Manual
538 of 725
COOLING FAN (CONT’D) Figure 70-60-39
Figure 70-60-37
P2963
Install the long housing on the shaft [Figure 70-60-37]. Figure 70-60-40
Figure 70-60-38
P2964
Install the small snap ring in the groove above the shims
[Figure 70-60-40].
P2962
Figure 70-60-41
P2966
P2968
P2967
Short Housing
Align the key and gear. While supporting the bearing on Install a bearing in the flanged end of the housing
the other end, press the gear on the shaft until it seats [Figure 70-60-44].
against the bearing [Figure 70-60-42].
Figure 70-60-45
P2971
P2975
P2970
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-48].
Install the large snap ring in the groove above the shims
[Figure 70-60-46]. NOTE: This will prevent damage to the shims when
the bearing is installed later.
Figure 70-60-49
P2974
Figure 70-60-52
Install the shaft in the housing, tapered end in the bearing
at the round flange end of the housing [Figure 70-60-49].
P2973
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-50].
Figure 70-60-53
1 P2981
Install the washer (Item 1) [Figure 70-60-53] on the Set the long housing on the short housing with the
shaft. Put liquid adhesive (LOCTITE #242) on the screw sealant (LOCTITE 518) which is a gasket eliminator that
Gearbox Checking Backlash NOTE: If square shims are used, put a small amount
of (LOCTITE 518) on both sides of all shims.
Figure 70-60-54
Figure 70-60-56
Part Number
Tag
P2987
P2983
1.0”
(25,4 mm)
1
P2979
Install the long key (Item 1) [Figure 70-60-57] and the Hold the locking pliers against the long housing and
pulley (Item 2) [Figure 70-60-57]. rotate the pulley back and forth to read the dial gauge
P2986
P2985
(S175)
1
Compression Pressure should be 412-469 PSI (2840-
3233 kPa).
(S185)
Figure 70-70-2
P-4309
P-4308
Figure 70-70-4
3
2
P-4300
P-4304
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-70-6] from the top of
each glow plug.
Figure 70-70-7
P-4310
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-70-5].
P-4302
Repeat the procedure for each glow plug. Installation: Tighten the glow plug to 14.5-18.1 ft.-lb.
(19,6-24,5 N•m) torque.
Figure 70-70-8
N-19450
Figure 70-70-9
Linkage Lever
0.050”
(1,27 mm)
Stop
1
B-13704
P-34452
Adjust shut-off linkage for maximum distance of 0.050
inch (1,27 mm) between the lever and stop when
Stop the engine and open the rear door [Figure 70-70-9]. solenoid plunger is seated [Figure 70-70-11].
Figure 70-70-12
N-19426
Figure 70-70-15
Stop the engine and open the rear door [Figure 70-70-
12].
1
N-19425
The injection pump contains parts which have a very Fuel Tightness of Pump Element
close tolerance and its operation has a direct effect on Allowable Limit ............................2133 PSI (14707 kPa)
the performance of the engine.
Measure the time needed to decrease the pressure from
2133-1990 PSI (14707 -13721 kPa). If the measurement
is less than the allowable limit, replace the delivery valve.
Figure 70-70-16
P-4319
1
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-17] from the fuel injectors.
2
B-8235
Figure 70-70-18
P-4316
1
Figure 70-70-19
1
1
P-4356
P-4312
Remove the seven mounting bolts (Item 1) [Figure 70-
70-21] from the intake manifold (Item 2) [Figure 70-70-
Disconnect the fuel inlet hose (Item 1) [Figure 70-70-19] 21].
and the fuel return hose (Item 2) [Figure 70-70-19] from
the injection pump vent. Installation: Tighten the mounting bolts to 16-20 ft.-lb.
(22-27 N•m) torque.
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1
2 Figure 70-70-24
P-4357
IMPORTANT P-4363
Figure 70-70-25
Figure 70-70-23
1
2
P-4362
P-4359
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
P-4364 I-2028-0289
2
1
P-4360
P-4306
Install the injection pump in the engine.
Disconnect the fuel shut-off linkage (Item 1) [Figure 70-
Put the pin (Item 1) [Figure 70-70-27] on the control rack
70-28] from the injection pump.
in the slot of the fork lever (Item 2) [Figure 70-70-27]
located inside the injection pump chamber.
Turn the fuel supply lever (Item 2) [Figure 70-70-28] to
the ON position (to the right).
Figure 70-70-31
1
P-4361
1 MC-1542A
Rotation
Direction
P-4315
WARNING
AVOID INJURY OR DEATH
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. 1
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 P-4318
from a physician familiar with this injury.
W-2072-0807
Disconnect the fuel return hoses (Item 1) [Figure 70-70-
32] & [Figure 70-70-33] from the injectors.
The following are some problems caused by faulty
injectors:
Figure 70-70-34
- Engine is hard to start or will not start
- Rough engine operation and idle
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
P-4330
Figure 70-70-32
P-4311
Figure 70-70-35
1
2
P-4358
2
Remove the retainer nut from the top of the fuel injectors Installation: be sure the nozzle cap (Item 1) [Figure 70-
(Item 1) [Figure 70-70-35]. 70-37] and copper washer (Item 2) [Figure 70-70-37] are
Figure 70-70-36
P-4354
IMPORTANT
Do not disassemble or test the injector nozzles 1
unless you have the correct service and testing
tools.
I-2121-0297 2
3
The tool listed will be needed to do the following 4 (1) Nozzle Holder
procedure: 5 (2) Adjusting Washer
(3) Nozzle Spring
OEM1064 - Injector Nozzle Tester 6 (4) Push Rod
(5) Distance Piece
Check for inside leakage. Operate the hand lever until 7 (6) Nozzle Piece
the pressure is 1850 PSI (12755 kPa). Keep the nozzle (7) Nozzle Retaining Nut
under this pressure for 10 seconds, check to see if fuel
PI-9981
leaks from the nozzle. If fuel leaks, replace the nozzle.
A-2621
Figure 70-70-42
1 2 3 4 5 6 7 8
A-2513
Valve
I = Intake I E I E I E I E
E = Exhaust
2 1
Adjust the valve clearance as follows: c. With the rocker arm rocking (valves 1 & 2) on No. 1
cylinder set clearance at No. 4 cylinder (valves 7 & 8).
Loosen the lock nut (Item 1) [Figure 70-70-41].
d. With the rocker arm rocking (valves 5 & 6) on No. 3
Turn the adjustment screw (Item 2) [Figure 70-70-41] cylinder set clearance at No. 2 cylinder (valves 3 & 4).
until the correct clearance is obtained.
Figure 70-70-44 4
5
2
1 3 1
2
Measure the rocker arm I.D. (Item 1) [Figure 70-70-44] Remove the engine. (See Removal And Installation on
with the inside micrometer. Page 70-80-1.)
Never work on a machine with the lift arms up unless Figure 70-80-2
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
Figure 70-80-1 1
3
1
P-26964
2
P-26414
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Figure 70-80-3
1
1
2
P-26965
3
Remove battery cable bracket (Item 1) [Figure 70-80-5].
P-28237
Figure 70-80-6
P-34385
1
Disconnect negative battery cables from starter mount
bolt (Item 1) [Figure 70-80-6].
P-28136
Figure 70-80-7
3
2
2
1
2
P-28135
1
Disconnect fuel line (Item 1) [Figure 70-80-9].
P-26969
Cut tie straps (Item 2) [Figure 70-80-9].
Disconnect the fuel stop wire harness (Item 1) [Figure Mark and disconnect loader harness wire connectors
70-80-7]. (Item 3) [Figure 70-80-9].
3
1
P-26971
Disconnect engine oil pressure wire harness (Item 1) Disconnect glow plug wire (Item 2) [Figure 70-80-10].
[Figure 70-80-8].
Remove bolt (Item 3) [Figure 70-80-10] from wiring
harness clamp and move to the left side of loader to allow
clearance for engine removal.
Figure 70-80-11 1
P-28137
Figure 70-80-12
1
2
P-26957
1
Remove fan belt shield (Item 1) [Figure 70-80-14].
P-28054
Figure 70-80-15
1
P-26959
Figure 70-80-18
Remove fan belt (Item 1) [Figure 70-80-15] from pulley.
P-28142
1
P-26068 Mark and disconnect the left drive motor hoses (Item 1)
[Figure 70-80-18].
Disconnect inlet gear pump hose (Item 1) [Figure 70-80- Cap or plug all hoses and fittings.
16].
NOTE: Due to left drive motor hoses (Item 1) [Figure
Cap or plug all hoses and fittings. 70-80-18] orientation, hoses may not be
completely removed from fittings until engine
and pump removal.
1 1
P-28141
P-26068
2
P-28231 1
P-28140
P-28139
Figure 70-80-23
13”
2.5”
1-1/2” I.S. Dia.
2-1/2” O.S. Dia.
2.5” 1
1-1/2” Square Tubing 1/4” (4)
Thick Gusset
1” P-28234
28”
4”
Figure 70-80-25
2”
1”
4”
2”
1”
.5”
1
.375”
.3125” (2)
Figure 70-80-26
Spacer
5 Snubbing
Washer
MC-1765
6
Replace all four engine mounts two front and two rear.
Figure 70-90-1
1
1
3
P-4234
P-4223
1
1
P-4237
P-4234
Fit the ring on the flywheel and be sure the gear is seated
correctly.
Figure 70-90-5
P-4223
3
2
1
P-4235
P-4233
Figure 70-90-8 1
P-4238
Figure 70-90-11
P-4231
Adjustment
Figure 70-91-1
P-34731
Figure 70-91-2
P-34732
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of .050 inch (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 70-91-2].
Figure 70-100-1
B-14333
Remove the nuts from the valve cover, remove the valve
cover and gasket [Figure 70-100-1]
B-14332A B-14332
Figure 70-100-5 4
3
6
2 1
Valve Spring
Retainer
Seal
Collets Cap
B-4122A
Figure 70-100-8
1
4
3
5 6 2
PI9987A
B-3643
Figure 70-100-9
2
1
3
2
PI9989A
A-2735 Install the cylinder head gasket. Put the piston (Item 1)
[Figure 70-100-11] being checked at T.D.C.
Clean the surface of the cylinder head. Put three pieces of 0.060 inch (1,5 mm) diameter solder
PI9988
Figure 70-100-12
B-14335
Figure 70-100-15
Figure 70-100-16
Exhaust
Intake
15° 45° (60°)
PI9994A
2
Grind the valve seat surface in the cylinder head to the
correct angle [Figure 70-100-18].
PI9992A
Figure 70-100-19
Press the used valve guide out of the cylinder head using
1 2
the special driver tool [Figure 70-100-16].
Figure 70-100-17
PI9995A
Valve Spring
Figure 70-100-20
A-2759
Figure 70-100-22
3 1
2 1
2
B-14336
Measure the rocker arm I.D. (Item 1) [Figure 70-100-22] Remove the cylinder head, rocker arms and push rods.
with the inside micrometer.
If the clearance still exceeds the allowable limit after the Figure 70-100-24
bushing is replaced, replace the rocker arm shaft.
Kubota V2203-EB
Oil Clearance Between Rocker Arm Remove the speed control plate with the governor
& Shaft . . . . . . 0.0006-0.0018 inch (0,016-0,045 mm) springs [Figure 70-100-24].
Allowable Limit . . . . . . . . . . . . . . 0.0059 inch (0,15 mm)
Figure 70-100-25
2 1
2
B-14339
1
Remove the crankshaft pulley (Item 1) [Figure 70-100-
27] and key (Item 2) [Figure 70-100-27].
Figure 70-100-26
B-4095
3 Figure 70-100-31
4
B-14340
Figure 70-100-32
0.003-0.009”
(0,07-0,22mm) PI-10002
Installation: Tighten the mounting bolts to 17-20 ft.-lb. Servicing The Camshaft
(23-27 N•m) torque.
Figure 70-100-35
Align the holes on the camshaft gear with the camshaft
retainer plate bolts.
Figure 70-100-33
B-3620
B-3655
Figure 70-100-38
A-2761
Camshaft Alignment
Allowable Limit . . . . . . . . . . . . . 0.00039 inch (0,01 mm)
Camshaft Alignment
Allowable Limit . . . . . . . . . . . . . 0.00039 inch (0,01 mm)
B-5001
1.258-1.259”
(31,96-35,97 mm)
1.413-1.415”
(35,9-35,95 mm)
MC-1366
Kubota V2203-EB
Figure 70-100-42
2
B-14342
B-14343
Oil Pump Gear &
Crank Gear . . 0.0016-0.0043 inch (0,0415-0,109 mm)
Allowable Limit . . . . . . . . . . . . . . 0.0059 inch (0,15 mm) Remove the fuel camshaft and fork lever assembly (Item
1) [Figure 70-100-44] at the same time.
Figure 70-100-45
5 4
1
3
2 9
12
6
7 B-3686
8 10
11 Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
13
100-7.)
1. Start Spring
Figure 70-100-47
B-3616
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-100-47].
Figure 70-100-49
PI-10009
Figure 70-100-51
2 3
PI-10011A
Figure 70-100-53
1 PI-10013A PI-10013B
Figure 70-100-56
1
2 2
3
5
PI-10014B
Figure 70-100-57
180°
1
3
A-2733
PI-10015A PI-10015B Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-100-59].
Installation: When installing new rings, assemble the If the measurement exceeds the allowable limit, replace
ring so the mark (Item 1) [Figure 70-100-57] near the the piston.
gap faces the top of the piston. When installing the oil
ring, place the expander joint (Item 2) [Figure 70-100-57] Piston Pin Bore I.D. . . . . . . . . . . . . . 0.9843-0.9848
on the opposite side of the oil ring gap (Item 3) [Figure inch
70-100-57].
(25,0-25,013 mm)
Allowable Limit . . . . . . . . . . . . . 0.9862 inch (25,05 mm)
Servicing The Piston And Connecting Rod (Cont’d) 6.38” (162 mm)
1.063” (27 mm)
Figure 70-100-60
0.984-0.985”
1.098-1.1004” (25,0-25,011 mm)
1.378” (35 mm) (27,9-27,95 mm)
2 MC-1366
Figure 70-100-65
B-3622
Install new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [Figure
If the gap exceeds the allowable limit, replace the NOTE: The small end bushing is the basis of this
cylinder liner. check, check the bushing for wear before
doing this check.
Compression Ring Gap . . . . . . . . . 0.0118-0.0170 inch
Install the piston pin into the connecting rod.
(0,3-0,45 mm)
Allowable Limit . . . . . . . . . . . . . . 0.0492 inch (1,25 mm) Install the connecting rod on a alignment tool.
Oil Ring Gap . . . . . 0.0098-0.0177 inch (0,25-0,45 mm)
Allowable Limit . . . . . . . . . . . . . 0.0492 inch (1,25 mm) Put the gauge over the piston pin and move it against the
face plate.
Figure 70-100-64
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-100-65].
PI-10017
B-9565
B-3648
Install two bolts into the bearing case cover and pull the 2
cover out [Figure 70-100-66].
Figure 70-100-67
B-14346
1
2
Remove the main bearing case bolt (Item 1) [Figure 70-
100-69].
Figure 70-100-70
PI-10021
Figure 70-100-71
A-2763
Installation: Tighten the bearing case bolts to 34-38 ft.- Alignment (Allowable Limit) . . . . 0.0008 inch (0,02
lb. (46-52 N•m) torque. mm)
Figure 70-100-74
120
PI-10022
PI-10023A PI-10023B
Calculate the oil clearance. Heat the sleeve to about 300°F (150°C). Install the
sleeve on the crankshaft using the special driver tool
Crankpin Bearing I.D. . . . . . . . . . 1.8504-1.8522 inches (Item 3) [Figure 70-100-77].
(47,0-47,046 mm)
Crankpin O.D. . . . . . . . . . . . . . . . 1.8488-1.8494
inches
(46,959-46,975 mm)
Oil Clearance . . 0.0009-0.0034 inch (0,025-0,087 mm)
Allowable Limit . . . . . . . . . . . . . . . 0.0079 inch (0,2 mm)
0.8”
(20 mm)
Figure 70-100-78
2.83”
(72 mm) 2.0413-2.0433”
(51,85-51,90 mm)
MC-1367
0.8”
Figure 70-100-79 (20 mm)
0.35”
(9 mm)
2.83” 2.2328-2.2402”
(72 mm) (56,85-56,90 mm)
Figure 70-100-84
PI-10024A
PI-10025
Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
Figure 70-100-85
B-5324A
Put the water pump in a vise and remove the nut [Figure
70-100-87].
A-2717
Remove the pulley using a puller. Remove the key and
snap ring.
Measure the six points show in figure [Figure 70-100-85]
to find the maximum wear.
Figure 70-100-86
B-5325
Drive the shaft out of the impeller side of the water pump
housing [Figure 70-100-88].
B-5318
Figure 70-100-89
A-2783A
Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Too Much Lubricating Oil at Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too Much Lubricating Oil at Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In the Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside the Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 32, 33, 34, 35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35
Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Figure 70-110-3
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Figure 70-110-1
P16226
Figure 70-110-4
The turbocharger (Item 1) [Figure 70-110-1] is placed
between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
Figure 70-110-2
P16227
P16201
Figure 70-110-5
1
1
P16231
2
1
P16230
P16233
Remove the oil supply line fitting (Item 1) [Figure 70-110-
5] and the brass washer(s) (Item 1) [Figure 70-110-6]
from the turbocharger. Remove the mounting bolt (Item 2) [Figure 70-110-8]
from the oil return line.
Installation: Tighten to 12-15 ft.-lb. (16,0-20,3 N•m)
torque. Installation: Tighten to 84-132 in.-lb. (9,5-15,0 N•m)
torque.
Figure 70-110-9
1
1
P16236
1
Figure 70-110-10
1
P16230
2
Remove the turbocharger assembly (Item 1) [Figure 70-
P16206 110-12] from the engine.
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Dessicant
3 Receiver Drier
Status Of R134a_______________________________________________
b-16691
Identification
Figure 80-20-1 2
1
1
P-24219
Figure 80-20-2 1
1 N-22206
Identification (Cont'd)
Figure 80-20-5
N-22087
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-24227 20-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-20-7]
1) [Figure 80-20-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
P-21902
N-22100
Identification (Cont'd)
1
Figure 80-20-9
2
3 4
P-24229
Figure 80-20-10
P-24232
Safety Equipment
Figure 80-30-1
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-30-2
WARNING
Figure 80-40-1
P-28820
1
Figure 80-40-4
P-28819
2
1
Remove the filter cover and filter (Item 1) [Figure 80-40-
2] from the loader.
P-34333
Figure 80-40-5
1
1
P-24288
P-34332
It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Remove the recirculating air filter (Item 1) [Figure 80-40-
5] from the rear of the cab. Open the rear door.
N-22274
Figure 80-40-8
P-24313
Figure 80-40-9
P-24213A P-24213
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-1.)
N-22273
WARNING
Figure 80-50-2 Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Figure 80-50-3
N-22411
Figure 80-50-4
1
2
N-22119
1
Remove the two mounting nuts (Item 1) [Figure 80-50-6]
N-22120
N-22129
Figure 80-50-8
2
1
1 N-22125
N-22127
N-22124
Figure 80-50-14
P-24288
Checking The Electrical System NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
Figure 80-50-13 for both the Heater and the A/C systems.
2 1
N-22284
Figure 80-50-15
1
P-24314
Raise the operator cab. (See Raising The Operator Cab If there is power at the clutch, reconnect the wiring
on Page 10-30-1.) harness to the compressor clutch.
Figure 80-50-16 2
1 1
P-24299
Figure 80-50-19
1
N-22258
Figure 80-50-22
Using a multimeter check the loader wiring harness (Item
1) [Figure 80-50-19] for voltage.
Figure 80-50-20
N-22259
P-24315
Figure 80-50-23
N-22129
Figure 80-50-26
If there is voltage at the wiring harness, check the
thermostat (Item 1)[Figure 80-50-23] for resistance.
Figure 80-50-24
N-22260
2
Check the loader harness (Item 1) [Figure 80-50-26] for
voltage. The voltage should be 12 volts.
N-22130
Figure 80-50-27
1
N-22262
Figure 80-50-30
If there is voltage at the wiring harness, check the
resistance to the blower fan at the blower fan wiring
Figure 80-50-28
N-22265
Figure 80-50-31
H C
M B
N-22264
L
Figure 80-50-35
1
2
N-22289
N-22263
If there is voltage at the wiring harness, check the A/C
switch [Figure 80-50-33] for resistance.
Figure 80-50-34
C
A
N-22290
1
Figure 80-50-37
C
A
1 N-22290
The white wire B, (Item 1) [Figure 80-50-37], on the Check the resistance between the wire terminal C and
potentiometer, is a resistor wire. wire terminal B frame [Figure 80-50-39] should be
1
1
N-22175
N-22175
C
A
P-34347
N-22290
Engine Coolant By-Passing The Heater Valve If the hose is hot, the heater valve is leaking by, and
needs to be replaced.
Figure 80-50-42
2 3
1
N-22284
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Figure 80-50-44
2 3
1 P-34347
Place the remote start tool on the left fender of the loader,
N-22284 so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-50-45], as the key of the remote
start is turned to the ON position without starting the
Raise the lift arms and install an approved lift arm support loader. The heater valve should rotate.
device. (See Installing Lift Arm Support Device on Page
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-50-45], as the key of the remote
start tool is turned to the ON position without starting the
loader. The heater valve should rotate. Place a mark on
the loader shaft.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Compressor Oil
Figure 80-60-1
N-22243
Compressor Oil Check Remove the compressor from the loader. (See Removal
And Installation on Page 80-110-1.)
Figure 80-60-2
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Figure 80-60-4
1
N-22245
Figure 80-60-3
N-22246
P-16534A
Figure 80-60-5
P-24229
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
Chart
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Chart
N-23024
P-24208
P-24230
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-100-4
N-22291
Connect the Refrigerant Identifier to its power source. HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
Follow the steps displayed on the refrigerant identifier if it contacts the eyes and may cause serious
screen. frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
Allow two minutes for the refrigerant identifier to display when it contacts open flame or very hot
the type of refrigerant and air content. An alarm will substances.
sound if potentially flammable hydrocarbons are present • NEVER SMOKE when there is the possibility of
and will also indicate on the visual display. even small amounts of 134A in the air.
Any servicing work that involves release or addition
Disconnect the refrigerant identifier from the loader A/C. of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
If the refrigerant is dangerous or flammable, it must be knowledge, and experience to service refrigeration
evacuated from the A/C system into a separate container equipment.
and properly and safely disposed of. W-2373-0500
Figure 80-100-6
N-22381
Figure 80-100-7
N-22292
Charging Procedure With A Manifold Gauge Set Connect the Red hose (Item 1) [Figure 80-100-10] to the
high pressure port and open the valve.
Figure 80-100-9
Connect the Blue hose (Item 2) [Figure 80-100-10] to the
low pressure port and open the valve.
Figure 80-100-11
1
P-24318
P-24321
Determine the problem with the A/C system and repair it.
Figure 80-100-14 2
P-24323
P-24322
P-24324
Figure 80-100-17
2
1
N-22284
Start loader engine, with the remote start switch, and run
at medium speed.
Figure 80-110-1
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
P-24325
Figure 80-110-3
Remove drive belt guard.
Figure 80-110-2
P-24327
3
1
2
P-24326
Figure 80-110-4
1.32”
1.32”
1.32”
2
1
1
N-22275
Figure 80-110-5
N-22278
N-22277
Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-5] on the armature plate as shown in [Figure 80-
To remove the armature plate (Item 1) [Figure 80-110-5] 110-7].
from the clutch face, you must make an armature plate
puller.
Figure 80-110-8
1
1 N-22283
Figure 80-110-11
Attach a slide hammer puller (Item 1) [Figure 80-110-8]
to the armature puller disk.
Figure 80-110-9
1
N-22369
N-22280
Figure 80-110-12
N-22373
Figure 80-110-15
Remove the pulley from the compressor [Figure 80-110-
12].
N-22374
Figure 80-110-16
1 1
N-22372
Figure 80-110-17
N-22375
Figure 80-120-1
P-24328
WARNING
In the event of a leak, wear safety goggles. Escaping P-24313
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas. Remove the condenser from the loader [Figure 80-120-
W-2371-0500 3].
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-120-4
P-24303
WARNING 2
P-24298
Figure 80-130-1
1
WARNING
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Figure 80-130-3
P-24295
Figure 80-140-1
N-22205
N-22206
This will cause the A/C system to shut down, saving the
compressor.
Figure 80-150-1
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-150-3
P-24299
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
1 on Page 10-20-1.)
With a tire valve core removal tool, remove the valve core
from the hose.
Figure 80-160-1
N-22129
Figure 80-160-4
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
Figure 80-160-2
N-22119
N-22130
Figure 80-160-5
1
N-22128
N-22126
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-160-8
1
1
N-22065
Figure 80-170-1
N-22072
Figure 80-170-2
N-22072
A Blue
1 B White
C Black
N-22071
Figure 80-180-1
N-22073
Raise the lift arms and install an approved lift arm support Remove the expansion valve from the loader.
device. (See Installing Lift Arm Support Device on Page
10-20-1.) Figure 80-180-3
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic N-22074
gas.
W-2371-0500
Cap and plug the evaporator tubelines (Item 1) [Figure
80-180-3] and the expansion valve fittings with the
Remove the two A/C hoses (Item 1) [Figure 80-180-1]
proper A/C caps and plugs.
from the expansion valve.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Figure 80-180-4
1
1
N-22074
Figure 80-180-5
N-22085
Figure 80-190-1
N-22075
N-22074
Figure 80-190-5
N-22078
Figure 80-200-3
1
N-22128
Raise the lift arms and install an approved lift arm support
N-22087
device. (See Installing Lift Arm Support Device on Page
Remove the evaporator/heater unit from the back of the Figure 80-200-4
cab. (See Removal And Installation on Page 80-160-1.)
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
2
Installation: Tighten the two heater hose fittings to 22 ft.-
lb. (29,8 N•m) torque. 2
Figure 80-200-2
N-22089
1
Remove the three mount bolts (Item 1) [Figure 80-200-4]
and remove the mount plate from the end of the unit.
1
N-22086
Removal And Installation With A/C (Cont'd) Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
Figure 80-200-5
Installation: Tighten the two heater hose fittings to 22 ft.-
lb. (29,8 N•m) torque.
Figure 80-200-7
1 1
N-22090
2
The heater coil [Figure 80-200-5] can be cleaned with
low air or water pressure.
N-22093
Figure 80-200-8
N-22128
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
10-20-1.)
N-22094
Figure 80-210-1
N-22099
Figure 80-210-4
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
N-22097
Figure 80-210-5
1
2
1 1
N-22107
Remove the eight mount bolts (Item 1) [Figure 80-210-5] Figure 80-210-7
from the blower wheel cover.
2
N-22108
Figure 80-210-8
N-22112
Figure 80-210-11
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-8].
1 N-22111
Figure 80-210-12
1
1
2
N-22103
N-22116
Figure 80-210-14
N-22104
Figure 80-210-15
1 1 1
N-22105
Figure 80-210-16
N-22106
Figure 80-220-1
1
3
1 4
2
3
N-22155
P-34347
Remove the three mount bolts (Item 1) [Figure 80-220-2]
from the heater valve actuator.
Remove the solenoid mounting screw (Item 1) [Figure
80-220-1]. Figure 80-220-3
Figure 80-220-4
1
N-22159
Figure 80-220-7
Remove the three mounting bolts (Item 1) [Figure 80-
220-4] from the heater valve mount plate.
1
1
N-22160
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS - KUOBTA V2003T-EB (TURBO). SPEC-21-1
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-5
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 DRIVE
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 SYSTEM
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
TIRE DESCRIPTION WIDTH (OVER TIRES) WHEEL TREAD BUCKET WIDTH WIDTH (OVER BUCKET)
10-16.5 TIRES 66.0in. (1676mm) or 54.5in. (1385mm) or 62” 62.0in. (1575mm)
60.0in (1524mm) 48.5in. (1232mm) 68” 68.0in. (1727mm)
31-15x15 TIRES 74” 74.0in. (1880mm)
72.0in. (1829mm) 55.9in. (1420mm)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
Performance
S175 S185
Rated Operating Capacity (ISO) 1750 lb. (794 kg) 1850 lb. (839 kg)
Tipping Load (SAE Rating) 3900 lb. (1769kg)
Operating Weight 5808 lb. ( 2635 kg)
SAE Breakout Force-Lift 3400 lb. ( 15123 N)
-Tilt 3240 lb. (14412 N)
Axle Torque 4900 ft.- lb. (6644 N•m)
Travel Speed 7 MPH (11,3 km/hr.)
Controls
Vehicle Steering Direction and Speed controlled by two hand levers.
Loader Hydraulics Lift and Tilt Controlled by separate foot pedals or optional hand controls.
Front Auxiliary Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option) Controlled by electrical switch on LH steering lever.
Engine Hand lever throttle: Key-type starter switch and shutdown.
Keyless start and shutdown with deluxe instrumentation.
Engine
Hydraulic System
S175 S185
Pump Engine Driven, Gear Type
Pump Capacity 16.7 GPM (63,1 L/min.) at High Idle
High Flow (Option) 27 GPM (102 L/min.) at High Idle
System Relief at Quick Couplers 3300 PSI (206 Bar)
Filter Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders Doubleacting;
Tilt cylinders have cushioning feature on dump
Bore Diameter: Lift Cylinder (2) 2.50 (63,5)
Tilt Cylinder (1) 2.75 (69,9)
Rod Diameter: Lift Cylinder (2) 1.50 (38,1)
Tilt Cylinder (1) 1.375 (34,9)
Stroke: Lift Cylinder (2) 23.67 (601,2)
Tilt Cylinder (1) 13.19 (335,0)
Control Valve 3-spool, open center type w/float detent on lift and electrically controlled auxiliary
spool.
Electrical
Drive System
S175 S185
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors.
Final Drive #80 HSOC endless roller chain & sprockets in sealed chaincase with oil
lubrication.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 (50,8)
Wheel Bolts (8) 9/16”
Capacities
Cooling System W/Heater (Includes 9.8 qt. (9,3 L) 9.8 qt. (9,3 L)
Recovery Bottle)
Cooling System W/O Heater (Includes 9.2 qt. (8,7 L) 9.2 qt. (8,7 L)
Recovery Bottle)
Fuel 23.0 Gal. (87,1 L) 23.0 Gal. (87,1 L)
Engine Oil W/Filter 7.5 qt. (7,1 L) 7.5 qt. (7,1 L)
Tires
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Tightness Plunger 10 sec: initial pressure 2133-1990 PSI (14707-13721 kPa)
Limit Permitted 5 seconds
Injection Timing 17-19 degrees B.T.D.C.
High Idle 2860-3000 RPM
Low Idle 1125-1175 RPM
Cylinder Head
Valves
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Valve Timing
Camshaft
Tappet
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinders
Piston Rings
Connecting Rod
Oil Pump
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
Timing Gear
Thermostat
Crankshaft Re-Grind Data 6.) The crank journal side surface must be fine-
finished to higher than 0.4-S (0.000016''-S).
If the standard size bearing cannot be employed due to
excessive wear of the crank pin and crank journal use Figure SPEC-20-1
undersize or oversize bearings.
CRANKSHAFT PROCESSING
SIZE CODE NO. NAME OF BEARING BEARING MARK
DIM.
-0.008” Crankshaft Bearing 1
020 US
(-0,2 mm) 17331-2391-1 0.008” minus (0,2 minus) 2.0363-2.037”
-0.008” Crankshaft Bearing 2 (51,721-51,74mm)
020 US
(-0,2 mm) 17331-2393-1 0.008” minus (0,2 minus)
A
-0.016” Crankshaft Bearing 1
040 US
(-0,4 mm) 17331-2392-1 0.016” minus (0,4 minus) 2.0284-2.0291”
-0.016” Crankshaft Bearing 2 (51,521-51.54mm)
040 US
(-0,4 mm) 17331-2394-1 0.016” minus (0,4 minus)
-0.008” Crank Pin Bearing 1.8409-1.8415”
020 US
(-0,2 mm) 17331-2297-1 0.008” minus (0,2 minus) (46,759-46,775mm)
B
-0.016” Crank Pin Bearing 1.8330-1.8337”
040 US
(-0,4 mm) 17331-2298-1 0.016” minus (0,4 minus) (46,559-46,575mm)
Thrust Bearing 1-0.008”plus
+0.008” 15221-2395-1 (0,2 mm plus) 1.0315-1.0335”
020 OS
(+0,2 mm) Thrust Bearing 2-0.008”plus (26,20-26,25mm)
19202-2397-1 (0,2 mm plus)
C
Thrust Bearing 1-0.016”plus
+0.016” 15221-2396-1 (0,4 mm plus) 1.0394-1.0413”
040 OS
(+0,4 mm) Thrust Bearing 2-0.016”plus (26,40-26,45mm)
19202-2398-1 (0,4 mm plus)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Liner
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
Thread
sae grade 5 sae grade 8
size
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(N•m) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(N•m) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
Figure SPEC-40-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until
Figure SPEC-40-7
TS-1619
1
P13573
The hex portion of the nut does not contact the surface of Tighten the nut until it just makes metal to metal contact,
the component when the nut is tight. you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
Diesel fuel or hydraulic fluid under pressure can five minutes at less than half throttle. This warm-up
penetrate skin or eyes, causing serious injury or period is necessary for foot pedal operation and safe
death. Fluid leaks under pressure may not be visible. stopping. Do not operate controls during warm-up
Use a piece of cardboard or wood to find leaks. Do period.
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention When temperatures are below -20°F (-30°C), the
from a physician familiar with this injury. hydrostatic oil must be heated or kept warm. The
W-2072-0496 hydrostatic system will not get enough oil at low
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Product:Bobcat Loader
ALL ALL
WIRING SCHEMATIC WIRING SCHEMATIC
Printed May 2002 Printed June 2002
Printed in U.S.A.
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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
S175, S185 Service Manual (P/N 6901828) Dated (3-06) contains updated service information which replaces the
previous S175, S185 Service Manual (P/N 6901828) Dated (5-02.
Printed in U.S.A.
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FOREWORD
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