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Service Manual
S100 Skid-Steer Loader
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
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MAINTENANCE SAFETY
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner /
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
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4 of 521
ALPHABETICAL INDEX
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CONTENTS
SAFETY &
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V
HYDRAULIC
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII SYSTEM
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
DRIVE
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 SYSTEM
SPECIFICATIONS
SPECIFICATION
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
FW SSL-0308 SM
18. Inspect the air cleaner for 23. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: back-
approved tires or tracks. up alarm, fire extinguisher,
rotating beacon, lift kits, etc.).
21. Inspect for loose or broken 26. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
FW SSL-0308 SM
SI SSL-0308 SM
SI SSL-0308 SM
Maintenance Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
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. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Battery gas can explode and cause serious injury. Use the
procedure in the Operation & Maintenance Manual for
connecting the battery and for jump starting. Do not jump
start or charge a frozen or damaged battery. Keep any
open flames or sparks away from batteries. Do not smoke
in battery charging area.
SI SSL-0308 SM
Fire Extinguishers
Know where fire extinguishers and first aid kits are located
and how to use them. Inspect the fire extinguisher and
service the fire extinguisher regularly. Obey the
recommendations on the instructions plate.
SI SSL-0308 SM
Figure 1
S4043
1
S4464
Module 2. - Production
Sequence (Series)
Figure 3
B-16315
FRONT LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
FRONT AUXILIARY
TILT QUICK COUPLERS
CYLINDER
STEPS
BUCKET S0183
BUCKET STEP
OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
DEVICE
LIFT ARM
REAR
GRILL
LIFT
BACK-UP CYLINDER
ALARM
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
S0184
* TIRES
* TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.
Level II is available.
Bucket - Several different Buckets and other Attachments are available.
Procedure
Figure 10-10-1
S6030
Figure 10-10-3
WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operators
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
S6031
WARNING Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners NOTE: Make sure the jack stands do not touch the
of the frame before running the engine for service. tires. Make sure tires clear floor or any
Failure to use jackstands can allow the machine to fall obstacles.
or move and cause injury or death.
W-2017-0286
Installing
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 1
to fall and cause injury or death. 1
W-2059-0598
P43747
Figure 10-20-2
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or with
missing parts can cause lift arms to drop causing
injury or death.
W-2271-1197
P54468
Installing (Contd) Remove the retaining pin (Item 1) [Figure 10-20-4] from
the lift arm support device.
Figure 10-20-3
Figure 10-20-5
P54469
P54472
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure Connect the spring (Item 1) [Figure 10-20-5] from the lift
10-20-3] to the lift arm support device so the spring does arm support device to the bracket below the lift arms.
not interfere with the support device engagement.
Sit in the operators seat, fasten the seat belt and lower
Sit in the operator seat, fasten the seat belt and lower the the seat bar. Start the engine.
seat bar. Start the engine.
Figure 10-20-6
Figure 10-20-4
P54468
P54470 N20524
Raise the lift arms a small amount. The spring will lift the
Raise the lift arms until the lift arm support device drops support device off the lift cylinder rod. Lower the lift arms.
onto the lift cylinder rod [Figure 10-20-4]. Stop the engine.
Lower the lift arms slowly until the support device is held Raise the seat bar, unbuckle the seat belt, move the
between the lift arm and the lift cylinder. Stop the engine. pedals until both lock and exit the cab.
Raise the seat bar and move the pedals until both lock.
Disconnect the spring from the bracket.
Install the retaining pin (Item 1) [Figure 10-20-4] into the
rear of the lift arm support device below the cylinder rod. Raise the support device into storage position and insert
the retaining pin (Item 1) [Figure 10-20-6] through the lift
arm support device and through the bracket. Connect the
spring to the retaining pin.
Description Always stop the engine before raising or lowering the cab.
The Bobcat loader has an operator cab (ROPS and Stop the loader on a level surface and lower the lift arms.
FOPS) as standard equipment to protect the operator If the lift arms must be up while raising the operator cab,
from rollover and falling objects. Check with your dealer if install the lift arm support device. (See LIFT ARM
the operator cab has been damaged. The seat belt must SUPPORT DEVICE on Page 10-20-1.)
be worn for rollover protection.
Figure 10-30-1
ROPS / FOPS - Roll Over Protective Structure per ISO
3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
WARNING P43747
Never modify operator cab by welding, grinding, Install jackstands (Item 1) [Figure 10-30-1] under the rear
drilling holes or adding attachments unless corners of the loader frame.
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from Figure 10-30-2
rollover and falling objects, and result in injury or
death.
W-2069-0200
2
1
S4011 S4012
Raising (Contd)
Figure 10-30-3
WARNING
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
S4078
Lowering 2
N20120 S4013
Figure 10-30-6
S3999A
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] will
be ON when the door is open, the key switch is turned to
RUN or the RUN / ENTER button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER button
1
2 is pressed.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] will
be OFF when the door is closed, the key switch is turned
to RUN or the RUN / ENTER button is pressed, the seat
bar is lowered and the PRESS TO OPERATE LOADER
button is pressed.
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when S4759 S4758
S1848 S1075
A loader with an empty bucket or no attachment must be Engage the parking brake.
loaded backward onto the transport vehicle [Figure 10-
40-1]. Install chains at the front and rear loader tie down
positions [Figure 10-40-2].
The rear of the trailer must be blocked or supported
[Figure 10-40-1] when loading or unloading the loader to Fasten each end of the chain to the transport vehicle.
prevent the front end of the trailer from raising up.
Procedure
Figure 10-60-1
P16117
1
Figure 10-60-3
2
1 1
P16114
P16116
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-5] to
Figure 10-60-4 the electrical system on the loader.
1 Figure 10-60-6
P16120
S6014
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the cap (Item 1) [Figure 10-60-6] from the loader
harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
Figure 10-60-7 2
2
1 1
P16119
EM1024
The service tool harness communicator (Item 1) is
required to connect remote start tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-8].
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-7].
Figure 10-60-9
EM1024
Figure 10-60-12
P16115
1
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the 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
S6014 start tool in the run position disconnects the operator
panel key switch from the start circuit. If the service
technician will be working in the engine area it is
important to remove the operator panel keys.
W-2357-0899
P16116
Figure 10-60-14
NOTE: With the engine running; pushing and holding
the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
2 Figure 10-60-15
3 1
P16118
Description
Figure 10-61-3
1
EM1024
2
The loader service tool harness (Item 1) is used to When the remote start procedure is completed, replace
connect the remote start tool (service tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. reconnect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
S6014
Figure 10-61-6
3 1
2
P-76450
1
P-76454
WARNING 1
Figure 10-61-8 2
1
EM1024
Figure 10-61-11
5 3
3
6 4
2
P-76439
P-76454
Figure 10-61-13
1 2
P-34661
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
Figure 10-80-1
S4020
1 2
Pull the element straight out (Item 1) [Figure 10-80-3].
Figure 10-80-2
1
S4019
S4021
S4014 NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Open the evacuator valve (Item 1) [Figure 10-80-2] to get
rid of large particles of dust and dirt. Install a new inner element.
Remove the dust cover by lifting the lever (Item 2) [Figure Install the outer element.
10-80-2].
Install the dust cover [Figure 10-80-2].
Cleaning
Figure 10-90-1
S0297
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
S0297
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Remove the coolant fill cap (Item 1) [Figure 10-90-3].
Always add a premixed solution. Adding full strength
Connect a hose to the engine block drain valve. Open the concentrated coolant can cause serious premature
drain valve, connect a hose to it and drain the coolant into engine damage.
a container. I-2124-0497
After all the coolant is removed, close the drain valve and
remove the hose.
Install and tighten the fuel fill cap (Inset) [Figure 10-100-
WARNING 1].
S4014
Fuel Filter
S4014
Replacing Element
S4018
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten. S4014
Checking And Adding Engine Oil For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
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 10-110-3
2
S4023
1
S4024
2 S4014
Open the rear door.
Open the rear door and remove the dipstick (Item 1) Remove the drain hose from its storage position. Remove
[Figure 10-110-1]. the drain plug (Item 1) [Figure 10-110-3].
Keep the oil level between the marks on the dipstick. Drain the oil into a container and dispose of used oil in an
environmentally safe manner.
Engine Oil Chart Remove the oil filter (Item 2) [Figure 10-110-3].
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
B16320 Failure to use care around combustibles can cause
explosion or fire.
Use a good quality motor oil that meets API Service W-2103-0508
Classification of CD or better. (See Engine Oil Chart
[Figure 10-110-2].)
Lower the lift arms and tilt the Bob-Tach fully back.
P64023A
Figure 10-120-3
2
3
S4029 S4030
Add oil until it is at the center of the sight gauge (Item 2) S4080
[Figure 10-120-1]. Do not overfill.
Clean the surface of the filter housing where the filter seal
contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.
WARNING 1
S4028
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.
S4031
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 Raise the operator cab. (See Raising on Page 10-30-1.)
from a physician familiar with this injury.
W-2072-0807 Remove the fill cap (Item 1) [Figure 10-120-4].
Figure 10-120-5
Start the engine and operate the loader hydraulic controls.
WARNING 1
Removing And Replacing Hydraulic Fluid and Case Reconnect the hose when the reservoir is empty.
Drain Filters
NOTE: Fluids such as engine oil, hydraulic fluid,
For the correct service interval (See SERVICE coolant, etc. must be disposed of in an
SCHEDULE on Page 10-70-1.) environmentally safe manner. Some
regulations require that certain spills and
Replace the fluid if it becomes contaminated or after leaks on the ground must be cleaned in a
major repair. specific manner. See local, state and federal
regulations for correct disposal.
Always replace the hydraulic / hydrostatic filter and the
case drain filters whenever the hydraulic fluid is replaced.
(See Removing And Replacing Hydraulic / Hydrostatic
Filter on Page 10-120-1)
Figure 10-120-7
S4032
1
The case drain filters are located under the cab, next to 2
the transmission, one on each side (Item 1) [Figure 10-
120-6].
1
Disconnect the fittings at the end of the case drain filters
and remove both filters.
S4254
Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains. Use the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system. (See Fluid Specifications on Page
SPEC-10-5.)
Figure 10-130-1
P31287A
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
Figure 10-140-3
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
B17460
Figure 10-141-1
S2849 S4050
Figure 10-141-2
If the wedge does not contact the lower edge of the hole
[Figure 10-141-2], the attachment will be loose and can
come off the Bob-Tach.
Lubrication Locations
Figure 10-150-1 2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure
10-150-2] and [Figure 10-150-3].
Figure 10-150-4
3
2
4
1 3
S4036
S4086
Figure 10-150-2 3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure 10-
150-1] and [Figure 10-150-4].
S1080
Figure 10-150-5
4 8
8
S4039
4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure Figure 10-150-8
10-150-1] and [Figure 10-150-5].
Figure 10-150-6 9
7 9
5
P43829 P43830
S4038
S4503 Avoid excessive pressure which can rupture the tire and
cause serious injury or death.
See the SERVICE SCHEDULE for the service interval to
During inflation of the tire, check the tire pressure
check the wheel nuts [Figure 10-160-1]. (See SERVICE
frequently to avoid overinflation.
SCHEDULE on Page 10-70-1.)
When checking wheel nut torque, set the torque wrench to WARNING
140 ft.-lb. (190 Nm) to prevent over-tightening.
AVOID INJURY OR DEATH
Rotating Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
Check the tires regularly for wear, damage and pressure. explosion which can result in injury or death.
Inflate tires to the maximum pressure shown on the W-2078-1007
sidewall of the tire.
Figure 10-160-2
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
B9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires to
the front [Figure 10-160-2].
Cleaning Procedure
Figure 10-170-1
WARNING
1
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
S4014
Never use machine in atmosphere with explosive dust
or gases or where exhaust can contact flammable
Remove the plug (Item 1) [Figure 10-170-1] from the
material. Failure to obey warnings can cause injury or
bottom of the muffler.
death.
W-2068-1285
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
Figure 10-180-1
3
1 4
1 2
5
S4036
Figure 10-180-3
N20575A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].
6
Check that the lock nuts are tightened to 25-28 ft.-lb. (34-
38 Nm) torque.
S4038
Park the loader in a dry protected shelter. Be sure all shields and guards are in place.
Lower the lift arms all the way and put the bucket flat Lubricate the loader.
on the ground.
Check tire inflation and remove blocks from under
Put blocks under the frame to remove weight from the frame.
tires.
Remove cover from exhaust pipe opening.
Put grease on any exposed cylinder rods.
Start the engine and let run for a few minutes while
Put fuel stabilizer in the fuel tank and run the engine a observing the instrument panels and systems for
few minutes to circulate the stabilizer to the pump and correct operation.
fuel injectors.
Operate machine, check for correct function.
Drain and flush the cooling system. Refill with
premixed coolant. Stop the engine and check for leaks. Repair as
needed.
Replace all fluids and filters (engine, hyd. / hydro.).
Stop the Bobcat Loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Deluxe Instrumentation
Lower the lift arms fully and put the attachment flat on the Panel allows operation of the loader without
ground. using a password.
S4006
Figure 10-200-2
Exit the loader [Figure 10-200-3].
WARNING
Before you leave the operators seat:
2 Lower the lift arms, put the attachment flat on the
ground.
Stop the engine.
P-76603 B-15553L
Engage the parking brake.
Raise the seat bar, move pedals until both lock.
Turn the key switch to the STOP position (Item 1) [Figure Move auxiliary hydraulic control lever out of
10-200-2]. detent position.
W-2164-0108
Turn the key switch to the STOP position (Item 1)
(Standard Key Panel) or press the STOP button (Item 2)
(Deluxe Instrumentation Panel) [Figure 10-200-2].
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Pull the tag on the top of the rear window [Figure 10-200- Pull the plastic loop (Item 1) [Figure 10-200-6] at the top
4] to remove the rubber cord. of the window in the front door to remove the rubber cord.
Push the rear window out of the rear of the operator cab. Figure 10-200-7
Figure 10-200-5
1 1
1
1
6707852 S0363
Push the window out with your foot at any corner of the
P45260A window (Item 1) [Figure 10-200-7].
Figure 10-210-1
S4006
85 of 521
HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 A8ET19999)
(PRINTED JANUARY 2009)
(V-0887)
QUICK COUPLERS
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE
HYDRAULIC FILTER
16
13
21
OIL
DRIVE MOTOR 12 14 COOLER
FEMALE
22
7 8 15
D
26
6
B A HYDRAULIC
46 24
POWERED
BOB-TACH
HYDRAULIC AND (OPTIONAL)
HYDROSTATIC PUMPS
42 43 A
1 HYDRAULIC CONTROL VALVE
4 4 23 C
25
44
5 41
39 27
45
40 38
AUXILIARY
36 SPOOL B
B A
CHARGE 37
INLET
Dealer Copy -- Not for Resale
1
TILT CYLINDERS
19 20 BICS CONTROL VALVE
4 4
28
D C
2 TILT CYLINDER
B A SPOOL 30
3 OUTLET
INLET
19 20 28
18
LIFT CYLINDERS
6 18
30
LIFT CYLINDER
B A SPOOL
29
9
20
7 8 IN-LINE FILTER
10 34 33
17 32 31
11 35
V-0887 (01-01-09)
86 of 521
HYDRAULIC SYSTEM INFORMATION
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting fitting SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
bypass valve stuck. 12
bypass valve stem bent or broke. 13
Testing
2
WARNING
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 P-45266
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
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
P-45265
WARNING
Lower the lift arms. Stop the engine. Pull up the lift arm
bypass control to release the hydraulic pressure. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Check only one cylinder at a time. Open the rear door. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Disconnect the negative ground cable from the battery. explosion or fire.
W-2103-0508
S3467
S4324
To remove the lift cylinder rod end pivot pin use a pin
puller (Item 1) [Figure 20-20-5].
Parts Identification
S4379
Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
damage. Replace any damaged parts. and head (Item 4) [Figure 20-20-7].
Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-20-7] to
600 ft.-lb. (814 Nm) torque.
Lubricate all O-rings and seals with hydraulic oil during
installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit. Use
Hold the hydraulic cylinder over a drain pan and move the locktite while tightening the nut.
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-20-8
Put the base end of the cylinder in a vise.
Figure 20-20-6 2
2
1 1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
20-8] from the piston.
Use a spanner wrench to loosen the head (Item 1) NOTE: If the fiber surface (Item 3) [Figure 20-20-8] on
[Figure 20-20-6] from the cylinder case. the piston head, becomes damaged, the
complete piston head must be replaced.
Assembly: Tighten the head with a spanner wrench until
the head is seated all the way into the cylinder (Item 1)
[Figure 20-20-6].
Figure 20-20-9
1
P-48040
Figure 20-20-12
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-9]. Allow the
seal to stretch for 30 seconds before installing it on the
piston. 2
P-48041A P-48042
P-48039
Figure 20-20-13
P7425
Figure 20-20-14
P-48043A P7427
Testing
Figure 20-21-1
S4300
1
2
S4321
Figure 20-21-4
WARNING
1
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
2
explosion or fire.
W-2103-0508
S4309
Parts Identification
S4378
Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2) and head (Item
damage. Replace any damaged parts. 3) [Figure 20-21-7].
Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-21-7] to
100 ft.-lb. (136 Nm) torque.
Lubricate all O-rings and seals with hydraulic oil during
installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. Figure 20-21-8
Figure 20-21-6
P-48088 P-48089
Assembly: Mark the end of the shaft and nut. Tighten the
P-48034
nut an additional 135 degrees or 2-1/4 flats [Figure 20-
21-8]. Use locktite while tightening the nut.
2
2
P-48039
Figure 20-21-12
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
21-9] from the piston.
Figure 20-21-10
1
P-48040
Figure 20-21-13
1
P-48043 P7427
P7425
P-48042
Testing
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. 1
W-2103-0508
S5919
Figure 20-22-2
1 1
S5918
2
1 Remove the bolts (Item 1) [Figure 20-22-3].
S5919
Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm)
torque.
Disconnect and cap the hoses (Items 1 and 2) [Figure 20-
22-2] from the cylinder fittings. Remove the washers and cylinder from the lever pivots.
Parts Identification
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod
3
2
14
13 12
11
10
9
8 7 6
5
4
15
PE1064
Figure 20-22-6
3
2
1
1
4
P-43212
Figure 20-22-7
1
P-48040
Figure 20-22-10
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-22-7]. Allow the
seal to stretch for 30 seconds before installing it on the
piston. 2
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 10].
P-48039
Figure 20-22-11
P7425
Figure 20-22-12
P-48043A P7427
Description
Testing
S2851
Figure 20-30-2
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
WARNING
Put jackstands under the front axles and rear corners S0186
Testing (Contd) Raise the operator cab (See Raising on Page 10-30-1.)
Watch the flow meter on the hydraulic tester to make sure Figure 20-30-4
the flow is correct. Increase the engine speed to full RPM.
Adjusting
S4268
Figure 20-30-3
Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [Figure 20-30-4].
Description Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
The hydraulic control valve is located inside the main 20-1).
frame, below the operator cab.
Raise the operator cab (See Raising on Page 10-30-1).
The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the Clean the area around the control valve.
lift, tilt and auxiliary functions.
Drain the hydraulic reservoir (See Removing And
The lift and tilt functions are operated using mechanical Replacing Hydraulic Fluid and Case Drain Filters on Page
linkages to connect the foot pedals to the lift and tilt 10-120-2).
spools.
Open the rear door of the loader.
The auxiliary functions are operated using mechanical
linkages to connect the right steering lever to the auxiliary NOTE: Before disconnecting the tubelines, first mark
spool. Move the lever to the right or left to activate the the tubelines and the fittings to make sure the
auxiliary hydraulics. tubelines are on the right fitting when
reconnecting.
The hydraulic control valve contains a main relief valve
which is adjustable. Remove the bucket position valve (See Removal And
Installation on Page 20-110-1).
Removal And Installation
Figure 20-40-1
WARNING
Never work on a machine with the lift arms up unless
S4268
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 Remove the right and left steering linkage (Item 1)
to fall and cause injury or death. [Figure 20-40-1] by removing the bolts and nuts on both
W-2059-0598 ends of the steering linkage.
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 20-40-2
1
1 1 2 2
1
S4183
Disconnect the three plugs (Item 1) [Figure 20-40-2] from Figure 20-40-5
the hydraulic control valve.
Figure 20-40-3 1
6 11 7
12 1
9
10
5 1
4
3 2
S2906
8
S4181 Remove the two screws (Item 1) [Figure 20-40-5].
Figure 20-40-6
S4184
Identification Chart
Figure 20-40-7
G1 E2 C1
J1 F4
F5
J3 B1 MR
E3 F3
A1
H1
H2
E1
B2
A2
A3
B3 D1 F1
E1 D5
C3 C2
D3 F2 D4
D2 J4 J5
J2
S5948
Figure 20-40-8
2 1 3
1
2
2
1
S4188
S4185
1 S4203
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 20-40-12
1
S5922
S5922
Loosen the tilt circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-14] from the control valve.
Loosen the lift circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-10] from the control valve. Figure 20-40-15
Figure 20-40-13
S4202
S4202
Replace the O-ring (Item 1) [Figure 20-40-17] before
installation.
Replace the O-ring (Item 1) [Figure 20-40-17] before
installation. Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.
Figure 20-40-16
S4201
Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-40-19
[Figure 20-40-16] from the control valve.
Figure 20-40-17
1
S4204
Figure 20-40-20
1
2
3
1
S4189
S4189
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-21] from the
Remove the four screws (Item 1) [Figure 20-40-20] on the end cap / spool lock block.
rubber boot retainer plate.
Remove the four end cap / spool lock block mount screws
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3 (Item 3) [Figure 20-40-21].
Nm) torque.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Remove the rubber boots (Item 2) [Figure 20-40-20] from Nm) torque.
the retainer plate.
Remove the rubber boots and retainer plate from the lift
and tilt spools.
Figure 20-40-22
S4200
S5923
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-23] from the lift spool.
Figure 20-40-24
1 2
S5926
1
Remove the screws (Item 1) [Figure 20-40-26] from the
detent bonnet.
S5924
IMPORTANT
Remove the end cap (Item 1) [Figure 20-40-24].
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-27
S5929
Figure 20-40-28
S5930
3 2 1
2 S5928
Figure 20-40-31
1
2
N-18916
2 1
1
3
N-19004
N-18915
Figure 20-40-35
N-18918
Remove the stud from the end of the spool [Figure 20-40-
37].
N-19009
Figure 20-40-38
Figure 20-40-36
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), collar (Item 2), spring (Item tap drill
3) and washer (Item 4) [Figure 20-40-36].
Turn a 6-32 tap (Item 1) [Figure 20-40-38] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Figure 20-40-39
2
Plastic
1 Plug
0.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
N-18961 20-40-41].
Figure 20-40-42
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-39].
NOTE: Check the O-ring for damage. The lift spool will
have an internal leak if there is damage to this
O-ring. Always replace the o-ring and recheck 1
the lift spool before the control valve is
replaced.
Figure 20-40-40
N-18967
N-18963
Install the plastic plug and O-ring in the spool [Figure 20-
40-40].
Figure 20-40-43
1
N-19004
1 3
2 Install the spring tool (Item 1) [Figure 20-40-45] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-46
Install the spring (Item 1) and detent balls (Item 2) into the 2
adapter (Item 3) [Figure 20-40-43] and compress with the
detent pliers (Item 1) [Figure 20-40-44].
Figure 20-40-44
N-18917
N-18968
Figure 20-40-47
N-19007
CD-15051
1
S5924
Install the lift spool assembly in the spool bore [Figure 20-
40-51].
S5930
1
2
S5925
Figure 20-40-55
2 2
1
3
S5932
Install the end cap / spool lock block (Item 1) [Figure 20-
40-57].
S5923
Install the lift and tilt spool rubber boots and mount plate
(Item 2) and install the four mounting screws (Item 3)
Install the O-ring (Item 1) and bushing (Item 2) [Figure [Figure 20-40-57].
20-40-55] on the lift spool.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Figure 20-40-56 Nm) torque.
Figure 20-40-58
1
2
S5931
S5933
Install the O-ring (Item 1) [Figure 20-40-56] on the control
valve.
Use an Ohm meter to measure the lock solenoid coils
resistance.
Remove the lift and tilt end cap / spool lock block. (See
End Cap / Spool Lock Block Removal And Installation on
Page 20-40-9.)
Figure 20-40-59
1
2
S5936
Figure 20-40-60
S5937
Figure 20-40-63 1
N-18942
Put the linkage end of the spool in the vise [Figure 20-40-
S5938 65].
N-19014
S5939
Tilt Spool Removal And Installation (Cont'd) The tool listed will be needed to do the following
procedure:
Figure 20-40-67
MEL 1278 - Detent Tool
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 1
3) and washer (Item 4) [Figure 20-40-67].
Figure 20-40-68
2
1 S5941
Figure 20-40-70
S5940 N-18943
1
S5935
Figure 20-40-71
1
2
S5938
Figure 20-40-74
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-71].
Figure 20-40-72
1 S5942
Figure 20-40-75
3 2
1 1
S5945
2
Figure 20-40-78
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-75].
Figure 20-40-76
1
P-8988
1
3
N-19004
Figure 20-40-82
Install the spring tool (Item 1) [Figure 20-40-79] over the
centering spring.
1
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-79] from the centering
spring, as it is under spring pressure.
Figure 20-40-80
N-19009
1
2
N-18916
Figure 20-40-83
1
2
3
1
4
N-18920
Inspect the adapter (Item 1), collar (Item 2), spring (Item Drill a hole all the way through the plug using a 7/64 inch
3) and washer (Item 4) [Figure 20-40-83]. tap drill
Figure 20-40-84 Turn a 6-32 tap (Item 1) [Figure 20-40-85] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Figure 20-40-86
2
1
N-18918
Remove the stud from the end of the spool [Figure 20-40-
84].
N-18961
Figure 20-40-87
N-18967
Install the plastic plug and O-ring in the spool [Figure 20-
40-87].
Figure 20-40-88 2
O-Ring
1 3
2
Plastic N-18958
Plug
0.60 inch
(15,2 mm) Apply grease on all the detent component surfaces before
assembly [Figure 20-40-90].
B-14712
Install the spring (Item 1) and detent balls (Item 2) into the
adapter (Item 3) [Figure 20-40-90] and compress with the
Install the stud and tighten until the other end of the stud detent pliers (Item 1) [Figure 20-40-91].
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-88].
Figure 20-40-91
2
1 N-18917
Figure 20-40-94
Install the detent adapter to the collar [Figure 20-40-91].
Figure 20-40-92
N-19005
1
Install the spring assembly to the auxiliary spool hand
tight [Figure 20-40-94].
Install the spring tool (Item 1) [Figure 20-40-92] over the NOTE: The adapter must fit in the center of the washer
washer, spring, collar and detent adapter. (Item 1) [Figure 20-40-94].
Figure 20-40-95
N-19008
Figure 20-40-96
N-19007
Figure 20-40-98
1
1
S4186
1
2 2
S4187
N-18693A
Clean all parts in solvent and dry with compressed air.
The correct resistance for the coil is 9.79 0.29 Ohms. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
2
1
2 2 2
S4194
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-102] is for the lift circuit.
Figure 20-40-103
S4193
Figure 20-40-105
S5946
1
1
1 1
1
2 2 2
S4194
S4191
Figure 20-40-109
S4191
Figure 20-40-110
S4192
Description
Testing
WARNING
Figure 20-50-1
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.
1 W-2059-0598
Figure 20-50-2
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm bypass Control Knob until the lift arms
slowly lower. 1
S4225
Figure 20-50-3
1
1 2
S4228
Figure 20-50-4
2 3
1
S4229
S2910
Remove the lift arm bypass control valve (Item 1) [Figure
20-50-6].
Disconnect the base end lift tubeline (Item 1) [Figure 20-
50-4] from the Lift Arm bypass valve. Remove the rubber washer (Item 2) [Figure 20-50-6].
Figure 20-50-7
2 3
1
S4229
A seal kit is available to service the hydraulic pump. If any NOTE: DO NOT EXCEED 3300 PSI.
of the main components of the pump are damaged, the
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-60-1] on the
tester counterclockwise to obtain free flow, the flow should
Pump Test at Quick Couplers be approximately 16-17 GPM (60,6-64,5 L/min).
The tools listed will be needed to do the following Start turning the restrictor clockwise, causing more
procedure: restriction on the flow. The GPM should drop off slightly
until the pressure reaches approximately 2400 PSI (165
MEL10103 - Hydraulic Tester bar). At approximately 2400 PSI (165 bar) the flow should
MEL10106 - Hydraulic Test Kit start decreasing rapidly until the pressure reaches 2650-
2750 PSI (183-190 bar). At 2650-2750 PSI (183-190 bar)
Figure 20-60-1 the flow should be at 0 GPM (0 L/min). Turn the restrictor
(Item 2) [Figure 20-60-1] counterclockwise to free flow.
Shut the front auxiliary hydraulics off.
1
If flow and pressure specs are not obtained, go to Direct
Pump Testing. (See Direct Pump Test on Page 20-60-2.)
P-16903 S6029
1
WARNING
S4268
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 Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286 tubeline on the control valve.
Figure 20-60-3
Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) 2 1
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 S5999
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose from the tester to the OUTLET
hose (Item 1) [Figure 20-60-2] and [Figure 20-60-3] of
Raise the operator cab (See Raising on Page 10-30-1.) the pump.
Open the rear door of the loader. Connect the OUTLET hose (Item 2) [Figure 20-60-2] and
[Figure 20-60-3] from the tester to the tubeline on the
Connect the remote start tool (See Remote Start control valve.
Procedure on Page 10-60-4.)
Hydraulic Pump
Out In Hydraulic Control
Valve
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
1 Failure to use jackstands can allow the machine to fall
or move and cause injury or death.
W-2017-0286
BH-196
Start the engine and run at low idle RPM. Make sure the Raise the lift arms and install an approved lift arm support
tester is connected correctly. If no flow is indicated on the device (See LIFT ARM SUPPORT DEVICE on Page 10-
tester, the hoses are connected wrong. With the hoses 20-1.)
connected correctly, increase the engine speed to full
RPM*.
1 Figure 20-60-8
P-39250 1
Figure 20-60-6
S4269
1
1
P-39247
Figure 20-60-9
P-39255A
Be sure all connections are tight and that the hoses are
S4270 not touching any moving parts before starting the loader
[Figure 20-60-10].
Connect the inlet hose from the hydraulic tester to the Start the engine and run at low idle RPM. Make sure the
outlet fitting (Item 1) [Figure 20-60-9] of the charge pump. tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
Connect the outlet fitting on the hydraulic filter to the hose connected correctly, increase the engine speed to full
that was removed from the charge pump. RPM*.
Connect the outlet hose on the hydraulic tester to the inlet Warm the fluid to 140F. (60C.) by turning the restrictor
fitting on the hydraulic filter assembly. control (Item 1) [Figure 20-60-10] on the tester to about
1000 PSI (68,95 bar). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.
1
S4205
IMPORTANT
Remove the hydraulic reservoir bracket by removing the
When repairing hydrostatic and hydraulic systems, two screws (Item 1) [Figure 20-60-11].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Figure 20-60-12
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 1
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
2.5
1
16
1 9
S4207 45
Figure 20-60-16
1 1
S4744
S2903
Figure 20-60-17
1
S4207
Figure 20-60-18
S4745
Parts Identification
1. Bolt (8)
2. Washer
3. Shaft seal
4. Washer
5. Pump Flange Section
6. Plug
7. O-ring
8. Pre-Load Seal
9. Load Seal
10. Wear plate
11. Drive Gear
12. Key
13. Idler Gear
14. Hydraulic Pump Section
15. O-ring
16. Pump Center Section
17. O-ring
18. Drive Gear NOT AVAILABLE AT TIME
19. Idler Gear OF PRINTING
20. Pre-Load Seal
21. Load Seal
22. Wear plate
23. Charge Pump Section
24. O-ring
25. Pump End Section
S4746
Figure 20-60-20 1
1 3
1
S4209
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 S4749
damage the system.
I-2003-0888
Remove the shaft seal (Item 1) [Figure 20-60-23] from
the pump flange section.
2
S4212
Figure 20-60-26
S6033
Figure 20-60-24
S4213
Figure 20-60-27
1
S4216
Remove the pump center section (Item 1) [Figure 20-60- Figure 20-60-30
27] with drive gear and drive shaft by lifting it up.
Figure 20-60-28
1
1
S4217
3
Inspect the drive gear and drive shaft (Item 1) [Figure 20-
S4215
60-30] for wear. Replace if needed.
S4219
Figure 20-60-34
S4218
Figure 20-60-32
S4213
Figure 20-60-35
1
S4223
Figure 20-60-38
Remove the drive gear (Item 1) [Figure 20-60-35] from
the charge pump section.
Figure 20-60-36
S4224
IMPORTANT S5973
1 2
S4105
Figure 20-70-3
1
1
S2905
The hydraulic fluid reservoir is a storage container for the Figure 20-80-1
loaders hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
Figure 20-80-2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 S4132
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 20-80-3
1 1
S5916
S4133
Remove the fill cap (Item 1) [Figure 20-80-5] from the
hydraulic reservoir.
Disconnect the three hydraulic tubelines (Item 1) [Figure
20-80-3] from the hydraulic reservoir. Cap the tubelines. Figure 20-80-6
Figure 20-80-4
1
1
2
S5917
S4134
Remove the hydraulic fluid screen (Item 1) [Figure 20-80-
6] from the reservoir.
Remove the bracket (Item 1) by removing the two screws
(Item 2) [Figure 20-80-4]. Wash the screen in clean solvent and air dry, before
installing.
Installation: Tighten the screws to 15-20 ft.-lb. (20-27
Nm) torque.
Description
S4134
IMPORTANT
Disconnect the two plugs (Item 1) [Figure 20-90-1].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-90-2
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
Open the rear door of the loader.
S4252
Figure 20-90-3
1 2
3
S4253
Figure 20-90-4
S6032
Description
Figure 20-100-1
Remove the solenoid stem (Item 1) [Figure 20-100-2]
from the bucket position valve.
S4294
Installation: Tighten the solenoid nut to 60 in.-lb. (6,78 Inspect the solenoid stem and replace the O-rings (Item
Nm) torque. 1) and back-up washers (Item 2) [Figure 20-100-3].
Solenoid Testing Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
Figure 20-100-4 20-1)
Figure 20-100-5
P9175
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
Figure 20-100-6
1
S4172
Remove the left steering linkage by removing the bolts Figure 20-100-9
and nuts on both ends of the steering linkage [Figure 20-
100-6].
Figure 20-100-7
S4173
S4171
Figure 20-100-10
1
1
S4176
Figure 20-100-13
Disconnect the two hydraulic tubelines by loosening the
nuts (Item 1) [Figure 20-100-10]. Cap the tubelines and
the fittings after disconnection. 1
1
Figure 20-100-11
S4177
1 1
S5913
Remove the tilt cylinder check valve (Item 1), spring (Item
S5911 2) and plug (Item 3) [Figure 20-100-16]. Check for wear,
check O-ring and replace as needed.
Figure 20-100-15
2
1
1
S5914
Remove the plug (Item 1) and the flow control spool (Item
2) [Figure 20-100-17].
S5912
Check the flow control spool for wear, check the O-ring on
the plug and replace if needed.
Remove the plug and O-ring (Item 1) [Figure 20-100-15].
Figure 20-100-18
S5915
The Power Bob-Tach block is mounted on the front right Remove the steering linkages.
side of the machine.
Figure 20-110-1
Removal And Installation
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 1
to fall and cause injury or death.
W-2059-0598
S4390
Figure 20-110-2
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,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S4391
Figure 20-110-3
3 S4393
1
3
S2853 1 S4398
Disconnect the hose (Item 1) [Figure 20-110-3] and Remove the four mounting bolts (Item 3) [Figure 20-110-
[Figure 20-110-4] from the Power Bob-Tach block. 6].
Figure 20-110-7
1
3
2
2 1 S5900
Remove the spring guide (Item 1), spring (Item 2) and the
S4399 spool (Item 3) [Figure 20-110-8].
1
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 S5901
Figure 20-110-10
1 3
S5903
Installation: Oil the check valve and O-rings and tighten Figure 20-110-13
the check valve to 20-25 ft.-lb. (27,1-34 Nm) torque.
Figure 20-110-11
1
2 1
P-48384
3
S5902 Remove the plug (Item 1) [Figure 20-110-13], inspect the
O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-110-13]
(Item 2) [Figure 20-110-11]. to 12-14 ft.-lb. (16,3-19 Nm) torque.
Figure 20-110-14
1 1 2
2
S5904
Figure 20-110-15
1
1
2
P-48386
Figure 20-110-18
S5905
1
2
2
1
1
S4394
P-48173
Description
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 20-120-1
1 2
S4044
Description
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
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
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
Description
S4499
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
S4372
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Figure 30-20-3
1
1
S4257
S4230
1
S4231 S4258
Remove the hydrostatic motor from the loader by Remove the O-rings (Item 1) [Figure 30-20-6] from the
removing the four mounting bolts (Item 1) [Figure 30-20- end cap and check for wear. Replace if needed
4] and pulling it out of the loader.
Figure 30-20-7
2 S4495
Figure 30-20-8
2
1 1
2
S4261
S4260
Remove both inner and outer seals (Items 1 and 2) and
the two springs (Item 3) [Figure 30-20-10] from the cone.
Remove the valve (Item 1) and check the O-ring (Item 2)
[Figure 30-20-8] for wear. Replace if needed.
S4271
NOTE:
2
Figure 30-20-12 1
S4272
1
2 NOTE: Do not disassemble the gerotor section (Item
S4262 1) [Figure 30-20-14]
Figure 30-20-15
S4277
Figure 30-20-18
Remove the drive shaft (Item 1) [Figure 30-20-15] from
the hydrostatic motor by pulling it out.
1
Turn the hydrostatic motor upside down.
2
3
Figure 30-20-16
S4278
1
Remove the seal (Item 1) [Figure 30-20-18] from the
drive shaft and inspect for wear. Replace if needed.
Remove the plate from the drive shaft by removing the Remove the upper bearing (Item 3) [Figure 30-20-18]
eight bolts (Item 1) [Figure 30-20-16]. from the drive shaft by pulling it back.
Figure 30-20-19
2
S4280
Description
Figure 30-30-1
P-43197
The tools needed to check charge pressure, hydraulic Raise the operator cab. (See Raising on Page 10-30-1.)
hose (Item 1), Hydraulic gauge 1000 PSI (68,95 bar)
(Item 2) and adapter fitting (P/N 93F-5) (Item 3) [Figure
30-30-1].
Figure 30-30-3
1
1
2
S5907
S5907
Disconnect the charge pressure sender connector (Item
1) [Figure 30-30-4] from the sender.
Remove the cap (Item 1) [Figure 30-30-3] from the fitting.
Remove the sender (Item 2) [Figure 30-30-4] from the
Install the hose that is attached to the pressure gauge, to adapter fitting.
the fitting, where the cap was removed.
Installation: Tighten the charge pressure sender to 7.4-
Tighten the hydraulic fittings. 8.1 ft.-lb. (10-11 Nm) torque.
Adjusting
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 30-30-5
S4376
Description
The hydrostatic pump contains the charge pressure relief. Remove the replenishing / high pressure relief valve (Item
The charge pressure relief is adjustable with shims. 1) [Figure 30-40-2] from the pump.
The hydrostatic pump is located in the center of the Assembly: Tighten the plug to 30-50 ft.-lb. (41-68 Nm)
mainframe mounted to the engine flywheel housing. torque.
Replenishing / High Pressure Relief Valve Removal Check for damage and replace as needed.
And Installation
Check O-ring (Item 2) [Figure 30-40-2] for damage and
Figure 30-40-1 replace as needed.
S4147
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
IMPORTANT 2
Figure 30-40-5
1
S4109
1
Figure 30-40-6 1
2
2
2
1
1
1
S4146
1
Install the puller (Item 1) on the hydrostatic pump drive Figure 30-40-9
pulley. Remove the drive pulley (Item 2) [Figure 30-40-6]
from the pump shaft.
1 S4147
Figure 30-40-10
S4148
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
Parts Identification
1. Bolt (2)
2. Washer
3. O-ring
4. Coupler
5. O-ring
6. Replenishing/High Pressure Relief Valve
7. Pin
8. Bearing
9. Valve Plate
10. Gasket
11. Block
12. Wear Plate
13. Swash plate
14. Tapered Roller Bearing
15. Plug
16. O-ring
17. Housing
18. O-ring
19. Bearing Race
20. Cover
21. Washer
22. Bolt (6)
23. Bearing
24. Crush Ring
25. Seal
26. Cover
27. Shaft (For Left Pump)
28. Key
29. Retainer Ring
30. Bearing Thrust
31. Bearing
32. Washer
33. Seal
34. Retainer Ring
35. Shaft (For Right Pump)
36. O-ring
37. Charge Pressure Relief Valve Housing
38. Piston
39. Spring
40. Washer
41. Retainer Ring
42. Pin
43. End Cap
S4747
Disassembly
1
Figure 30-40-11
1
S4151
1
Screw the two replenishing/high pressure valves (Item 1)
1 S4149 [Figure 30-40-13] out of the end cap.
Figure 30-40-12
1
3
1
2 S4152
Disassembly (Contd)
Figure 30-40-15
S4157
Figure 30-40-18
Remove the charge inlet relief valve (Item 1) [Figure 30-
40-15].
Figure 30-40-16
1
2
2
6 5 4 3 1
S4158
Disassembly (Contd)
Figure 30-40-19
1
2 7
5 6
1 3 4
8 S4160
Pull the two washers (Items 3 and 4) and the spring (Item 1 2 3 4 5 4
5) [Figure 30-40-19] out of the cylinder block. 6
Disassembly (Contd)
Figure 30-40-22
2
1 3
S4164
Remove the O-ring (Item 1), the crush ring (Item 2) and
S4162
the bearing race (Item 3) [Figure 30-40-24] from the
cover. Inspect them and replace if needed.
Remove the bearing (Item 1) [Figure 30-40-22] from the
Figure 30-40-25
pump housing.
Figure 30-40-23
1
1
1
1
S4165
S4163
Remove the lower cover from the pump housing by
removing the three bolts (Item 1) [Figure 30-40-25].
Remove the cover from the pump housing by removing
the three bolts (Item 1) [Figure 30-40-23].
Disassembly (Contd)
Figure 30-40-26
1
1
S4168
Slide the swash plate from side to side and remove the
lower tapered roller bearing (Item 1) [Figure 30-40-26]
from the swash plate shaft.
Figure 30-40-27
S4167
Assembly
Figure 30-40-29
1
S4165
Install the wear plate (Item 1) [Figure 30-40-29] onto the Figure 30-40-32
swash plate.
Figure 30-40-30
2
1 3
S4164
S4166
Install the O-ring (Item 1), the crush ring (Item 2) and the
bearing race (Item 3) [Figure 30-40-32] on the cover.
Install the swash plate and the upper tapered roller
bearing into the pump housing [Figure 30-40-30].
Assembly (Contd)
Figure 30-40-33
1 2 3 4 5 4 6
1
1
1
S4161
Install the retaining ring (Item 1), the two metal rings (Item
S4163 4) and the bearing (Item 5) [Figure 30-40-35] onto the
pump shaft.
Install the cover on the pump housing and tighten the Install the retaining ring (Item 3) [Figure 30-40-35] onto
bolts (Item 1) [Figure 30-40-33] to 29 ft.-lb. (39,3 Nm). the pump shaft.
Figure 30-40-34 Install the big metal ring (Item 2) and the seal ring (Item 1)
[Figure 30-40-35] onto the pump shaft.
Figure 30-40-36
1
1
S4162
Install the pump shaft into the pump housing and install
the retaining ring (Item 1) [Figure 30-40-36].
Assembly (Contd)
Figure 30-40-37
2 7
5 6
1 3 4
S4157
8
Figure 30-40-40
Install the two rings (Items 3 and 4) and the spring (Item
5) [Figure 30-40-37] into the cylinder block.
Figure 30-40-38
S4156
Install the cylindric part (Item 5), the spring (Item 4), the
the ring (Item 3) and the retaining ring (Item 1) into the
valve housing (Item 2) [Figure 30-40-40].
S4158
Install the ring and pistons into the cylinder block [Figure
30-40-38].
Assembly (Contd)
Figure 30-40-41
S4152
Figure 30-40-44
Screw the cylinder (Item 1) [Figure 30-40-41] into the end
cap after first installing the O-ring (Item 6) [Figure 30-40-
40]. 1
Figure 30-40-42
1
S4151
Assembly (Contd)
Figure 30-40-45 1
1 1
1 S4149
S6017
S4232
Belt Removal And Installation Remove the drive belt from the engine (See Belt Removal
And Installation on Page 30-50-2).
Open the rear door of the loader.
Figure 30-50-4
Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance
(See Removal And Installation on Page 60-20-1.) 1
Figure 30-50-3
S4233
1
S4234
Description
Figure 30-60-4
1
3
P-76212
1
Remove the filter housing nut (Item 1) from the filter
housing (Item 2) [Figure 30-60-1].
2
Figure 30-60-2
P-76216
The larger taper spring (Item 1) slides over the end of the
2
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-60-4] slides into the filter element.
P-76214
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
CHAINCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-30-2
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-30-2
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
Figure 40-10-1 20-1.)
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
S2849
Raise the operator cab (See Raising on Page 10-30-1.)
1 S0364
Figure 40-10-3
3
P-54222
1
Snap ring pliers with 90 tips is necessary for removing
N-19105 the parking brake discs.
Description
S4265
Figure 40-20-1
1
1
P-4159
2
Install the puller tool (Item 1) [Figure 40-20-2] on the axle
P-4157 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
Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is flush
with the edge of the axle tube [Figure 40-20-5].
P-4181
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
P-4147A
Figure 40-20-8 1
P-4170
Figure 40-20-9
P-4171
Figure 40-20-12
4
3
P-4175
2
When the bearing reaches the bearing mounting surface,
continue the installation until the bearing is fully seated
P-4169 [Figure 40-20-13].
Figure 40-20-14
Installation: A piece of round tubing (Item 1) [Figure 40-
20-12] is needed to install the bearing on the axle shaft.
Be sure to hold on to the axle during installation, as it will Use the long rod and the bearing cup tool to remove the
slide freely along the axle shaft after the spline end has inner bearing cup [Figure 40-20-14].
passed through the bearing and until it reaches the
bearing mounting surface on the axle. Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].
P-4174A
2
1
Figure 40-20-18
P-4179
1
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-15] on the tool. 2
Put the inner bearing cup in the axle tube (Item 2) [Figure
40-20-17].
Install the long threaded rod into the axle tube and
through the installation tool (Item 1) [Figure 40-20-17].
P-4180
Secure the tool to the threaded rod with a nut (Item 3)
[Figure 40-20-17].
Use the slide hammer and remove the bearing cup from
the axle tube [Figure 40-20-16]. Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
tool.
Secure the tool to the threaded rod with a nut [Figure 40-
20-18].
WARNING
Never work on a machine with the lift arms up unless
Hold the inside nut with a wrench and tighten the outside
the lift arms are secured by an approved lift arm
nut as shown in photo [Figure 40-20-18].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
Tighten the nut until the bearing cup is seated.
to fall and cause injury or death.
W-2059-0598
Figure 40-20-19
Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Figure 40-20-20
1 B-13504A
Remove the parking brake disc (Item 1) [Figure 40-20- Installation: If a new chain is installed, a connector link
20]. (See Disk Removal And Installation on Page 40-10- must be used to connect the chain together.
1.)
Use MEL1037 Chain Link Tool and #80 chain adapter.
Remove the six mounting bolts (Item 2) [Figure 40-20-20]
from inside the chaincase. Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Installation: Tighten the mounting bolts to 125-140 ft.-lb.
(170-190 Nm) torque. Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22].
Figure 40-20-21
Tighten the threaded rod of the chain link tool to 130 ft.-lb.
(176 Nm) torque.
1
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307
P-54226
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain from the sprocket.
Description
Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1)
1
Raise the operator cab (See Raising on Page 10-30-1)
S2912
1 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
S4237
Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Disconnect the two electrical connectors (Item 1) and
Page 10-20-1)
remove the nut (Item 2) [Figure 40-30-3].
Raise the operator cab (See Raising on Page 10-30-1)
Remove the two solenoid coils (Item 3) [Figure 40-30-3]
from the solenoid stem.
Remove the remote control panel (See Removal and
Installation on Page 50-100-2).
Figure 40-30-4
Remove the hydraulic control valve (See Removal And
Installation on Page 20-40-1).
Figure 40-30-2 1
S4238
Figure 40-30-5
2 S4241
Remove the side bracket (Item 1) by removing the screw Figure 40-30-8
(Item 2) [Figure 40-30-5].
Figure 40-30-6
3 1
1 2
3
2
2
S4242
Remove the side bracket (Item 1) by removing the screw Remove the traction lock solenoid by removing the two
(Item 2) [Figure 40-30-6]. screws (Item 2) [Figure 40-30-8].
Figure 40-30-9
1
INCORRECT CORRECT
2
3
2
P11337
1
Installation: Install the traction wedge assembly (Item 1)
N-19106 N-19105 into the solenoid traction lock guides (Item 2) [Figure 40-
30-10]. Tighten the four bolts and check to make sure the
shaft assembly is moving freely in the guides.
Installation: Install the traction lock guides (Item 1)
[Figure 40-30-9] to the chaincase cover using the four Installation: Apply polyurethane sealant to mating
screws. Do not tighten at this time. surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage.
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR
BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
P-43383
Figure 50-10-2
N-18463
Figure 50-10-3
N-18572
Remove the nuts and plates (both sides) [Figure 50-10- Figure 50-10-6
3].
S4010
S4078 Reverse the above procedure to install the seat bar into
the operator cab.
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].
4 3
6
5
7
2 7
3
2 9 8
10 1
1 N-19340
Figure 50-10-10
N-19383
4
5
Figure 50-10-8
3 6
2
4
5 7
9 8
1
3 6
2 10
7
1
N-19220
Assemble the parts as shown for the right side of the seat
N-19219 bar pivot assembly [Figure 50-10-9] and [Figure 50-10-
10].
Assemble the parts as shown for the left side of the seat Seat Bar Mount (Item 1)
bar pivot assembly [Figure 50-10-7] and [Figure 50-10- Mounting Nut (Item 2)
8]. Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar Mount (Item 1) Seat Bar (Item 5)
Mounting Bolt (Item 2) Keyed Plastic Bushing (Item 6)
Keyed Plastic Bushing (Item 3) Mounting Bolt (Item 7)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5) Installation: Tighten the mounting bolt (Item 7) [Figure
Pivot Bushing (Item 6) 50-10-9] and [Figure 50-10-10] to 50-70 in.-lb. (5,6-7,9
Sensor Bracket (Item 7) Nm) torque.
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
5
Pin (Item 6)
4 6
Bushing (Item 7)
3
2
1
N-19384
Figure 50-10-12
N-19222
WARNING 1
P1518 P1528
WARNING Remove the cab nut and holddown plate (Item 1) [Figure
50-20-2] (both sides).
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Installation: Tighten the nut to 40-50 ft.-lb. (54-68 Nm)
support device. Failure to use an approved lift arm torque.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 50-20-3
W-2059-0598
1
Figure 50-20-1
N-20617D
P-54018
Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Remove the operator cab stop (Item 1) (both sides) Raise the operator cab. (See Raising on Page 10-30-1.) to
[Figure 50-20-1]. release the tension on the gas cylinder.
Figure 50-20-4
2 1
P-48587
Figure 50-20-5 Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.
DUAL GAS CYLINDER
Installation: Tighten the screws to 100-130 in.-lb. (11,3-
14,7 Nm) torque.
1 2
P-43354
Figure 50-20-7
2
1
1
P1008
P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.
DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.
Figure 50-20-10
1
P-68819
1
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.
W-2245-0796 S0365
Figure 50-20-11
Disconnect the cab harness connector (Item 1) [Figure
50-20-12].
1
Installation: Tighten connector screw to 30-35 in.-lb.
(3,4-4 Nm) torque.
Figure 50-20-13
N-20617D
1 2
Remove the operator cab gas cylinder(s) (See Gas
Cylinder Removal And Installation on Page 50-20-1.)
Figure 50-20-14
N-20627A S4299
Figure 50-30-1
1 1
1
2
1 1
N-20729A
N-20729
Raise the operator cab. (See Raising on Page 10-30-1.)
Raise the operator cab (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Items
1 and 2) [Figure 50-30-3] and peel back or cut insulation
Remove the four seat mounting nuts (Item 1) [Figure 50- to gain access to the head.
30-1] and washers from the operator seat mounting studs.
Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
Nm) torque.
Figure 50-30-2
2 N-20655
Lower the cab and install one of the plates and nuts Repeat for other half of seat belt and guide.
[Figure 50-30-2].
Figure 50-31-1
1 1
1
1 1
S4352
Figure 50-31-4
S4355
S4351
P10564 P10563
Figure 50-31-5
1
1
2
2
1
1
1
S4352
S4351
Remove the operator seat (See Removal And Installation
on Page 50-31-1.)
Remove the operator seat (See Removal And Installation
on Page 50-31-1.) Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5]. Remove the seat belt.
Remove the slide rail (Item 2) [Figure 50-31-5] from the Installation: Tighten the mounting nuts to 58 to 62 ft.-lb.
bottom of the seat frame. (78,6 to 84 Nm) torque.
Figure 50-31-7
1
N-18583
S4353
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-9] and tilt the seat back all the way forward.
Remove the retainer clips (Item 1) [Figure 50-31-7] and
lift the seat cushion. Figure 50-31-10
Figure 50-31-8
1 1
N-18578
S4354
Remove the two mounting screws (Item 1) [Figure 50-31-
10] from the seat back and remove the back.
Inspect the seat ride adjustment [Figure 50-31-8].
Reverse the removal procedure to install the operator
Reverse the removal procedure to install the operator seat.
seat.
Shock Removal And Installation Raise the operator cab (See Raising on Page 10-30-1.)
Figure 50-31-11 Remove the operator seat (See Removal And Installation
on Page 50-31-1.)
Figure 50-31-12
2
1
2
1
1
P-43118
3
P16284
Figure 50-31-14 1 2
P16126
1
INSIDE OF CAB
P16128
Description
Figure 50-40-1
S4309
S4304
Figure 50-40-3
2
1
1 S4316
Figure 50-40-5
S5991
1
Remove the Bob-Tach lever (Item 1) [Figure 50-40-7].
S5989
Figure 50-40-8
S5992
Figure 50-40-9
1
2
S4316
1
Remove the spring, bolt and clevis assembly (Item 1) Remove the rubber seal (Item 1) [Figure 50-40-11].
[Figure 50-40-9].
Installation: Use a new seal when assembling.
Remove the wedge (Item 2) [Figure 50-40-9] from the
Bob-Tach frame. Figure 50-40-12
Figure 50-40-10
2
1 1
S5995
4
3
Remove the bushing (Item 1) [Figure 50-40-12] with a
S5994
slide hammer.
Description
The Bob-tach is located on the front of the loader Installation: Tighten the retainer bolt and nut to 25-28 ft.-
connected to the loader lift arms. lb. (34-38 Nm) torque.
Removal And Installation Remove the pivot pin (Item 3) [Figure 50-41-2] from the
tilt cylinder rod end.
Figure 50-41-1
Remove the tilt cylinder rod end (Item 4) [Figure 50-41-2]
from the Bob-Tach.
S5919
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to secure
the clamp.
Figure 50-41-3
2
1
1 S4316
Use a punch to push the pivot pins all the way inside the
Bob-Tach frame.
S5997
1
5
S5998
Figure 50-41-9
4
1
3 2 S4316
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) or Remove the rubber seal (Item 1) [Figure 50-41-11].
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise. Installation: Use a new seal when assembling.
Remove the bolt and replace the damaged parts as Figure 50-41-12
needed.
Figure 50-41-10
S5995
Use a punch and hammer to drive the roll pin (Item 1) Installation: Install the bushing with a driver tool and
[Figure 50-41-10] flush with the face of the Bob-Tach. hammer.
Figure 50-50-1
1
2
1
S5954
Left Side
Figure 50-50-2
S4044
Right Side
Figure 50-50-4
1
1
S5955
Figure 50-50-5
1
2 S4312
1
1
Remove the lift arm support device mounting bolt (Item 1)
[Figure 50-50-7] spacer and nut.
S5982
Installation: Tighten the mounting bolt and nut to 25-28
ft.-lb. (34-38 Nm) torque.
Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.
Figure 50-50-8
1 2
1
S5986
Wrap one of the 7 ft. lifting straps around the lift arm
S5983 crossmember as shown [Figure 50-50-10].
Remove the right side lift cylinder pivot pin (Item 1) Use a chain hoist and lifting strap to raise the lift arms
[Figure 50-50-8]. enough to remove the tilt cylinder base end pivot pin
[Figure 50-50-10].
NOTE: Put a piece of cardboard under the rod end of
the lift cylinders to protect the fender from Figure 50-50-11
scratches.
Figure 50-50-9
1 S5985
Remove the two tilt cylinders (Item 1) from the lift arm
crossmember by removing the bolts and nuts (Item 2)
[Figure 50-50-11] and removing the pivot pins.
S5984
Remove the left side lift cylinder pivot pin (Item 1) [Figure
50-50-9].
Figure 50-50-12
1 3
1
S4323
2
Remove the upright pivot pin mounting bolt (Item 1) and
S5987 nut (Item 2) [Figure 50-50-14] (Both sides.)
Tighten the pivot pin mounting bolt and nut to 25-28 ft.-lb.
Put the middle of the second lifting strap (Item 1) [Figure (34-38 Nm) torque.
50-50-12] up into the lift arm as shown.
Remove the upright pivot pin (Item 3) [Figure 50-50-14].
Install the lift cylinder pivot pin (Item 2) [Figure 50-50-12] (Both sides.)
and secure the pin with the mounting bolt and nut.
Figure 50-50-15
Wrap both ends of the strap around the top of the lift arm
and down the back of the lift arm [Figure 50-50-12].
Figure 50-50-13
S5956
S5987
Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-15].
Continue to wrap the lifting strap around the lift arm a
second time [Figure 50-50-13].
Use the chain hoist and lower the lift arms so they rest on
the blocking.
Figure 50-50-16
S5953
Pull the lift arms away from the loader [Figure 50-50-16].
Figure 50-60-1
P-48130
Open the rear door. Reverse the removal procedure to install the grill.
Figure 50-60-2
S4082
P-43360
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the engine harness. hinge as shown.
Remove both rear lights from the door (See Rear Installation: Tighten the mounting bolts and nuts to 25-28
Removal And Installation on Page 60-60-1.) ft.-lb. (34-38 Nm) torque.
Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.
P-34588
Figure 50-70-4
WARNING
AVOID INJURY OR DEATH
1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1 1
P-31126
Figure 50-70-5
Remove the rollers (Item 2) and the spacer (Item 3) from Close the rear door.
the bost (Item 4) [Figure 50-70-5].
Figure 50-70-7
1
P-31128
Figure 50-70-8
P-31127
1
2
3
3 5
S4243
Disconnect the fuel fill hose (Item 1) and the vent hose
P1616 (Item 2) [Figure 50-80-3] from the fuel tank.
P1619A
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
Figure 50-80-4
S5981
1
Disconnect the fuel fill hose (Item 1) [Figure 50-80-5]
2 from the fuel tank.
S5980
Figure 50-80-6
S5959
Figure 50-80-7
1
S5981
Remove the fuel supply hose assembly from the fuel tank.
Remove the fuel supply screen from the hose and check
the screen for damage. Replace if needed.
Description
WARNING S2907
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Installation: Tighten the bolt and nut to 25-28 ft.-lb. (34-
to fall and cause injury or death. 38 Nm) torque.
W-2059-0598
Check the rubber bushing in the pedal for wear and
Raise the lift arms and install an approved lift arm support replace as needed.
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) Figure 50-90-2
P-28909
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-3 spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-90-5
S2907
Figure 50-90-4
P-28909
Figure 50-90-6
1 2
S2908
Description
Figure 50-100-1
S5947
The steering system [Figure 50-100-1] consists of The steering system returns the levers to their starting
independent steering levers the operator uses to provide position by means of the centering spring and the
steering input to the loader. returning force of the torsion bushings.
The steering levers are attached to pivoting bellcranks NOTE: Torsion bushings need to be replaced if torn or
that pivot on a steering shaft and plastic bushings. The
rotating in the housing. Loosen torsion
bellcranks have grease fittings.
bushing bolts slightly before adjustments are
The forward travel is adjusted by drift adjustment bolts. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
The bellcranks are attached to steering linkage bars with been made first.
rubber torsion bushings pressed into the bellcranks.
Bellcranks mount to the control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, creep
linkage bars are adjustable in length for full travel 2. Set linkage travel at steering linkage bars
adjustment. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a
rubber torsion bushing is pressed into the pintle arms.
S4225
WARNING Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
Never work on a machine with the lift arms up unless 20-1.)
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising on Page 10-30-1.)
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the engine speed control. (See Removal And
W-2059-0598 Installation on Page 70-20-1.)
Loosen the jam nut from the bypass control knob (Item 1)
[Figure 50-100-2].
S6040
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-3].
Figure 50-100-4
1
1
1
S4381
Disconnect the control harness connector (Item 1) Remove the four steering linkage mounting bolts (Item 1)
[Figure 50-100-4] from the control levers. [Figure 50-100-6].
Figure 50-100-5 Installation: Align the marks on the steering linkage bars.
Tighten the steering linkage mounting bolts to 35-40 ft.-lb.
(47,5-54,2 Nm) torque.
S2855
Figure 50-100-7
1
1
1
P-
263
29
1 1
S4387 S2858
1
S2857
2
2
P-4154
Remove the steering linkages (See Linkage Removal And NOTE: The bellcranks should pivot freely on the cross
Installation on Page 50-100-6.). shaft when assembled correctly.
1
1
1
S4227
S2857
Remove Control Handle Lever (See Lever Removal And To remove the steering shaft mounting bracket, remove
Installation on Page 50-100-1.) the three mounting bolts (Item 1) [Figure 50-100-13] from
the front of the control panel.
Remove the steering shaft pivot bolt (Item 1) [Figure 50-
100-11] from both sides of the control panel. Remove the steering shaft mounting bracket.
Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38 Installation: Tighten the mounting bolts to 15-20 ft.-lb.
Nm) torque. (20-27 Nm) torque.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
S2855
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
S2860
2
5
2
P-48630
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-16]. 1 Bolt
2 Bushings
Remove the bolt / spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a NEW 4 Bushing Spacer
lock nut to 25-28 ft.-lb. (34-38 Nm) torque.
5 Spring
Figure 50-100-17 6 Lock Nut
7 Centering Plate
8 Guide Bushings
1
P-48632
Figure 50-100-19
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-19]. 20] from the pintle.
If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
bolts (Item 2) [Figure 50-100-19]. Remove the centering Nm) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 35-40 ft.- 100-20].
lb. (47,5-54,2 Nm) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-20].
centering plate.
Figure 50-100-21
2
2
3
4
3 1
P-48659
2
NOTE: The washers (Item 2) [Figure 50-100-21] are NOTE: After installing the linkage onto the
hardened, and should only be replaced hydrostatic pumps the linkage neutral
through Bobcat Parts. adjustment procedure must be performed.
1
1
P-54615 P-54625
Loosen the bolt (Item 1) and remove the pintle base (Item Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-22]. 2) [Figure 50-100-24] and inspect the pintle solid cams
for damage or excessive wear.
Figure 50-100-25
4 1 3
2
2
P-48619
3
3
Loosen the bolt / nut (Item 1) [Figure 50-100-28] only
until the tension is released from the torsion bushing.
Figure 50-100-29
2
1
1
P-48450 2
To make this tool use a locking grip C-Clamp and grind P-54613
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-27] to a small rounded edge.
Loosen the nut (Item 1) only until the tension is released
A steering centering block (Item 3) [Figure 50-100-27] is from the torsion bushing (Item 2) [Figure 50-100-29].
also needed. The centering block can be placed as shown
and welded to the C-clamp if desired. NOTE: The bolt must be loose enough to allow the
torsion bushing (Item 2) [Figure 50-100-29] to
turn freely between the torsion bushing and
the steering linkage bar.
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 50-100-30
2
2 P16121
Using the remote start tool, turn the key (Item 1) [Figure
S5974 50-100-32] to the run position.
Figure 50-100-33
2 1
1
P-54610
Linkage Neutral Adjusting (Contd) NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
Figure 50-100-35 adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
1
2 2 1
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.
P-48632 W-2059-0598
Torque the left pump pintle adjustment lock bolts (Item 1) Raise the lift arms and install an approved lift arm support
[Figure 50-100-35] to 35-40 ft.-lb. (47,5-54,2 Nm). device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Repeat the adjustment procedure for the right pump.
Figure 50-100-36
1
1
S2861
Figure 50-100-37
3 2
4
1
P-51173
P-54613 Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) [Figure
Loosen the nut (Item 1) only until the tension is released 50-100-39].
from the torsion bushing (Item 2) [Figure 50-100-37].
Figure 50-100-40
2
2
1
P-51133
1 3 4
Before adjusting the linkage, check that the base pintle
P-51174 arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-41] and tighten to
35-40 ft.-lb. (48-54 Nm) torque. There should be no play
Move the right side steering lever forward and install a 15/ between the pintle arm and the square pump shaft.
16 inch (24 mm) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50- Also check that the cam mounting nuts or bolts (Item 4)
100-40]. [Figure 50-100-39] are tight, 35-40 ft.-lb. (48-54 Nm)
torque.
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel speed.
Figure 50-100-42
P-51175
1
1
S4381
Remove the spacer (Item 1) [Figure 50-100-43].
P-54613
Figure 50-100-45
1
1
S2861
Tighten the two bolts and nuts (Item 1) [Figure 50-100- Repeat steps on the other control lever.
45] to 35-40 ft.-lb. (47,5-54,2 Nm) torque at the steering
bell cranks. Drive the loader forward and check for drift.
Figure 50-110-1
1
1
P-28845
S2863 Install the new boot and reinstall the control lever.
Removal
Figure 50-120-1
P16015A
Using gloves, push the rear window out the rear of the Figure 50-120-4
operator cab.
Installation
P-64997
Installation (Contd)
Figure 50-120-5
1
P16013
Use a plastic stick (Item 1) [Figure 50-120-5] under the Tapping the window corners will help seat the window in
molding lip to guide the window into the molding groove. the molding.
Figure 50-121-1
1 1
1
1
P-24378
1
1
Remove the bolts (item 1) [Figure 50-121-2], lift the
N-20950 window and remove the bushings.
Figure 50-122-1
2
N-20814
Release the latch (Item 1) [Figure 50-122-1] and slide the Move the window slide rail using the two thumb pads
front window back towards the rear of the operator cab. (Item 2) [Figure 50-122-2] and [Figure 50-122-3] towards
the rear of the operator cab and then down towards the
Figure 50-122-2 bottom of the operator cab.
2 2 Figure 50-122-4
P-66019
2
1
P-66021
Figure 50-122-5
P-66020
Figure 50-123-1
3 1
2
1
1
1 S0366
Figure 50-123-2
N-20171
Figure 50-123-4
1
P-66059
P-66058 Install the window from the outside of the door frame.
If replacing the rubber molding (Item 1) [Figure 50-123-4] Work the window downward until the window is fully
cut off the excess molding. seated in the lower portion of the molding.
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-123-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-123-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.
1
P-66049A
P-66051
Description
Figure 50-130-1
3
2
P-76520
1
P-76526
Open the cab door.
Remove the gas spring (Item 1) [Figure 50-130-1] from Lift the door (Item 1) [Figure 50-130-2] off the hinges.
the threshold.
2 1
P-76523A P-76524A
Figure 50-130-5
CORRECT CORRECT
1
2
N-20132
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-130-
3] from the cab. P-76522A P-76525A
Figure 50-130-6
1
1
EM1026
P-76521
Sit in operators seat. Turn key ON. (Standard Key Panel),
press RUN / ENTER button (Deluxe Instrumentation
Loosen the two bolts (Item 1) [Figure 50-130-6] and Panel), lower seat bar and close the door. Press the
adjust the latch as needed. PRESS TO OPERATE LOADER button (Item 1) [Figure
50-130-8].
NOTE: For the initial adjustment, position the latch
towards the bottom of the door. Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will flash, an audible tone will sound,
Figure 50-130-7 and the message [door] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will go out and the display will return to
machine hours.
P-76516
ALTERNATOR 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
BATTERY 60-20-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2 ELECTRICAL
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . 60-20-3 SYSTEM &
ANALYSIS
BOBCAT CONTROLLER (MAIN) 60-70-1
Connector Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4
LIGHTS 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
STARTER 60-40-1
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
3600
3800
3200
8250 1010
2370
2380
3110
2410
8200
1020
3410
1800
2015
4370
3420
3400
4410
4380
2510
3200
2500
3100
8800
4200
9600
9500
2820
3010 3910
1210
3920 3920
3900 3900
2810 8080 8080
2790
3300 2780
3310
7000 7000
2760 7010
9800
2775 2775 2745
3430 7010
1440
2770 2765
1430
6100
3520
6010
6330
9360
9380
4110
3000
8000
6320
9370
8210
6230
8110
6210
8550
8510
4150
8150
6415
6515
6500
6400
6510
6410
1720
2720
8100 8100
8150 8800
2800 2800
6410
6510
6200
6310
6600
1410
8550
8500
8510
1440
1430
8100
8150
8110
3000
8000
2000
6230
6000
4150
1400
6200
6330
6210
6310
6320
8200
1370
4110
8210
4100
2600
7100
2010
1050
8000
1360
1330
1070
1060
1030
1320
1140
1520
1800
1700
1720
1730
1390
1770
2730
1710
1340
2900
7200
1080 1450 2510 1720
2500 2110 2720
2765
1070 2745
1040 2790 2090 1740
2710
1730
1390
1730
9600
9500
9800
3800
3910
3310 3010
3410
3110
321 of 521
ELECTRICAL SYSTEM INFORMATION
CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting two harnesses together or represent an component that is
C107
3520 C C 3520
3510 B B 3510
a harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example:
three pin connectors shown). The
LIGHT -
C107 connector pins can be numbered
3500
A A
3500 alphabetical (shown) or numerical (1,
C C
3520
B B
3520 2, 3 etc.). The harness wires numbers
3510 3510
are called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch to
warn personnel.
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
A
SPEED SENSOR - magnetic pickup -
detects RPM.
B
Figure 60-10-1
C490
C480
C479
S1
S2
C260
C635
C408
C611
S6038
Figure 60-10-2
S5950
Description
Figure 60-10-3
S6015
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
Troubleshooting
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
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The cable and wire connection are not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
3 7 19
S0188 4 8 16 20
10 12 14
7135574
R - Relay
S4016
Figure 60-10-7
P9175
S6036
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
S6037
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.
3
3
2
S4114
Servicing
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.
3 1
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on P-31860
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.
Connect the end of the first cable (Item 1) to the positive
In case of acid contact, wash immediately with water. (+) terminal of the booster battery. Connect the other end
In case of eye contact get prompt medical attention of the same cable (Item 2) [Figure 60-20-4] to the positive
and wash eye with clean, cool water for at least 15 terminal on the loader starter.
minutes.
Connect the end of the second cable (Item 3) to the
If electrolyte is taken internally drink large quantities negative (-) terminal of the booster battery. Connect the
of water or milk! DO NOT induce vomiting. Get prompt other end of the same cable (Item 4) [Figure 60-20-4] to
medical attention. the engine.
W-2065-0807
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first.
WARNING Remove the cable from the positive terminal (Item 2)
[Figure 60-20-4].
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
IMPORTANT
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F (16C) before Damage to the alternator can occur if:
connecting to a charger. Unplug charger before Engine is operated with battery cables
connecting or disconnecting cables to battery. Never disconnected.
lean over battery while boosting, testing or charging. Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
Battery gas can explode and cause serious injury. both cables from the battery.)
W-2066-0705 Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Belt Adjustment
Stop the engine and raise the operator cab (See Raising
on Page 10-30-1.) WARNING
Figure 60-30-1
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.
S4014
2 WARNING
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Figure 60-30-3
2
S5960
1
If the charging system malfunctions:
Check the fuse for the alternator in the fuse panel. If Open the rear door.
the fuse is burnt, find the cause and repair / replace. If
the fuse is in doubt, remove it and check for continuity. Connect the remote start tool to the loader (See Remote
Start Procedure on Page 10-60-4.)
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free Turn the engine on with the remote start tool and run at
batteries.) idle. With a voltmeter, check the voltage between the B+-
terminal (Item 1) and ground (Item 2) [Figure 60-30-3] at
Verify the charge of the battery. Make sure the battery the starter.
is fully charged.
The voltage must be higher than 13.5 volts but lower than
Disconnect the battery cables (negative first, then 14.7 volts at 70F (21 C) (Alternator temperature).
positive). Inspect the cable clamps and battery posts
for corrosion. Remove acid or corrosion from the If the voltage is higher than 14.7 volts, proceed to the
battery and cables with a sodium bicarbonate and following high voltage test.
water solution. Put grease on the cable ends and
battery terminals to prevent corrosion. Reconnect the If the voltage is lower than 13.5 volts, run the engine at
cable to the positive terminal. With the key off, connect high idle and recheck the voltage. If the voltage is still
a test light between the negative battery post and the below 13.5 volts, proceed with the following low voltage
disconnected negative cable clamp test.
Figure 60-30-4
1 S4249
S4249
Turn engine OFF and remove the L&S-terminal connector
(Item 1) [Figure 60-30-6] from the alternator.
Turn engine OFF and remove the L&S-terminal connector
(Item 1) [Figure 60-30-4] from the alternator. NOTE: Check the continuity between the "S" terminal
and the positive (+) terminal on the battery or
Turn the remote start tool key to the ON position. starter. There should be continuity. If no
continuity, replace wire harness.
Figure 60-30-5
If the voltage is still above 14.7 volts at 70F (21 C)
(Alternator Temperature), then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-2.). for further component testing.
2 S5971
If the wire harness, relay and fuses are good then remove
the alternator for replacement or repair. To repair, (See
Alternator Voltage Testing on Page 60-30-2.) for further
component testing.
S5972
IMPORTANT 1
Figure 60-30-9
S4022
Parts Identification
14
13
4 7
3
12 5
2
11
10
9
8
19
18
17
15 16 C-3529B
Testing
Figure 60-40-1 2
Bat 1
S
M
Cranking
Motor
S2864
The key switch must be in the OFF position. Disconnect the S-terminal on the starter (Item 1) [Figure
60-40-3].
The battery must be fully charged.
Hold-In Test: Use circuit tester, attach one probe to the
The cable connections on the battery must be clean and L&S-terminal (Item 1) and one probe to the mounting bolt
tight. (Item 2) [Figure 60-40-3] on the magnetic switch
(solenoid). If there is no continuity replace the magnetic
Connect a jumper wire between L&S-terminal and BAT- switch (solenoid).
terminal [Figure 60-40-1].
Figure 60-40-4
If the starter turns but the engine does not turn, the starter
drive has a defect. 2
Figure 60-40-2
1
P-34675
Bat 1
S
M
2
Cranking
Motor
P-34674
Connect a jumper wire (of at least four gauge in size) Disconnect the L&S-terminal on the starter (Item 1)
between the M terminal and the BAT terminal [Figure 60- [Figure 60-40-4].
40-2].
Pull-In Test: Use circuit tester, touch one probe to the
If the starter turns, the defect is in the solenoid. L&S-terminal (Item 1) and one probe to the starter motor
terminal (Item 2) [Figure 60-40-4]. If there is no continuity
If the starter does not turn, the starter is defective. replace the magnetic switch (solenoid).
Remove the negative (-) and then the positive (+) cable
from the battery.
1
Figure 60-40-5
3 S5962
S4121
Parts Identification
1. Starter
2. Frame
3. Brush
4. Armature
5. Yoke
6. Housing 1
7. Pinion
8. Clutch
9. Housing 2
10. Plunger
4 3
10
B-19162
Figure 60-50-1
3 12
2
7 16
1
13
4
8 10 11 15
6 9
14
5
17 20
18 19
21 22
23
EM1026
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 ENGINE OIL PRESSURE Engine oil pressure low or sensor error.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information.
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right turn signals are ON.
13 HYDRAULIC OIL PRESSURE Hydraulic oil pressure low or sensor error.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and
right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW Not used.
19 AUXILIARY HYDRAULICS Not used.
20 INFORMATION Cycles through (after each button press):
Hourmeter (On start up)
Engine RPM
Battery voltage
Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
to move the loader forward or backward when using the backhoe
attachment or for service. (See TRACTION LOCK OVERRIDE in this
manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS System when the seat bar is down and
operator is seated in operating position. Button will light.
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* For further description on Service Codes (See DIAGNOSTIC SERVICE CODES on PAGE 60-80-1.)
Figure 60-50-2 1
2
1
6
3
S4002
S4498
5 4 3 2 S4001A
5. ENGINE PREHEAT
6. HOURMETER
1 7 Figure 60-50-5
4
5
2 3 6
ENTER PASSWORD
8 LANGUAGES
B-16165
The first screen you will see on your new loader will be as
10 11 B-15553N shown in [Figure 60-50-5].
Figure 60-50-6
S4005
1 2 3 4 5 6 7 8 REF.
DESC. FUNCTION / OPERATION
NO.
S2849
1 POWER PLUG Provides a 12 V receptacle for
accessories.
REF. 2 NOT USED ----
DESC. FUNCTION / OPERATION
NO. 3 FRONT WIPER Press the top of the switch to start
the front wiper (press and hold for
1 NOT USED ----
washer fluid).
2 BUCKET Press the top of the switch to retain Press the bottom to stop the wiper.
POSITION the bucket fixed in its relative 4 NOT USED ----
position to the ground. 5 NOT USED ----
Press the bottom to return to normal
6 NOT USED ----
operation.
7 FAN MOTOR Turn the knob clockwise to increase
3 BOB-TACH Press the top of the switch to move fan speed.
WEDGES UP/ the Bob-Tach wedges up (Power Turn counterclockwise to decrease.
DOWN Bob-Tach option). There are four positions; OFF-1-2-3.
Press the bottom to move the Bob-
8 NOT USED ----
Tach wedges down.
9 TEMPERATURE Turn the knob clockwise to increase
4 PARKING BRAKE Press the top of the switch to engage CONTROL the temperature.
the parking brake. Turn counterclockwise to decrease.
Press the bottom to disengage the
parking brake.
5 NOT USED ----
6 HAZARD LIGHTS Press the top of the switch to turn
(Option) the hazard lights ON.
Press the bottom to turn the hazard
lights OFF.
7 ROTATING Press the top of the switch to turn
BEACON (Option) the rotating beacon ON.
Press the bottom to turn the rotating
beacon OFF.
8 NOT USED ----
Figure 60-50-8
1
1
1
EM1026
1
Figure 60-50-9
3
2
1
S5976
Pull the right instrument panel down and disconnect the Disconnect the two wire harness connectors (Item 2)
key switch wiring harness connector (Item 1) [Figure 60- [Figure 60-50-11] from the loader instrument panel.
50-9] from the panel.
Disconnect the connector (Item 3) [Figure 60-50-11] from
Remove the panel from the loader cab. the loader instrument panel.
Figure 60-50-12
S5978
1
2 Remove the left side instrument panel (See Removal And
Installation (Left And Right) on Page 60-50-6.)
Remove the ignition key (Item 1) from the switch. Remove Remove the alarm from the loader instrument panel.
the ignition switch retaining nut (Item 2) [Figure 60-50-12]
from the switch.
Figure 60-50-13
S5977
Figure 60-50-15
3
2 1
1 1
S5979
Remove the two mounting bolts (Item 1) [Figure 60-50- Remove the panel.
15].
Reverse the procedure to install the front accessory
Installation: Be careful to not overtighten the front panel.
accessory panel mounting bolts to prevent damage to the
plastic panel.
Figure 60-60-1
S4326
S4339
Gently press the rear light through the light housing
[Figure 60-60-2].
Open the rear door.
Figure 60-60-3
Disconnect the negative (-) cable from the battery. (See
Removal And Installation on Page 60-20-1.)
S4327
With 1/3 of a turn, twist the light bulb out [Figure 60-60-3].
Figure 60-60-4 1
1
1
P-66222
NOTE: The wires for the switch will hold the light
cover. Do not pull the light cover too far away
from the light housing to prevent damage to
the wires.
Description
The main controller provides information to all other controllers. All loaders have a main controller.
The main controller is located behind the rear door, in the engine compartment, on the left side.
Connector Identification
Controller
S6041 / S6042
S6043
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
Figure 60-70-1
1
P-67074
Figure 60-80-2
3 4
Press
TOOL / SETUP
2
Press
OWNER UTILITIES
1 EM1028
Press the INFORMATION button (Item 1) to cycle the Enter PASSWORD (owner
DATA DISPLAY (Item 2) [Figure 60-80-1] until the service or master) on Keypad
then press ENTER
code screen is displayed. If more than one SERVICE to Continue
CODE is present, the codes will scroll on the DATA
DISPLAY.
H1221 Right Primary out of range high L0102 Left panel button 1 error ON
H1222 Right Primary out of range low L0202 Left panel button 2 error ON
H1224 Right Primary not in neutral L0302 Left panel button 3 error ON
H1321 Left Primary out of range high L0402 Left panel button 4 error ON
H1322 Left Primary out of range low L7404 Left panel main controller no communication
H1324 Left Primary not in neutral L7672 Left panel programming error
H2305 Rear base solenoid short to battery
H2306 Rear base solenoid short to ground M0116 Air filter not connected
H2307 Rear base solenoid open circuit M0117 Air filter plugged
H2332 Rear base solenoid overcurrent M0216 Hydraulic/Hydrostatic filter not connected
H2405 Rear rod solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2406 Rear rod solenoid short to ground M0309 Battery voltage low
H2407 Rear rod solenoid open circuit M0310 Battery voltage high
H2432 Rear rod solenoid overcurrent M0311 Battery voltage extremely high
H2505 Rear aux relief short to battery M0314 Battery voltage extremely low
H2506 Rear aux relief short to ground M0322 Battery voltage out of range low
H2605 Front base solenoid short to battery M0409 Engine oil pressure low
1 2 3 4
EM1027
EM1026
3. Fasten the seat belt, lower the seat bar and make sure
the parking brake is engaged.
Troubleshooting 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 chart (See Troubleshooting Chart on Page 60-90-4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into
place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
5. Possible low or high voltage.
Troubleshooting Chart
The following list shows the probable causes when the BICS system lights are off or flashing and the associated service
codes (See DIAGNOSTIC SERVICE CODES on Page 60-80-1.)
1
Seat Bar is down. Seat Bar is up. Lift and tilt functions will not Continuous Flashing M-11-21
operate. Continuous Flashing M-11-22
2
Control valve can Control valve Lift and tilt functions will not
Continuous Flashing M-17-05
be used. cannot be operate. Continuous Flashing M-17-06
used. Continuous Flashing M-17-07
Continuous Flashing M-18-05
3 Continuous Flashing M-18-06
Continuous Flashing M-18-07
Continuous Flashing M-54-05
Continuous Flashing M-54-06
Continuous Flashing M-54-07
Continuous Flashing M-79-74
Solid (battery) Icon M-03-09
Solid (battery) Icon M-03-10
Solid (battery) Icon M-03-11
Solid (battery) Icon M-03-14
Solid (battery) Icon M-03-22
Loader can be Loader cannot Loader cannot be moved forward Continuous Flashing M-15-02
moved forward be moved and backward. Continuous Flashing M-15-03
and backward forward and Continuous Flashing M-16-05
backward.
Continuous Flashing M-16-06
4 Continuous Flashing M-16-07
Continuous Flashing M-25-02
Continuous Flashing M-25-03
Continuous Flashing M-25-07
Solid (battery) Icon M-03-09
Solid (battery) Icon M-03-10
Solid (battery) Icon M-03-11
Solid (battery) Icon M-03-14
Solid (battery) Icon M-03-22
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
Testing
Figure 60-100-1
1
P-4698
Figure 60-100-4
Use a Sensor Tester (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
Figure 60-100-2
P-4699
1
Lower the seat bar. The Sensor Test light (Item 1) [Figure
N-19557
60-100-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-100-4] should go off.
If the above test fails, there is a problem with the seat bar
N-19558 sensor.
Figure 60-100-5
1 3
2
S4010
N-19219
Figure 60-100-7
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
2 I-2088-1095
1
3
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.
1 1
N-18463
P-4699
P-4703
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11
WARNING 2
1 1
S5964 2
Installation: Tighten the mounting screws to 80-90 in.-lb. Remove the traction lock assembly (Item 1) [Figure 60-
(9-10 Nm) torque. 110-3] from the chaincase.
Remove the electric solenoid (Item 2) from the chaincase Inspect gasket (Item 2) [Figure 60-110-3], replace if
cover [Figure 60-110-1]. necessary.
1
4 1
3 2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
P-68143 washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-110-5]. Inspect all parts for
damage or wear. Replace if necessary.
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-110-4] for wear or Installation: Thoroughly clean and dry the shaft mounting
damage. Replace if necessary. The spring may also stay bolt (Item 1), the shaft (Item 5) and wedge (Item 4)
with the shaft when the electric solenoid and bracket are [Figure 60-110-5]. Use LOCTITE #242 when assembling
removed from the chaincase. these parts to the traction lock assembly.
S5967
3
1 2
2 2 1
N-19106 N-19105
NOTE: Notice the direction of the groove (Item 1) Do not tighten at this time.
[Figure 60-110-7] in the traction lock guides.
Figure 60-110-10
To remove the traction lock guides remove the four bolts
(Item 2) [Figure 60-110-7].
1
Installation: Thoroughly clean the polyurethane from the
chaincase cover, traction lock guides (Item 1) and bolts
(Item 2) [Figure 60-110-7] and dry.
Figure 60-110-8
S5970
Inspecting
Figure 60-110-11
S5969
2
Check the wire connections at the engine flywheel RPM
speed sensor (Item 1) [Figure 60-110-12].
Figure 60-120-1
1 2
2
3
1
P-76450
Tools that will be needed to complete the following steps Order from Bobcat Parts P/N: 6689779 - Remote Start
are: Tool (Service Tool) Kit
Kit Includes:
MEL1563 - Remote Start Tool 6689778 - Remote Start Tool (Service Tool)
MEL1565 - Service Tool Harness Control 6689747 - Loader Service Tool Harness
MEL1566 -Service Tool Harness Communicator 6689746 - Computer Service Tool Harness
(Computer Interface) 6689745 - BOSS Service Tool Harness
NOTE: Make all connections with the key in the OFF NOTE: Make all connections with the key in the OFF
position. position.
The Service PC (Item 1) with the remote start tool (Item 2) The Service PC (Item 1) with the Remote Start Tool
[Figure 60-120-1]. When connected to the loader, the (Service Tool) (Item 2) [Figure 60-120-2]. When
Service PC is used to monitor, conduct diagnostic and connected to the loader, the Service PC is used to
load software. monitor, conduct diagnostics, and upgrade software.
Connect the Service Tool Harness Communicator Connect the Remote Start Tool (Service Tool) Computer
(MEL1566) (Item 3) [Figure 60-120-1] to the designated Service Tool Harness (Item 3) [Figure 60-120-2] to the
serial port on the Service PC. designated serial port on the Service PC.
NOTE: The recommended serial cable length should NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing 15 feet will create a degraded signal causing
communication errors. communication errors.
Connect the other end to the connector on the remote Connect the other end to the connector on the Remote
start tool. Start Tool (Service Tool).
Connect the remote start tool to the loader. (See Remote Connect the Remote Start Tool (Service Tool) to the
Start Procedure on Page 10-60-4.) loader. (See Remote Start Procedure on Page 10-61-5.)
Description
2
The flywheel RPM sensor has a magnet located on the
end of the sensor which senses breaks between the ring 1
gear teeth. The sensor relays this information back to the
main Bobcat controller which registers the RPM of the
engine.
Figure 60-130-1 NOTE: New RPM sensors have a plastic tip which is
used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
S4374
SELECTION
EXAMPLE
BUTTONS
Press
LOADER FEATURES
B-16162
Press
ICON DESCRIPTION
DISPLAY OPTIONS
LOCK / UNLOCK: Allows machine to be
locked / unlocked. You must lock machine to
activate security system.
When system is unlocked, the user can press
RUN / ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL / SETUP: Access system options.
Press
Use to set clock, check system warnings,
ADJUST CONTRAST
select language, set passwords, etc.
? HELP: Access help on current menu item.
Examples
Press . . .
TOOL / SETUP
LOADER FEATURES Press
DISPLAY OPTIONS TOOL / SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK / UNLOCK to unlock.
Enter Password and press RUN / ENTER.
Languages
Press . . . Press
TOOL / SETUP ATTACHMENTS
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER.
Press EXIT to return to previous level menu.
VITALS Press
UP OR DOWN
Press SELECTION ARROW to select METRIC or Arrow to
ENGLISH (M / E) readouts scroll through
attachments
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature Press
System Voltage the keypad number
Engine Speed of a switch to view
a description of the
The Deluxe Instrumentation Panel is easy to use. attachment function
Continue to set your own preferences for running / of the switch
monitoring your Bobcat loader.
B-16163/B-24288/B-16161A/B-15753A/B-15754A/B-15755A
Owner Password:
Allows for full use of the loader and to setup the Deluxe
Instrumentation Panel. There is only one owner Press MODIFY OWNER
password. It must be used to change the owner or user
passwords. Owner should change the password as
soon as possible for security of the loader.
User Password:
Allows starting and operating the loader; cannot Enter new OWNER
change password or any of the other setup features. PASSWORD on Keypad
then press ENTER
to Continue
For the procedures to change passwords. See Changing
of Owner Password on this page. (See Changing The
User Passwords on Page 60-150-2.)
Re-Enter new OWNER
PASSWORD on Keypad
then press ENTER
to Continue
B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294
Changing The User Passwords This feature allows the owner to unlock the password
feature so that a password does not need to be used
Figure 60-150-2 every time the engine is started.
Figure 60-150-3
Press TOOL / SETUP
Press
LOCK / UNLOCK
Press
Enter USER PASSWORD EXIT
on Keypad
then press ENTER to Continue
B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A
B-16163/P-76075/P-76076/P-76076A/P-76077
Description
Figure 60-160-1
1
2 P-76122
Setup
Figure 60-160-3
P-76110
P-64243A
Figure 60-160-4
1
1
P-76113
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-160-4] the information is now stored. This will
be displayed on Deluxe Instrumentation Panel equipped
loaders when the maintenance clock is less than 10 hours
until next planned maintenance.
Setup (Contd)
Figure 60-160-7
P-76112
1
Click the right arrow (Item 1) [Figure 60-160-9] to scroll
P-76114
through the tabs.
Figure 60-160-10
A green COMPLETE (Item 1) [Figure 60-160-7] message
will be displayed when the dealer information has been
transferred to the machine controller. 1
P-76111
Setup (Contd)
Figure 60-160-11
1
2
P-76110
Figure 60-160-14
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it can not be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-160-11].
P-76111
Reset
Figure 60-160-15
P-76455H
Description
Inspecting
Figure 60-170-1 2
P-69346
1 Figure 60-170-3
P-76108
1 1
Inspect for damaged or missing back-up alarm decal
(Item 1) [Figure 60-170-1]. Replace if required.
S4877
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start the Inspect the back-up alarm electrical connections (Item 1),
engine. Press the PRESS TO OPERATE LOADER button. wire harness (Item 2) [Figure 60-170-2] and back-up
Disengage the parking brake. alarm switches (if equipped) (Item 1) [Figure 60-170-3]
for tightness and damage. Repair or replace any
Move both steering levers into the reverse position. The damaged components.
back-up alarm must sound when all wheels or both tracks
are moving in reverse. If the back-up alarm switches require adjustment, (See
Adjusting Switch Position on Page 60-170-2.)
The back-up alarm is located on the inside of the rear
door.
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-170-4
2 1
S4877
Troubleshooting 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, Operators
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
Back-up alarm will not sound when the operator moves both steering levers in the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7
Alarm Removal And Installation Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Stop the engine and open the tailgate.
Figure 60-170-7
Figure 60-170-5
1
1
2 2
P-69346 S4880
Mark the wires for ease of assembly. Disconnect the wires Place the steering levers in the neutral position.
(Item 1) [Figure 60-170-5] from the alarm.
Loosen the screws (Item 1) securing the back-up alarm
Installation: Make sure the wire harness ends do not switches. Slide the switch assemblies (Item 2) [Figure 60-
touch the mounting bolts during assembly. 170-7] off the mounting bracket.
Figure 60-170-6 Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjusting the switches (See
1 Adjusting Switch Position on Page 60-170-2.) and
1 inspecting back-up alarm operation (See Inspecting on
Page 60-170-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-170-6]. Remove the alarm from the
mounting bracket.
Figure 60-170-8
1
3
2
3
P-62917
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Description
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Tightness Plunger 10 sec: initial pressure 1849 - 1991 PSI (127,5 - 137,3 bar)
Allowable Limit 5 seconds 1991 PSI (137,3 bar)
Injection Timing 18 degrees B.T.D.C.
High Idle 2600 RPM
Low Idle 850 - 950 RPM
Cylinder Head
Valves
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Tappet
Clearance Between Tappet and Guide 0.0008 - 0.0024 in (0,02 - 0,062 mm)
Allowable Limit 0.0028 in (0,07 mm)
Tappet O.D. 0.7858 - 0.7866 in (19,959 - 19,980 mm)
Tappet Guide I.D. 0.7874 - 0.7882 in (20 - 20,021 mm)
Cylinders
Piston Rings
Pistons
Connecting Rods
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Oil Pump
Crankshaft
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Timing Gear
Thermostat
Torque Values
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Grade Standard Screw and Bolt Special Screw and Bolt (7)
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening,
be sure to check out the numbers as shown below.
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11
2
WARNING S4115
Never work on a machine with the lift arms up unless Remove the screw (Item 1) to release the electrical cable
the lift arms are secured by an approved lift arm (Item 2) [Figure 70-10-1].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Figure 70-10-2
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1)
S4116
Raise the operator cab (See Raising on Page 10-30-1)
Figure 70-10-3
1
S4119
Figure 70-10-6
Remove the screw (Item 1) [Figure 70-10-3] to release
the two black cables from the engine.
Figure 70-10-4
2
2
1
1
2
S4120
Figure 70-10-7
1
1
2 S4123
1
Loosen the screw (Item 1) [Figure 70-10-9] to release the
S4121 two black cables.
Figure 70-10-10
Remove the red and the black covering (Item 1) and
loosen the two screws (Item 2) [Figure 70-10-7] to
release the wires and cables from the starter.
Figure 70-10-8
1
2
S4124
Figure 70-10-11
1
S4104
1
Remove the exhaust by removing the four screws (Item 1)
S4102 [Figure 70-10-13] that fix it to the engine.
Figure 70-10-12
1
1
S4132
S2909
Remove the screw (Item 1) [Figure 70-10-12] on the side Disconnect the hose (Item 1) [Figure 70-10-14] from the
of the engine to release the engine speed control cable hydraulic reservoir by loosening the strap.
from the engine speed control lever.
Figure 70-10-15
1
S4128
Figure 70-10-16
1
1
S4129
S4127
Figure 70-10-19
1
S4138
Figure 70-10-20
1
1
1
S4106
Figure 70-10-23
S4125
Remove the steering linkages (Item 1) [Figure 70-10-23]. Disconnect the five hydraulic tubelines between the
engine and the pump assembly.
Figure 70-10-24
Figure 70-10-26
1
1
S4141 1
S4107
Disconnect the two hydraulic tubelines (Item 2) [Figure Installation: Tighten to 70 ft.-lb. (95 Nm) torque.
70-10-24] from the T-fitting on the pump by screwing them
loose. After disconnection, cap the two tubelines and the Repeat the previous step for the three other foot supports
T-fitting. (total: four foot supports: two on the front and two on the
back of the engine).
Figure 70-10-27
11
2.5
1-1/2 I.S. Dia.
2-1/2 O.S. Dia.
2.5
1
16
1 9
45
4
1
0.5 S2904
1
Figure 70-10-28
S4109
NOTE: After lifting the engine out of the loader, put the
engine on a safe place and make sure it is well
supported [Figure 70-10-30].
S2903
4
1
2 3
1
3
S4285
Replace all four engine mounts two front and two rear.
Compression-Checking
Figure 70-10-33
S6034
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 speed control rod in the
W-2059-0598 bottom hole of the speed control lever.
Figure 70-20-3
Figure 70-20-1
1 1
P-34156
P-48565
Figure 70-30-1
S4288
Figure 70-30-2
S2905
Figure 70-40-1 1
S4136
Figure 70-40-2
S4205
Figure 70-50-1
1 1 S4288
S6000 S5951
S5951
Figure 70-50-2
S4287
Fan Removal And Installation Drain the radiator (See Removing And Replacing Coolant
on Page 10-90-2).
Figure 70-50-4
Remove the alternator (See Removal And Installation on
Page 60-30-4.)
Figure 70-50-6
1 1
2
S4134
2
Disconnect the two plugs (Item 1) [Figure 70-50-4]. 1
P13265
Figure 70-50-5
S4252
Installation: Always use a new gasket when installing the
water pump.
Water Pump Disassembly And Assembly Drain the radiator (See Removing And Replacing Coolant
on Page 10-90-2).
Figure 70-50-7
Figure 70-50-8
2 4
1 3 2
1
B-14859B
S6001
S6002
Figure 70-50-10
P-37172
1 1
P13272
Remove oil pan bolts securing oil pan. Slightly tapping on Remove the rear cover (Item 2) [Figure 70-60-3].
the oil pan with a soft mallet will break loose the oil pan
from the engine block. Figure 70-60-4
Figure 70-60-2
P13273
Figure 70-60-5
P13273
Figure 70-60-8
Measure the clearance between the lobes of the inner
rotor and the outer rotor with a feeler gauge [Figure 70-
60-5].
Figure 70-60-6 1
P13272
P13316
P13273 PI-10010
Remove the cover and measure the width of the pressed Install a pressure gauge [Figure 70-60-10].
plastigauge (Item 1) [Figure 70-60-9].
Start the engine and run until it is at operating
End Clearance 0.0010 - 0.0030 in temperature.
(0,025 - 0,075 mm)
If the oil pressure is less than the allowable limit, check
the following Items:
Fuel Camshaft Removal And Installation The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to
Remove the timing gearcase cover (See Timing Gearcase the engine according to changes in the engine load.
Cover Removal And Installation on Page 70-100-1)
Figure 70-70-2
Remove the idler gear (See Idler Gear And Shaft Removal
And Installation on Page 70-100-3)
3 2
Figure 70-70-1
1
3
1
4
P-69859
Figure 70-70-3
2
3
1
S6006
2
3
1 S6012
Figure 70-70-7
S6007
IMPORTANT
2
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289 1
Remove and cap the fuel inlet hose (Item 1) and the fuel
return hose (Item 2) [Figure 70-70-10] from the injection
pump vent.
1
Remove the high pressure fuel lines (Item 3) [Figure 70-
70-10] from the injection pump.
Figure 70-70-11
S6003
1
1
S6005
Figure 70-70-12
1 2
1
1 1
P-69916
2
2
P-69914
Align the control rack pin (Item 1) with the notch Item 2)
and remove the pump (Item 3) [Figure 70-70-15].
Fuel Injection Pump Removal And Installation Remove the fuel shutoff solenoid (See Fuel Shutoff
(Contd) Solenoid Removal And Installation on Page 70-70-3)
Figure 70-70-17
P-69917
Timing The Injection Pump Move the fuel lever on the injection pump to full fuel
position (or full throttle).
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-18
1 1
P-62662
P-62667
2
The size of shims (Item 1) [Figure 70-70-20] are identified
P-69918 by a symbol on the shims.
Figure 70-70-19
P13130
MEL1485 - Socket
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can S6004
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 Remove the injector tubelines (Item 1) [Figure 70-70-21]
not use your bare hand. Wear safety goggles. If fluid from the fuel injector pump.
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury. Installation: Tighten the high pressure fuel line nuts to
W-2072-0807 18-25 ft.lb. (24-33 Nm) torque.
Figure 70-70-22
IMPORTANT
1
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Fuel Injector Removal And Installation (Contd) Remove the fuel lines and injectors.
Figure 70-70-23
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.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
B-5970
The tool listed will be needed to do the following
procedure:
Loosen the fuel injector with a special socket (MEL-1485)
[Figure 70-70-23]. MEL 10018 - Injector Nozzle Tester
Figure 70-70-24
A-2513
B-5971
Connect the nozzle to the tester with the nozzle down
[Figure 70-70-25].
Remove the fuel injector nozzle from the engine [Figure Operate the hand lever at a slow rate and record the
70-70-24]. opening pressure. If the pressure is not correct, replace
the adjusting spacer.
3
4
5
1
6
A-2621
P-62152
Check that the spray pattern is correct [Figure 70-70-27].
1. Nozzle Holder 1. Fuel does not come out the side of the nozzle.
2. Adjusting spacer
2. Drops of fuel are not present at the nozzle.
3. Nozzle Spring
3. The injector has an even flow coming from the nozzle.
4. Push Rod
5. Distance Piece
6. Nozzle Piece
Figure 70-70-28
A-2513
Check for inside leakage. Operate the hand lever until the
pressure reaches 1849 PSI (127 bar). Make a record of
the pressure. Release the hand lever. Check the pressure
decrease in 10 seconds. If any leak is found, replace the
nozzle.
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.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Figure 70-80-1
S6013
S6008 Touch one probe to the end of the glow plug and the other
probe to the body of the glow plug.
Disconnect the glow plug cables and leads. The reading should be approximately 0.9 ohms. If the
resistance is infinite, the coil of the glow plug is broken. If
Remove the nut and wire harness (Item 1) [Figure 70-80- the resistance is 0 the glow plug is short circuited.
1].
Repeat the procedure for each glow plug.
Figure 70-80-2
S6009
Glow Plug Removal And Installation NOTE: The valve clearance must be checked and
adjusted when engine is cold.
Remove the glow plug wire harness and strap.
Remove the valve cover.
Figure 70-80-4
Bring number 1 piston to TDC (Top Dead Center).
1
Figure 70-80-6
2
1
S6010
Loosen and remove the glow plugs (Item 1) [Figure 70- P-62022
80-4].
Installation: Tighten the glow plug to 5.8 - 10.8 ft.-lb. (7,8 Remove the glow plug (See Glow Plug Removal And
-14,7 Nm) torque. Installation on Page 70-80-2)
Figure 70-80-7
1
0.0057-0.0073
(O,145-0,185 MM)
P-69972
A-2730A
Remove the engine (See Engine Removal And Installation
on Page 70-10-9.)
Make sure the piston is at TDC when adjusting the
clearance at the valves. The correct clearance is 0.0057- Remove the timing gearcase cover (See Timing Gearcase
0.0073 inch (0,145-0,185 mm) cold clearance [Figure 70- Cover Removal And Installation on Page 70-100-1)
80-7].
Make sure the timing marks (Item 1) [Figure 70-80-9] are
Figure 70-80-8 in correct alignment.
P-62023A
Figure 70-80-10
1
1
P-47245
Remove the valve cover nuts (Item 1) [Figure 70-80-10]. After installing the rocker arm assembly and push rods,
the valve lash must be adjusted.
Installation: Tighten the valve cover nuts to 5.1-8.3 ft.-lb.
(6,9-11,3 Nm) torque. Figure 70-80-13
Figure 70-80-11 1
1
P-47246
B-14332
Figure 70-80-14
14 6 3 11
18 10 2 7 15
B-3643B
17 9 1 8 16
13 4 12
5
Remove the four mounting bolts at the coolant housing
P-47247 (Item 1) [Figure 70-80-16].
Figure 70-80-15
1
P-47249A
When replacing just the gasket, use a new gasket that has
the same mark (Item 1) [Figure 70-80-17] as the original
gasket.
B-14334 After the gasket and cylinder head have been installed,
turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
Remove the cylinder head from the engine block.
Cylinder Head Disassembly and Assembly Clean the surface of the cylinder head.
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-20] on the
spring [Figure 70-80-18]. cylinder head.
Figure 70-80-21
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides and
70-80-18] and [Figure 70-80-19]. two diagonal as shown in figure [Figure 70-80-21].
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
Figure 70-80-23
1 3
P-51631
B-14335
Install the cylinder head gasket. Put the piston (Item 1)
[Figure 70-80-22] being checked at T.D.C.
Measure the valve stem O.D. [Figure 70-80-23].
Put three pieces of 0.06 inch (1,5 mm) diameter solder
(Item 2) [Figure 70-80-22] on the top of the piston. Use Measure the valve guide I.D. [Figure 70-80-23].
grease to hold them in position.
Calculate the clearance. If the clearance exceeds the
NOTE: Put the solder in position so they do not touch allowable limit, replace the valve and / or valve guide.
the valves.
Valve Guide I.D 0.2760-0.2765 inch
Turn the piston to bottom dead center. (7,01-7,025 mm)
Install the cylinder head. (See Cylinder Head Removal Valve Stem O.D 0.2741-0.2764 inch
And Installation on page 4.) (6,960-6,975 mm)
Clearance Between 0.0014-0.0025 inch
Turn the crankshaft until the piston exceeds T.D.C. Valve Stem and guide (0,035-0,065 mm)
Remove the cylinder head. Allowable Limit 0.0039 inch
(0,1 mm)
Remove the solder wire (Item 3) [Figure 70-80-22] and
measure it.
Figure 70-80-24
8.86 (225 mm)
0.460-0.468
(11,7-11,9 mm) 0.256-0.259
(6,5-6,6 mm)
0.2 0.350-0.358 0.787
(5,0 mm) (8,9-9,1 mm) (20,0 mm)
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-25]. recessing or protrusion with a depth gauge [Figure 70-80-
27].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-25], press the new guide until the tool
contacts the cylinder head.
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-30].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-28].
If the seat surface (b) is too wide, use a 30 degree cutter
(Item 2) on the intake, and a 15 degree cutter on the
Protrusion 0.002 inch (0,05 mm)
exhaust to get the correct width (Item 3) [Figure 70-80-
Recessing 0.0098 inch (0,25 30].
mm)
Allowable Limit (Recessing) 0.016 inch (0,4 mm) Valve Seat Width
Intake 60
Exhaust 45
45 Exhaust
15 Exhaust 60 Intake
30 Intake
PI-9994
Valve Spring
Figure 70-80-31
A-2759
Figure 70-80-33
1
2
B-3697
P-47267
Remove the top edge from the cylinder bore with a ridge
reamer.
Installation: Tighten the connecting rod bolts to 33-36 ft.- Installation: Make sure the marks on the connecting rod
lb. (44-49 Nm) torque. and bearing are aligned when installing the bearing cap
(Item 1) [Figure 70-90-2].
Figure 70-90-1
Repeat the procedure to remove the other piston /
connecting rod assemblies from the engine block.
Figure 70-90-3
4
1 3
5 2
7 1
PI-10013
Figure 70-90-4
5
6 4
2
P-47271
PI-10015
NOTE: Assemble the piston to the connecting rod
with the FW mark (Item 6) is facing the flywheel
side and the connecting rod mark (Item 1)
Installation: When installing new rings, assemble the ring [Figure 70-90-5] facing the injection pump
so the mark (Item 1) near the gap faces the top of the side.
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 70-90-4].
Figure 70-90-8
1 Figure 70-90-9
P-47273
PI-10016
Measure the O.D. of the piston pin (Item 1) [Figure 70-90-
7].
Use a press and special driver tool to remove the small
Measure the I.D. of the connecting rod small end (Item 2) end bushing [Figure 70-90-9].
[Figure 70-90-7].
Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until it
is flush [Figure 70-90-9].
Figure 70-90-10
PI-10017
Install a piston ring into the lower part of the cylinder bore. If the clearance exceeds the allowable limit, replace the
Measure the ring gap with a feeler gauge [Figure 70-90- ring. If the clearance still exceeds the allowable limit,
10]. replace the piston.
If the gap exceeds the allowable limit, replace the ring. Compression Rings 0.0033 - 0.0044 in.
(0,085 - 0,112 mm)
Top Ring Gap 0.0118 - 0.0177 in. Allowable Limit 0.0079 inch (0,2 mm)
(0,3 - 0,45 mm)
Oil Ring 0.0008 - 0.0021 in. (0,02
Oil Ring Gap 0.0098 - 0.0157 in.
(0,25 - 0,40 mm) - 0,06 mm)
Allowable Limit 0.0492 in. (1,25 mm) Allowable Limit 0.0059 in. (0,15 mm)
Second Ring Gap 0.0118 - 0.0177 in.
(0,30 - 0,45 mm)
Cylinder Bore Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-90-12 doing this check.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-14
B-4066
Figure 70-90-13
B-4067
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-14].
A-2717
Figure 70-90-15
1
2 5
4
P-47276
Figure 70-90-19
B-4092
Figure 70-90-20
PI-10021
Figure 70-90-23
A-2716
Put the crankshaft on V-blocks. Install a dial indicator on Crankpin Bearing I.D. 1.5750 - 1.5768 in.
the center journal [Figure 70-90-23]. (40,004 - 40,050 mm)
Crankpin O.D. 1.5732 - 1.5738 in.
Turn the crankshaft at a slow rate to obtain the
(39,959 - 39,975 mm)
misalignment (one half of the alignment measurement).
Oil Clearance 0.0011 - 0.0036 in.
(0,029 - 0,091 mm)
If the misalignment exceeds the allowable limit, replace
the crankshaft. Allowable limit 0.0079 in. (0,2 mm)
Figure 70-90-26
Alignment 0.0008 in. (0,02 mm)
1
Tighten the connecting rod bolts to 20 - 22 ft.-lb. (27 - 30
Nm) torque.
Figure 70-90-24
120
PI-10022
A-2727 If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Measure the crankpin bearing I.D. [Figure 70-90-24].
Figure 70-90-27
2 2 B-3631
1 3
Measure the I.D. of the No. 1 crankshaft bearing [Figure
70-90-28].
Figure 70-90-29
PI-10023
Figure 70-90-32
Measure the O.D. of the crankshaft journal [Figure 70-90-
30]. Installation Tool
5.12 (130 mm)
Calculate the oil clearance. 0.8
(20 mm)
0.16
If the clearance exceeds the allowable limit, replace the (4 mm)
crankshaft bearing. 2.551-2.555
2.83 (64,80-64,90 mm)
Bearing 1:
(72 mm)
2.68
Bearing I.D. 1.8891 - 1.8916 in. (47,984 - 48,048 (68 mm)
mm)
0.8 (20 mm)
Journal O.D. 1.8872 - 1.8878 in. (47,934 - 47,950
1.57 2.354-2.358
mm) 0.4 (59,80-59,90 mm)
Oil Clearance 0.0013 - 0.0045 in. (0,034 - 0,114 (40 mm) (9mm) MC-1365
mm)
Allowable Limit 0.0079 inch (0,2 mm) To install the front bearing make the tool as shown in
figure [Figure 70-90-32].
Figure 70-90-33
1. Seam 4
2. Bearing
3. Engine Block
4. Bearing Recession
3
PI-10025
2 1 2
Clean the crankshaft journal and bearing. Put a strip of
P-48778 press gauge on the center journal.
Install the main bearing case halves and tighten the bolts.
Remove the front bearing with the special removal tool Remove the bearing case halves.
[Figure 70-90-31].
NOTE: DO NOT turn the crankshaft with the press
Installation: Clean the new bearing (Item 2) and bore, gauge installed. Incorrect measurements will
apply oil to the bearing and bore. Install the new bearing be obtained.
with the seam (Item 1) [Figure 70-90-33] towards the
exhaust manifold side, using the installation driver tool. Measure the flattened press gauge [Figure 70-90-34].
Check the depth (Item 4) of the bearing (Item 2) from the If the clearance exceeds the allowable limit, replace the
face of the engine block (Item 3) [Figure 70-90-33]. This crankshaft bearing.
will ensure proper bearing alignment with the crankshaft.
Crankshaft Bearing 2
Bearing Number 1 0.0 - 0.0118 in. (0,0 - 0,3 Crankshaft Journal O.D. 1.8872 - 1.8878 in.
Recession mm) (47,934 - 47,950 mm)
Bearing I.D. 1.8891 - 1.8909 in.
(47,984-48,029 mm)
Oil Clearance 0.0013 - 0.0037 in.
(0,034 - 0,095 mm)
Allowable Limit 0.0079 in.
(0,2 mm)
Crankshaft Bearing 3
Crankshaft Journal O.D. 2.0441 - 2.0449 in.
(51,921 - 51,940 mm)
Bearing I.D. 2.0462 - 2.0480 in.
(51,974 - 52,019 mm)
Oil Clearance 0.0013 - 0.0039 in.
(0,034 - 0,098 mm)
Allowable Limit 0.0079 in.
(0,2 mm)
Figure 70-90-35
P-73020
1 1
1
P13270
1
NOTE: The bolts may vary in length. Keep the bolts in
their original location
Remove the crankshaft pulley bolt (Item 1) [Figure 70- Clean the gasket surface of timing cover.
100-1].
Figure 70-100-4
Installation: Tighten crankshaft pulley bolt to 101-116 ft.-
lb. (137-157 Nm) torque.
Figure 70-100-2
1
P13271
2
Remove the timing cover gasket (Item 1)
P13268
[Figure 70-100-4].
1 2 P13279
1
Installation: Install the timing gear case cover, then
1
install the crankshaft collar with the tapered side (Item 1)
P13272 [Figure 70-100-7] toward the O-ring.
Figure 70-100-8
Installation: Install four new O-rings (Item 1) and the oil
seal (Item 2) [Figure 70-100-5] into the timing gear case
cover
Figure 70-100-6 1
2
P13276
Timing Gears Backlash - Checking Remove the timing gearcase cover (See Timing Gearcase
Cover Removal And Installation on Page 70-100-1)
When the gears are installed, check the backlash of the
gears. Figure 70-100-10
Figure 70-100-9
1 2
P13269
P-47264
Remove the snap ring (Item 1) and flat washer (Item 2)
from the idler gear shaft [Figure 70-100-10].
Install a dial indicator [Figure 70-100-9].
Remove the idler gear (Item 3) [Figure 70-100-10].
Hold one gear while turning the other gear [Figure 70-
100-9]. Figure 70-100-11
Camshaft - Servicing
Figure 70-100-12
PI-10002B
1
Figure 70-100-14
Remove the tappets from the block.
P-47263
Figure 70-100-15
B-5001
Calculate the oil clearance. If the clearance exceeds the Cam Height of Intake 1.1339 in. (28,8 mm)
allowable limit, replace the camshaft.
Allowable Limit 1.1319 in. (28,75 mm)
Cam Height of Exhaust 1.1417 in. (29 mm)
Cylinder Block Bore I.D. 1.4173 - 1.4183 in.
(36 - 36,025 mm) Allowable Limit 1.1398 in. (28,95 mm)
Journal O.D. 1.4147 - 1.4153 in.
Figure 70-100-17
(35,934 - 35,950 mm)
Oil Clearance of Cam- 0.00197 - 0.00358 in.
shaft Journal (0,05 - 0,091 mm)
Allowable Limit 0.0059 in.
(0,15 mm)
A-2760
1.016-1.020 0.787
(28,8-28,9 mm) (20 mm)
1.016-1.020
(25,8-25,9) P-62615A
Measure the outside diameter of the idler gear shaft (Item Figure 70-100-21
1) [Figure 70-100-18].
Figure 70-100-19
1
2
PI-10004
Use a press and the driver tool, to remove the old bushing
and install the new bushing [Figure 70-100-21].
P13365
Figure 70-110-1
1
S2900
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operators Normally, But Air Flow Is Insufficient . . . . 80-30-1
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . 80-30-6
Heater Valve Not Opening Or Closing. . . . . . . . . . . . . . . . . . . . . . . 80-30-6
HEATER
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
Description
Figure 80-10-1 1
2 3
N-20876
Figure 80-10-4
2
1
N-22092
Heater Blower: The blower (Item 2) [Figure 80-10-2] is Heater Valve: The heater valve (Item 1) [Figure 80-10-4]
used to push air through the heater and into the cab. is used to control the amount of engine coolant that flows
to the heater coil.
Figure 80-20-1
P-28820
1 Figure 80-20-4
P-28819
Filter Elements Removal And Installation (Cont'd) Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
Figure 80-20-5 20-1.)
Figure 80-20-7
P-48008
1
1
2
P-48006
Figure 80-20-8
P-48007
Reverse the removal procedure to install the filter The heater coil (Item 1) [Figure 80-20-8], can now be
element. cleaned with low pressure water or air. High pressure may
damage the fins of the heater.
Electrical System
Figure 80-30-1
1 1
P-68444
Figure 80-30-4
P-68118
1
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-30-2] from the loader wiring harness.
N-20876
Figure 80-30-5
C
H
B
M
N-22288
Figure 80-30-8
A C
N-22290
If heater valve does not open, or close, check the If no resistance is found replace the potentiometer.
potentiometer.
Figure 80-30-11
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-8] from the potentiometer.
Figure 80-30-9
1
N-22201
Figure 80-30-12
N-22175
1
To check the resistance of the white wire, turn the Figure 80-30-15
potentiometer control (Item 1) [Figure 80-30-12] to the full
A/C position.
Figure 80-30-13
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire Check the resistance between the wire terminal C and
terminal B frame [Figure 80-30-13] should be wire terminal B frame [Figure 80-30-15] should be
approximately 49 K Ohm's. approximately 49 K Ohm's.
Check the resistance between the wire terminal C and If the resistance is not found replace the potentiometer.
wire terminal B frame [Figure 80-30-13] should be
approximately 39 K Ohm's.
Figure 80-30-16
1 2
N-20876
N-20876
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
Raise the lift arms and install an approved lift arm support 20-1.)
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) Turn the fan switch (Item 1) to position 1. Turn the
temperature control (Item 2) [Figure 80-30-18] to the
Turn the fan switch (Item 1) [Figure 80-30-16] to the High High cold position, with the loader ignition switch OFF.
Speed position, with the loader ignition switch OFF.
Raise the operator cab. (See Raising on Page 10-30-1.)
Raise the operator cab (See Raising on Page 10-30-1.)
Connect the remote start tool to the loader. (See Remote
Figure 80-30-17 Start Procedure on Page 10-60-4.)
Figure 80-30-19
P-68119
P-68117
Connect the remote start tool to the loader. (See Remote
Start Procedure on Page 10-60-4.)
Place the remote start tool on the left fender of the loader,
Start the loader and run at high idle, for ten minutes. so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
Check the heater hose (Item 1) [Figure 80-30-17] for start tool is turned to the ON position without starting the
temperature. loader. The heater valve should rotate. Place a mark on
the heater valve shaft.
If the hose is hot, the heater valve is leaking by, and needs
to be replaced.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Figure 80-40-1
P-68840
1
Figure 80-40-4
P-66829
Figure 80-40-2
P-68841
P-68118
Figure 80-40-5
P-66921
Figure 80-50-1 1 1
2
P-69829
Figure 80-50-3
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Cap the hoses and the heater coil to prevent coolant loss Remove the two mount bolts (Item 1) [Figure 80-50-3]
from the system. from the heater coil.
Remove the rear cover from the heater unit. (See Remove the heater coil from the unit.
Cleaning The Heater Coil on Page 80-20-2.)
Reverse the removal procedure to install the heater coil.
Figure 80-60-1
N-22099
Figure 80-60-3
Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) 1
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the heater unit from the back of the cab. (See
Removal And Installation on Page 80-40-1.)
1 1 2
N-22108
Remove the eight mount bolts (Item 1) [Figure 80-60-4] Figure 80-60-7
from the blower wheel cover.
Figure 80-60-5
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-60-7].
1
2
N-22107
Figure 80-60-8
N-22111
Figure 80-60-11
Figure 80-60-9
1
2
1
N-22116
N-22112
Connector Identification
Figure 80-60-12
P-68118
The wiring code for the blower fan connector [Figure 80-
60-12] is:
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Remove the Heater Unit from under the cab and place it
across the mainframe supported by blocks (See Removal
And Installation on Page 80-40-1.)
1
Remove any tie-straps that hold the heater hoses.
P-66922
Figure 80-70-1
1 2
3
P-66921
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.
Figure 80-70-3 1
P-66925
1
1 1
2
2
P-66926
P-66924
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Machine Dimensions
Dimensions are given for loader equipped with standard tires and C/I bucket and may vary with other bucket types.
All dimensions are shown in millimeters.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
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.
Machine Rating
Function Time
Weights
Engine
Electrical
Hydraulic System
Hydraulic Cylinders
Drive System
Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final drive chains Pre-stressed #80 HSOC endless roller chain (no master link) and sprockets in sealed
chaincase with oil lubrication. (Chains do not require periodic adjustments.)
Two chains per side with no idler sprocket.
Main drive Fully hydrostatic; four-wheel drive
Axle size 44.5 mm, heat treated. Axle tubes welded to chaincase.
Wheel bolts Six- 9/16-inch wheel bolts fixed to axle hubs
Traction
Environmental
Fluid Capacities
Fluid Specifications
Engine coolant Polypropylene glycol / water mix (53% - 47%) with freeze protection to -37C
Engine oil Oil must meet API Service Classification of CD, CE, CF4, CG4, or better.
Recommended SAE viscosity number for anticipated temperature range.
Controls
Instrumentation
The following loader functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored loader malfunctions by way of audible alarm and visual warning lights.
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe 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)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
(300-330) (410-450)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
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 SPEC-30-1
B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].
Figure SPEC-30-2
O-ring Face Seal Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (Nm)
1/4 9/16 - 18 13 (18)
3/8 11/16 - 16 22 (30)
1/2 13/16 - 16 40 (54)
5/8 1 - 14 60 (81)
3/4 1-3/16 - 12 84 (114)
7/8 1-3/16 - 12 98 (133)
1 1-7/16 - 12 118 (160)
1-1/4 1-11/16 - 12 154 (209)
Figure SPEC-30-3
1
Nut Nut
Washer
Washer
O-ring
O-ring
TS-1619A
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-30-4].
the washer is tight against the surface [Figure SPEC-30-
3]. Use the chart [Figure SPEC-30-5] to find the correct
tightness needed. If the fitting leaks after tightening,
Tubelines And Hoses disconnect it and inspect the seat area for damage.
Replace any tubelines that are bent or flattened. They will Figure SPEC-30-5
restrict flow, which will slow hydraulic action and cause
heat. Flare Fitting Tightening Torque
Tubeline x TORQUE
Replace hoses which show signs of wear, damage or Outside x ft.-lb.
weather cracked rubber. Diameter Thread Size (Nm)
1/4 7/16 - 20 13 (18)
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 5/16 1/2 - 20 17 (23)
3/8 9/16 - 18 22 (30)
1/2 3/4 - 16 40 (54)
5/8 7/8 - 14 60 (81)
3/4 1-1/16 - 12 84 (114)
7/8 1-3/16 - 12 98 (133)
1 1-5/16 - 12 118 (160)
1-1/4 1-5/8 - 12 154 (209)
1-1/2 1-7/8 - 12 163 (221)
2 2-1/2 - 12 252 (342)
Figure SPEC-30-6
Nut Seals
To Fitting
Nut Seals
To Port
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Figure SPEC-30-7
Port seal and nut, washer and O-ring (O-ring Boss) fittings
use the same tightening torque valve chart.
Specifications
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.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807