Service Manual Bobcat s220 530711001
Service Manual Bobcat s220 530711001
Service Manual Bobcat s220 530711001
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6904154 (3-09)
1 of 1035
Printed in U.S.A.
2 of 1035
MAINTENANCE SAFETY
WARNING
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT
B-10731a
B-15590
CORRECT
B-15591
WRONG
WRONG
WRONG
B-15592
B-15593
B-15599
WRONG
B-15600
WRONG
B-15601
B-16102
Keep body, jewelry and clothing
away
from
moving
parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep rear door closed except for
service. Close and latch door
before operating the loader.
WRONG
B-6589
B-16102
Lead-acid batteries
produce
flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.
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
3 of 1035
CORRECT
4 of 1035
ALPHABETICAL INDEX
OIL COOLER...........................................................20-01
OPERATOR CAB .........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS
START) ..................................................................60-01
PIVOT PINS ............................................................10-01
THERMOSTAT.........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING LOADER ON A TRAILER ..........10-01
TROUBLESHOOTING.............................................80-01
TURBOCHARGER ..................................................70-01
WINDOW (FRONT DOOR) .....................................50-01
WINDOW (REAR)....................................................50-01
WINDOW (SIDE) .....................................................50-01
WINDOW (TOP) ......................................................50-01
SAFETY &
MAINTENANCE
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
HYDRAULIC
SYSTEM
HYDROSTATIC
SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
HVAC
SPECIFICATIONS
SPECIFICATIONS
I
7 of 1035
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
9. The parking brake
function correctly.
must
11. Bob-Tach
wedges
and
linkages
must
function
correctly and be in good
condition.
oil
or
FW SSL-1008 SM
II
8 of 1035
22. Check
for
any
field
modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM
III
9 of 1035
IV
10 of 1035
WARNING
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-2003-0903
IMPORTANT
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
DANGER
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
D-1002-1107
WARNING
The signal word WARNING on the machine and in the
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1008 SM
V
11 of 1035
SAFETY INSTRUCTIONS
SI SSL-1008 SM
VI
12 of 1035
FIRE PREVENTION
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage
and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance
Fueling
Starting
Do not use ether or starting fluids on any engine that has
glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Operation
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material,
explosive dust or gases.
Electrical
VII
13 of 1035
Fire Extinguishers
SI SSL-1008 SM
VIII
14 of 1035
Figure 2
P-48339
DELIVERY REPORT
Figure 3
P-43900
XXXXX
Model 2.-Production
Sequence (Series)
B-16315
IX
15 of 1035
LOADER IDENTIFICATION
FRONT
LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDERS
STEPS
BUCKET
STEPS
B-19816A
BUCKET
OPERATOR CAB
(ROPS / FOPS)
REAR AUXILIARY
QUICK COUPLERS
LIFT ARM
LIFT ARM
SUPPORT DEVICE
REAR
GRILL
LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
TIRES
B-19813A
X
16 of 1035
FRONT AUXILIARY
QUICK COUPLERS
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
10-110-1
10-110-1
10-110-1
10-110-2
10-100-1
10-100-1
10-100-2
10-100-2
10-100-1
10-100-3
10-120-1
10-120-6
10-120-1
10-120-1
10-120-4
10-120-5
10-120-2
10-120-3
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
10-01
17 of 1035
10-90-1
10-90-2
10-90-1
10-90-2
10-30-1
10-30-3
10-30-1
10-30-2
10-30-1
10-60-1
10-60-4
10-60-1
10-60-3
10-60-2
10-61-1
10-61-4
10-61-1
10-61-3
10-61-5
10-61-2
10-160-1
10-160-2
10-160-1
10-160-1
10-02
18 of 1035
10-03
19 of 1035
Figure 10-10-5
Procedure
Figure 10-10-4
P-31290A
B-7023A
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.
P-31676
W-2003-0807
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-6].
NOTE: Make sure the jackstands do not touch the
tires.
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
10-10-1
21 of 1035
Figure 10-10-6
Figure 10-20-2
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.
P-43744
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure
10-20-2] to the lift arm support device so there will be no
interference with the support device engagement.
Figure 10-20-3
1
2
3
P-54470A
N-20524B
Raise the lift arms until the lift arm support device drops
onto the lift cylinder rod (Item 1) [Figure 10-20-3]
1
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move both pedals until both
pedals lock.
P-43747
P-43743
Install pin (Item 2) [Figure 10-20-3] into the rear of the lift
arm support device below the cylinder rod.
10-20-1
23 of 1035
Sit in the operators seat, fasten the seat belt and lower
the seat bar. Start the engine.
Figure 10-20-5
Removing
Remove the pin from the lift arm support device.
Figure 10-20-4
P-43746
Raise the lift arms a small amount. The spring will lift the
support device off the lift cylinder rod [Figure 10-20-5].
Lower the lift arms. Stop the engine.
P-43745
Sit in the operators seat fasten the seat belt and lower
the seat bar. Start the engine.
10-20-2
24 of 1035
Raise the seat bar, disconnect the seat belt, move pedals
until both pedals lock and exit the cab.
OPERATOR CAB
Figure 10-30-1
Description
The Bobcat Loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for rollover protection.
ROPS / FOPS - Roll Over protective Structure per ISO
3471, and Falling Object Protective Structure per SAE
J1043 and ISO 3449, Level I. Level II is available.
P-43747
Level I
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
P-31288
P-31289
Raising
Always stop the engine before raising or lowering the
cab.
Stop the loader on a level surface. Lower the lift arms. If
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
10-30-1
25 of 1035
Level II
P-31267
WARNING
Figure 10-30-5
N-20120
P-31268A
P-31288
10-30-2
26 of 1035
P-31289
B-15551J
P-68115
P-68116
The cab door (option) has a sensor (Item 1) [Figure 1030-6] installed which deactivates the lift and tilt valves
when the door is open.
CLOSE DOOR TO OPERATE lift and tilt valves.
The LIFT & TILT VALVE light (Item 2) [Figure 10-30-6]
will be ON when the door is closed and the PRESS TO
OPERATE LOADER Button is pressed.
10-30-3
27 of 1035
Fastening
Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
P-31228A
W-2058-0807
P-31230A
6595014
1
P-43631A
10-40-1
29 of 1035
P-43632A
Figure 10-40-1
10-50-1
31 of 1035
Figure 10-60-2
Figure 10-60-1
P16117
P16114
10-60-1
33 of 1035
Figure 10-60-5
Figure 10-60-3
P16114
P16116
Figure 10-60-4
The service tool harness control (Item 1) [Figure 10-605] is used to connect the remote start tool (Item 2)
[Figure 10-60-5] to the electrical system on the loader.
Figure 10-60-6
P16120
The 10-pin rectangular connector (Item 1) [Figure 10-603] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4].
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel
software.
N-19561
10-60-2
34 of 1035
Figure 10-60-8
Figure 10-60-7
2
1
1
P16119
N-19631
10-60-3
35 of 1035
Figure 10-60-11
Figure 10-60-9
1
N-19150
P16115
WARNING
1
N-19151
10-60-4
36 of 1035
Figure 10-60-12
Figure 10-60-14
2
3
P16118
10-60-5
37 of 1035
P16116
Figure 10-60-15
P-34661
10-60-6
38 of 1035
10-61-1
39 of 1035
The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-17] has five buttons.
Figure 10-61-16
Figure 10-61-17
2
P-76439
10-61-2
40 of 1035
Figure 10-61-20
Figure 10-61-18
1
1
P-76452
P-76678
The loader service tool harness (Item 1) [Figure 10-6118] is used to connect the remote start tool (service tool)
(Item 2) [Figure 10-61-18] to the electrical system on the
loader.
Figure 10-61-19
P-76451
10-61-3
41 of 1035
1
1
P-76450
The computer service tool harness (Item 1) [Figure 1061-22] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-22].
P-76453
The second connector (Item 3) [Figure 10-6121] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector
(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-21].
NOTE: The right instrument panel (Key Switch or
Keyless) must be in the off position or the
Remote Start Tool (Service Tool) will not
operate.
P-76454
10-61-4
42 of 1035
Figure 10-61-24
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
P-76451
W-2647-0707
2
6689779: Remote Start Tool (Service Tool) Kit
Figure 10-61-23
P-76452
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-23] is required when the operator cab is in the raised
position for service and the service technician needs to
turn on the loader or start the engine. Example: adjusting
the steering linkage.
Figure 10-61-27
2
1
1
P-76439
3
1
The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-27] has five buttons.
P-76453
The second connector (Item 3) [Figure 10-6126] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector
(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-26].
P-76454
10-61-6
44 of 1035
Figure 10-61-29
2
P-34661
P-76441
The gear icon with the left facing arrows (Item 1) [Figure
10-61-28] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)
[Figure 10-61-28] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
Loader S/N: xxxx60000 & Below
NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
and hold the AUXILIARY PRESSURE
RELEASE button on the left instrument panel
for three seconds after the engine has
stopped.
Loader S/N: xxxx60001 & Above
NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch on the to the right and left
several times.
10-61-7
45 of 1035
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Loader.
WARNING
SERVICE SCHEDULE
Engine Oil
Engine Air Filter and Air System
Engine Cooling System
Fuel Filter
Lift Arms, Cylinders, Bob-Tach
Pivot Pins and Wedges
Tires
SERVICE REQUIRED
50
100
250
500
1000
Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tire.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors
needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS)
bar raised. See details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab
Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights
Check for correct operation of all indicators and lights.
Heater and A/C Filters
Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid, Hoses and
Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines
replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals,
Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts
Check for loose wheel nuts and tighten to correct torque. (See TIRE
MAINTENANCE in this manual.)
Spark Arrestor Muffler
Clean the spark chamber.
Battery
Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots
Grease fittings.
Fuel Filter
Replace filter element.
Engine / Hydro. Drive Belt
Check for wear or damage. Check idler arm stop.
Drive Belts (Alternator, air
Check condition and tension. Adjust or replace as needed.
conditioner, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Hydraulic / Hydrostatic Filter,
Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir
Charge Filter, Reservoir Breather breather.
Engine Oil and Filter
Replace oil and filter.
Final Drive Trans. (Chaincase)
Replace the fluid.
Hydraulic Reservoir
Replace the fluid.
Case Drain Filters
Replace the filters.
Engine Valves
Adjust the engine valves.
Coolant
Replace the coolant
8-10
ITEM
HOURS
Every 2 years
Or every 12 months.
Perform at first 50 hours, then as scheduled.
Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when the transmission warning light
comes ON while operating or as scheduled.
Change oil and filter every 250 hours when operating under severe conditions.
Perform at first 500 hours, then as scheduled.
10-70-1
47 of 1035
Outer Filter
Figure 10-80-3
Figure 10-80-1
1
P-48340
B-15553G
Remove the wing nut and remove the dust cover (Item 1)
[Figure 10-80-3].
Figure 10-80-4
B-15552G
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Figure 10-80-2
1
2
P-48341
Remove the wing nut and pull the outer filter element
(Item 1) [Figure 10-80-4] out and discard.
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
B-15551
Press and hold the LIGHT Button (Item 1) [Figure 10-802] for two seconds.
Install new filter. Push all the way in until it contacts the
base of the housing. Install wing nut.
If the filter element needs replacement, the CODE [0117] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2].
Install the dust cover and the wing nut [Figure 10-80-3].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
10-80-1
49 of 1035
Figure 10-80-6
P-48340
Figure 10-80-5
Install the dust cover and the wing nut [Figure 10-80-6]
(Be sure the evacuator is down).
P-48342
10-80-2
50 of 1035
Figure 10-90-2
Check the cooling system every day to prevent overheating, loss of performance or engine damage.
1
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
P-76189
W-2019-0907
Figure 10-90-3
1
2
2
1
P-39459
P-76190
10-90-1
51 of 1035
Cleaning
Checking Level
Figure 10-90-5
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
P-34869
Figure 10-90-4
Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank. (See Checking Level on Page
PM-2.)
One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34F (-37C) freeze protection.
P-43636A
10-90-2
52 of 1035
P-48340
FUEL SYSTEM
Fuel Specifications
TEMPERATURE F (C)
NO. 2
NO. 1
+15 (9)
100%
0%
50%
50%
0%
100%
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
Fuel Filter
WARNING
Figure 10-100-3
Figure 10-100-1
2
P-31254
Figure 10-100-2
WRONG
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
B-15650
10-100-2
54 of 1035
P-48343
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 10-100-4
2
P-48360
10-100-3
55 of 1035
P-48345
10-110-1
57 of 1035
WARNING
Figure 10-110-2
1
P-48346
10-110-2
58 of 1035
Figure 10-120-3
P-64023A
P-31283A
Check the fluid level in the sight gauge (Item 1) [Figure 10120-1].
Figure 10-120-2
P-01502
P-31284
Figure 10-120-6
Remove the fill cap and raise the operator cab. (See
Raising on Page 10-30-1.)
P-31285
Figure 10-120-4
Remove the hydrostatic motor cover (Item 1) [Figure 10120-6]. (Left Side)
P-64240
Remove the two hose clamps and remove the hose (Item
1) [Figure 10-120-4].
P-31286
Figure 10-120-5
Pull the reservoir drain hose out the left motor cover hole.
Remove the plug (Item 1) [Figure 10-120-7] and drain
the fluid into a container.
Recycle or dispose of used fluid in an environmentally
safe manner.
P-76725
Figure 10-120-7
WARNING
Figure 10-120-8
W-2103-0508
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)
P-64239
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
10-120-3
61 of 1035
Figure 10-120-10
P-31565
P-31692
P-64076
WARNING
10-120-4
62 of 1035
Figure 10-120-13
Figure 10-120-11
WARNING
P-64239
Figure 10-120-12
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
P-76553B
10-120-5
63 of 1035
All Models
P-31284
P-01502
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
10-120-6
64 of 1035
Figure 10-130-2
10-130-1
65 of 1035
P-31287A
Figure 10-140-2
Wedge
must
contact
lower edge of hole in the
attachment.
P-31233
B-15177
WARNING
Figure 10-140-3
B-17460
Inspect the mounting frame on the attachment and BobTach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1) and (See Lubrication Locations on Page
10-150-1.)
10-140-1
67 of 1035
P-31693
Figure 10-141-2
Wedge
must
contact
lower edge of hole in the
attachment.
P-31233
B-15177
B-15891
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.
Figure 10-141-3
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
B-17460
10-141-1
69 of 1035
Figure 10-150-3
Lubrication Locations
Lubricate the loader as specified for the best
performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
Figure 10-150-1
Figure 10-150-4
P-31305
P-43782
Figure 10-150-2
Figure 10-150-5
5
6
2
P-31306
P-31307
P43783
10-150-1
71 of 1035
P-31308
P-37666
10-150-2
72 of 1035
TIRE MAINTENANCE
Rotating
Wheel Nuts
Figure 10-160-2
Figure 10-160-1
B-9976
P-31225
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].
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
WARNING
AVOID INJURY OR DEATH
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
10-160-1
73 of 1035
WARNING
Dealer Copy -- Not for Resale
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
10-160-2
74 of 1035
Figure 10-170-1
Cleaning Procedure
Use the correct service interval for cleaning the spark
arrestor muffler. (See SERVICE SCHEDULE on Page
10-70-1.)
Do not operate the loader with a defective exhaust
system.
1
IMPORTANT
P-64701
WARNING
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
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
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
10-170-1
75 of 1035
PIVOT PINS
Inspection And Maintenance
Figure 10-180-1
P-43783
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].
Check that the lock nuts are tightened to 35-40 ft.-lb. (4854 Nm) torque.
10-180-1
77 of 1035
Return to Service
Storage
Start the engine and let run for a few minutes while
observing the instrument panels and systems for
correct operation.
10-190-1
Lower the lift arms all the way and put the bucket flat
on the ground.
Put fuel stabilizer in the fuel tank and run the engine
a few minutes to circulate the stabilizer to the pump
and fuel injectors.
79 of 1035
Figure 10-200-3
Procedure
Figure 10-200-1
2
B-15553B
B-15552B
P-68656
Lift the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Key Switch) to prevent
operation of the loader by unauthorized personnel.
Figure 10-200-2
WARNING
P-68134
Pull the engine speed control fully backward [Figure 10200-2] to decrease the engine speed.
10-200-1
81 of 1035
P-68655
Figure 10-200-4
Figure 10-200-6
P0660
N-20171
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-200-6].
Push the rear window out of the rear of the operator cab.
Figure 10-200-7
Figure 10-200-5
X
X
6707852
P-24472
P-43752
10-200-2
82 of 1035
Emergency Exit
HYDRAULIC SYSTEM
HYDRAULIC
SYSTEM
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
20-01
83 of 1035
20-02
84 of 1035
20-90-1
20-90-1
20-90-4
20-90-1
HYDRAULIC/HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . .
Charge Filter Housing Removal And Installation . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .
20-80-1
20-80-3
20-80-1
20-80-1
20-03
85 of 1035
20-50-1
20-50-1
20-50-3
20-50-2
20-50-1
20-04
86 of 1035
20-30-1
20-30-4
20-30-1
20-30-5
20-30-2
20-120-1
20-120-1
20-120-4
20-120-2
20-120-1
20-05
87 of 1035
HYDRAULIC/HYDROSTATIC SCHEMATIC
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
11 ANTICAVITATION VALVE
27
12
13
10
54
Printed in U.S.A.
89 of 1035
V-0784legend (11-8-07)
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
DRIVE MOTOR
28
29
FEMALE
27
37
P-OUT
P-IN
32
38
D
34
HYDRAULIC FILTER
31
B
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
CHARGE
INLET
40
36
C
21
31
20
12
42
12
B
30
36
AUXILIARY
SPOOL
A
14
5
52
TILT CYLINDERS
10
50
51
FAN MOTOR
INLET
TILT
SPOOL
OUTLET
17
53
10
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
48
DRIVE MOTOR
37
46
4
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
90 of 1035
Printed in U.S.A.
V-0784 (11-8-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
50
CHECK VALVE
51
34
35
RESTRICTION
19
36
53
54
55
56
57
FILTER - BRAKE
58
59
7
8
10
24
41
25
42
26
43
61
44
45
29 RELIEF VALVE:
46
47
23
11 ANTICAVITATION VALVE
27
12
13
37
30
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
53
30
P-OUT
P-IN
52
32
38
D
34
HYDRAULIC FILTER
31
CHARGE
INLET
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
31
40
36
C
21
2
13
Dealer Copy -- Not for Resale
20
12
42
12
B
AUXILIARY
SPOOL
A
58
36
14
5
60
61
62
TILT CYLINDERS
10
FAN MOTOR
8
INLET
TILT
SPOOL
OUTLET
17
59
B
10
51
11
14
57
LIFT CYLINDERS
10
38
57
50
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
56
52
39
18
B
LIFT
SPOOL
47
15
53
C
35
14
54
48
46
49
55
2 SPEED
DRIVE MOTOR
50
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
92 of 1035
33
45
P1
A
44
19
V-0785 (11-8-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
10
11 ANTICAVITATION VALVE
27
12
13
50
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
55
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
28
29
2 SPEED
DRIVE MOTOR
FEMALE
27
37
P-OUT
P-IN
32
38
D
34
HYDRAULIC FILTER
31
B
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
CHARGE
INLET
40
36
C
21
31
20
12
42
12
B
58
36
AUXILIARY
SPOOL
A
14
5
TILT CYLINDERS
10
51
58
56
57
50
52
FAN MOTOR
INLET
TILT
SPOOL
17
55
53
OUTLET
10
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
48
2 SPEED
DRIVE MOTOR
37
46
4
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
94 of 1035
Printed in U.S.A.
V-0786 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
23
24
13
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
55
56
57
FILTER - BRAKE
58
59
41
61
42
43
44
26
45
29 RELIEF VALVE:
46
30
51
27
25
11 ANTICAVITATION VALVE
12
50
47
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
66
30
P-OUT
P-IN
65
32
38
D
34
HYDRAULIC FILTER
31
CHARGE
INLET
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
31
40
36
C
21
20
12
42
12
B
AUXILIARY
SPOOL
A
58
36
14
5
60
61
62
TILT CYLINDERS
10
FAN MOTOR
51
50
52
INLET
TILT
SPOOL
17
59
B
53
64
OUTLET
10
11
14
57
LIFT CYLINDERS
10
38
57
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
56
65
39
18
B
LIFT
SPOOL
47
15
66
C
35
14
54
48
46
49
55
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
96 of 1035
33
45
P1
A
44
19
V-0787 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
33 FILTER - BICS CONTROL VALVE
(SCREEN)
34
51
35
RESTRICTION
19
36
37
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
10
11 ANTICAVITATION VALVE
27
12
13
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
DRIVE MOTOR
28
29
FEMALE
27
37
P-OUT
P-IN
38
32
D
B
HYDROSTATIC PUMPS
31
55
56
5
34
HYDRAULIC FILTER
OIL
COOLER
22
57
40
36
C
21
13 for Resale
Dealer Copy -- Not
CHARGE
INLET
20
12
12
31
2
42
57
AUXILIARY
SPOOL
A
30
36
14
56
TILT CYLINDERS
10
55
50
52
FAN MOTOR
51
TILT
SPOOL
8
INLET
17
OUTLET
10
53
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
DRIVE MOTOR
37
48
46
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
98 of 1035
Printed in U.S.A.
V-0788 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND 2 SPEED OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
33 FILTER - BICS CONTROL VALVE
(SCREEN)
34
35
RESTRICTION
19
36
53
FILTER - BRAKE
37
54
56
57
58
59
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
7
8
10
16
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
23
27
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
13
55
11 ANTICAVITATION VALVE
12
30
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND 2 SPEED OPTION
S220 (S/N 530711001 - 540740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
50
30
P-OUT
P-IN
65
32
38
D
B
HYDROSTATIC PUMPS
31
55
CHARGE
INLET
56
5
34
HYDRAULIC FILTER
OIL
COOLER
22
57
40
36
C
21
2
13
Dealer Copy -- Not for Resale
20
12
42
12
B
3
57
AUXILIARY
SPOOL
A
58
36
14
56
TILT CYLINDERS
10
55
60
61
62
FAN MOTOR
C
TILT
SPOOL
8
INLET
OUTLET
10
59
64
17
11
14
53
LIFT CYLINDERS
10
38
53
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
52
65
39
18
B
LIFT
SPOOL
47
15
50
C
35
14
54
48
46
49
51
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
100 of 1035
33
45
P1
A
44
19
V-0789 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
11 ANTICAVITATION VALVE
27
12
13
50
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
56
57
58
59
55
ANTICAVITATION VALVE
V-0790legend (11-7-07)
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
DRIVE MOTOR
7
28
37
29
FEMALE
27
P-OUT
P-IN
38
32
D
B
HYDROSTATIC PUMPS
31
55
OIL
COOLER
56
5
34
HYDRAULIC FILTER
22
57
40
36
C
21
CHARGE
INLET
20
12
12
31
2
42
57
AUXILIARY
SPOOL
A
58
36
14
3
56
TILT CYLINDERS
10
55
60
51
50
52
B
30
61
FAN MOTOR
TILT
SPOOL
17
INLET
10
59
53
11
14
OUTLET
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
DRIVE MOTOR
37
48
46
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
102 of 1035
Printed in U.S.A.
V-0790 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
56
57
58
59
55
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
27
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
13
11 ANTICAVITATION VALVE
12
50
30
61
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530711001 - 530740000)
(S/N 530811001 - 530840000)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
66
30
P-OUT
P-IN
65
32
38
D
B
HYDROSTATIC PUMPS
31
55
CHARGE
INLET
OIL
COOLER
56
5
34
HYDRAULIC FILTER
22
57
40
36
C
21
2
13
Dealer Copy -- Not for Resale
20
12
42
12
B
3
57
AUXILIARY
SPOOL
A
58
36
14
56
55
60
61
62
TILT CYLINDERS
10
FAN MOTOR
51
50
52
TILT
SPOOL
17
INLET
10
59
64
11
14
69
53
OUTLET
LIFT CYLINDERS
10
38
69
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
68
65
39
18
B
LIFT
SPOOL
47
15
66
C
35
14
54
48
46
49
67
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
104 of 1035
33
45
P1
A
44
19
V-0791 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
10
11 ANTICAVITATION VALVE
27
12
13
54
55 FILTER - HYDRAULIC
56 SPRING LOADED FILTER BY-PASS
VALVE: 75-83 PSI (5,2-5,7 bar)
Printed in U.S.A.
105 of 1035
V-0929legend (11-8-07)
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
DRIVE MOTOR
28
29
FEMALE
27
37
P-OUT
P-IN
32
38
D
34
HYDRAULIC FILTER
31
B
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
6
40
36
C
21
CHARGE
INLET
13 for Resale
Dealer Copy -- Not
20
12
12
B
56
55
42
AUXILIARY
SPOOL
A
30
36
14
5
50
52
TILT CYLINDERS
10
51
8
FAN MOTOR
INLET
TILT
SPOOL
OUTLET
17
53
10
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
48
DRIVE MOTOR
37
46
4
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
106 of 1035
Printed in U.S.A.
V-0929 (11-8-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
50
CHECK VALVE
51
34
35
RESTRICTION
19
36
53
54
55
56
57
FILTER - BRAKE
58
59
7
8
10
24
41
25
42
26
43
61
44
45
63 FILTER - HYDRAULIC
29 RELIEF VALVE:
46
47
23
11 ANTICAVITATION VALVE
27
12
13
37
30
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
53
30
P-OUT
P-IN
52
32
38
D
34
HYDRAULIC FILTER
31
CHARGE
INLET
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
6
40
36
C
21
13
Dealer Copy -- Not for Resale
20
12
12
3
B
AUXILIARY
SPOOL
A
63
42
64
58
36
14
5
60
TILT CYLINDERS
10
61
62
FAN MOTOR
INLET
TILT
SPOOL
OUTLET
17
59
B
10
51
11
14
57
LIFT CYLINDERS
10
38
57
50
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
56
52
39
18
B
LIFT
SPOOL
47
15
53
C
35
14
54
48
46
49
55
2 SPEED
DRIVE MOTOR
50
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
108 of 1035
33
45
P1
A
44
19
V-0930 (11-8-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
50
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
55
ANTICAVITATION VALVE
23
59 FILTER - HYDRAULIC
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
10
11 ANTICAVITATION VALVE
27
12
13
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
28
29
2 SPEED
DRIVE MOTOR
FEMALE
27
37
P-OUT
P-IN
32
38
D
34
HYDRAULIC FILTER
31
B
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
6
40
36
C
21
CHARGE
INLET
20
12
12
B
59
42
58
36
60
AUXILIARY
SPOOL
A
14
5
56
TILT CYLINDERS
10
51
58
57
50
52
FAN MOTOR
INLET
TILT
SPOOL
17
55
53
OUTLET
10
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
48
2 SPEED
DRIVE MOTOR
37
46
4
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
110 of 1035
Printed in U.S.A.
V-0931 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 5530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
23
24
13
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
55
56
57
FILTER - BRAKE
58
59
41
61
42
43
44
26
45
29 RELIEF VALVE:
46
30
51
27
25
11 ANTICAVITATION VALVE
12
50
47
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
66
30
P-OUT
P-IN
65
32
38
D
34
HYDRAULIC FILTER
31
B
HYDROSTATIC PUMPS
OIL
COOLER
22
5
HYDRAULIC CONTROL VALVE
6
40
36
C
21
CHARGE
INLET
13
Dealer Copy -- Not for Resale
20
12
12
3
B
67
68
42
AUXILIARY
SPOOL
A
58
36
14
5
60
TILT CYLINDERS
10
51
61
62
50
52
FAN MOTOR
INLET
TILT
SPOOL
17
59
B
53
64
OUTLET
10
11
14
57
LIFT CYLINDERS
10
38
57
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
56
65
39
18
B
LIFT
SPOOL
47
15
66
C
35
14
54
48
46
49
55
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
112 of 1035
33
45
P1
A
44
19
V-0932 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
33 FILTER - BICS CONTROL VALVE
(SCREEN)
34
51
35
RESTRICTION
19
36
37
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
10
11 ANTICAVITATION VALVE
27
12
13
ANTICAVITATION VALVE
58 FILTER - HYDRAULIC
59 SPRING LOADED FILTER BY-PASS
VALVE: 75-83 PSI (5,2-5,7 bar)
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
7
DRIVE MOTOR
28
29
FEMALE
27
37
P-OUT
P-IN
38
32
D
B
HYDROSTATIC PUMPS
31
55
56
5
34
HYDRAULIC FILTER
OIL
COOLER
22
57
40
36
C
21
CHARGE
INLET
20
12
12
B
42
57
AUXILIARY
SPOOL
A
30
36
58
14
59
56
TILT CYLINDERS
10
55
50
FAN MOTOR
52
51
TILT
SPOOL
8
INLET
17
OUTLET
10
53
11
14
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
DRIVE MOTOR
37
48
46
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
114 of 1035
Printed in U.S.A.
V-0933 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND 2 SPEED OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
33 FILTER - BICS CONTROL VALVE
(SCREEN)
34
35
RESTRICTION
19
36
53
FILTER - BRAKE
37
54
56
57
58
59
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
7
8
10
16
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
23
11 ANTICAVITATION VALVE
27
12
13
30
55
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND 2 SPEED OPTION
S220 (S/N 540740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
50
30
P-OUT
P-IN
65
32
38
D
B
HYDROSTATIC PUMPS
31
55
56
5
34
HYDRAULIC FILTER
OIL
COOLER
22
57
40
36
C
21
CHARGE
INLET
13
Dealer Copy -- Not for Resale
20
12
12
B
42
57
AUXILIARY
SPOOL
A
58
36
14
66
67
56
TILT CYLINDERS
10
55
60
C
B
61
62
INLET
17
OUTLET
10
59
64
TILT
SPOOL
FAN MOTOR
11
14
53
LIFT CYLINDERS
10
38
53
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
52
65
39
18
B
LIFT
SPOOL
47
15
50
C
35
14
54
48
46
49
51
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
116 of 1035
33
45
P1
A
44
19
V-0934 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
23
24
41
42
43
44
45
29 RELIEF VALVE:
46
47
25
26
11 ANTICAVITATION VALVE
27
12
13
50
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
56
57
58
59
55
ANTICAVITATION VALVE
62 FILTER - HYDRAULIC
63 SPRING LOADED FILTER BY-PASS
VALVE: 75-83 PSI (5,2-5,7 bar)
V-0935legend (11-7-07)
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
DRIVE MOTOR
7
28
37
29
FEMALE
27
P-OUT
P-IN
38
32
D
B
HYDROSTATIC PUMPS
31
55
OIL
COOLER
56
5
34
HYDRAULIC FILTER
22
57
40
36
C
21
CHARGE
INLET
20
12
12
B
42
57
63
AUXILIARY
SPOOL
A
58
36
14
62
56
TILT CYLINDERS
10
55
51
50
60
52
B
30
61
FAN MOTOR
TILT
SPOOL
17
INLET
10
59
53
11
14
OUTLET
LIFT CYLINDERS
10
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
38
39
18
B
LIFT
SPOOL
47
15
35
14
54
DRIVE MOTOR
37
48
46
49
33
41
33
16
45
PP
43
32
P2
P1
DR
44
19
118 of 1035
Printed in U.S.A.
V-0935 (11-12-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . 18.8 qt. (17,8 L)
16
34
35
RESTRICTION
19
36
37
7
8
10
51
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 16.0 GPM (60,5 L/min) at High Engine Idle
54
56
57
58
59
55
23
24
41
25
42
26
43
44
45
29 RELIEF VALVE:
46
47
27
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
13
11 ANTICAVITATION VALVE
12
50
30
61
ANTICAVITATION VALVE
(REAR QUICK
COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
S220 (S/N 530740001 & ABOVE)
(S/N 530840001 & ABOVE)
BASE
MALE
ROD
INTEGRATED QUICK
COUPLER BLOCK
24
23
MALE
25
2 SPEED
DRIVE MOTOR
26
7
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
37
7
28
29
FEMALE
27
66
30
P-OUT
P-IN
65
32
38
D
B
HYDROSTATIC PUMPS
31
55
OIL
COOLER
56
5
34
HYDRAULIC FILTER
22
57
40
36
C
21
CHARGE
INLET
20
12
12
B
42
57
AUXILIARY
SPOOL
A
58
36
14
70
71
56
TILT CYLINDERS
10
55
51
50
60
52
FAN MOTOR
17
INLET
10
59
64
TILT
SPOOL
61
62
11
14
69
53
OUTLET
LIFT CYLINDERS
10
38
69
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
30
68
65
39
18
B
LIFT
SPOOL
47
15
66
C
35
14
54
48
46
49
67
2 SPEED
DRIVE MOTOR
63
37
41
33
16
PP
43
LIFT ARM BY PASS VALVE
P2
32
DR
120 of 1035
33
45
P1
A
44
19
V-0936 (11-12-07)
SYMBOL
DESCRIPTION
DESCRIPTION
CROSSING
TEMPERATURE
INDICATOR
(temperature
measurement
thermometer).
AND
FILTERED
(reservoir open to
PRESSURIZED,
VENTED
AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
OIL LINES
Connected).
TEMPERATURE
CONTROL
(Indication of temperature).
(NOT
Varies
DIFFERENTIAL
PRESSURE
SWITCH - Switch activates when
pressure difference reaches specified
level.
20-10-1
121 of 1035
(silencer)
Reduces
VARIABLE
ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
DESCRIPTION
DESCRIPTION
CONTROL MECHANISMS
CONTROL VALVE WITH DETENT
(Holds Valve in Position) - device for
maintaining
a
given
position
(mechanical).
CONTROL VALVE ACTIVATED BY A
PULL BUTTON (manual).
20-10-2
122 of 1035
SYMBOL
DESCRIPTION
DESCRIPTION
OUT
OUT
IN
IN
PILOT
CONTROLLED
NONRETURN VALVE- It is possible to
open the valve by pilot pressure.
IN
OUT
SOLENOID
ACTIVATED
DIRECTIONAL CONTROL VALVE
(Two Position) - controlled by an
electric solenoid (with return spring).
MANUALLY
ACTIVATED
DIRECTION
CONTROL
VALVE
(Variable
Position)
Joystick
Controlled, variable pressure to shift
the pilot activated directional control
valve spool.
IN
OUT
ST
IS
IN
FRON T
BACK
MANUALLY
ACTIVATED
FLOW
CONTROL VALVE (Two Position)
allows for changing pilot flow to
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING
CONTROL
VALVE
(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.
20-10-3
123 of 1035
SYMBOL
SYMBOL
DESCRIPTION
OUT
IN
IN
OUT
OUT
MISCELLANEOUS
ACCUMULATOR
Supplies
temporary reserve pressure to the
hydraulic system when the engine
has been stopped.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE When the Inlet pressure overcomes
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE When the Inlet pressure overcomes
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
IN
DESCRIPTION
20-10-4
124 of 1035
WARNING
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.
CAUSE
1, 2, 3, 5, 8
1, 3, 4, 6, 8
1, 4, 5, 6, 7
1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position.
The lift arms come down with the pedal in the neutral position.
4, 9, 10, 11
12
13
20-10-5
125 of 1035
CYLINDER (LIFT)
Figure 20-20-2
Testing
Figure 20-20-1
2
1
1
P-43777
P-43776
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
20-20-1
127 of 1035
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
Lower the lift arms. Stop the engine. Raise the seat bar.
Figure 20-20-5
1
1
P-43781
1
1
P-43778
P-43780
Remove the retaining bolt and nut (Item 1) [Figure 2020-6] from the pivot pin at the base end of the lift cylinder.
Remove the retaining bolt and nut (Item 1) [Figure 2020-4] from the pin on the rod end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 25-28 ft.lb. (34-38 Nm) torque.
Installation: Tighten the retainer bolt and nut to 25-28 ft.lb. (34-38 Nm) torque.
20-20-2
128 of 1035
P-43779
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
20-20-3
129 of 1035
9.
10.
11.
12.
13.
14.
15.
16.
Spacer
Washer
O-ring
Seal
Seal
Plug
O-ring
Tubeline
9
2
8
4
7
6
14
1.
2.
3.
4.
5.
6.
7.
8.
15
8
TS-1060a
TS-1060a
13
16
3
11
10
5
12
14 15
TS-1060b
20-20-4
130 of 1035
PE1519A
Figure 20-20-10
Disassembly
2
Figure 20-20-8
P-48038
Figure 20-20-9
4
3
P-48039
2
1
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-9].
20-20-5
131 of 1035
Remove the seal (Item 1) and O-ring (Item 2) [Figure 2020-10] from the piston.
P-48040
P-48042
20-20-6
132 of 1035
Figure 20-20-15
Assembly
Use the following tools to assemble the cylinder:
1
2
P-48038
Install the O-ring (Item 1) and seal (Item 2) [Figure 2020-15] on the cylinder piston.
P7424
P-48043
P7427
Install the rod seal on the rod seal tool [Figure 20-20-16].
NOTE: During installation the spring side of the seal
(Item 1) [Figure 20-20-16] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 2020-16].
20-20-7
133 of 1035
Figure 20-20-16
Figure 20-20-19
Assembly (Cont'd)
1
Figure 20-20-17
3
4
P-48036
P7425
Figure 20-20-18
P-48041
P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-2018].
P-48035
20-20-8
134 of 1035
Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-19].
CYLINDER (TILT)
Figure 20-21-2
Testing
Figure 20-21-1
1
P-31370
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port on the cylinder (Item
2) [Figure 20-21-2], remove the tilt cylinder for repair.
Repeat procedure to check the other tilt cylinder.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
20-21-1
135 of 1035
P-31369
Figure 20-21-5
1
P-31369
P-31371
Remove the attachment from the Bob-Tach. Roll the BobTach forward
Stop the engine. Raise the seat bar.
Remove the retainer bolt and nut (Item 1) [Figure 20-213] from the rod end pivot pin.
Installation: Tighten the retainer nut to 18-20 ft.-lb. (2427 Nm) torque.
Figure 20-21-4
1
P-31373
20-21-2
136 of 1035
P-31374
P-31375
Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-8].
20-21-3
137 of 1035
Figure 20-21-11
P-31378
1
Check pivot pin and replace as needed [Figure 20-2111].
P-31376
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-9]. (See Removal And Installation on
Page 20-21-2.)
Figure 20-21-10
P-31377A
20-21-4
138 of 1035
Case
Piston
Head
Rod
Bushing
Nut
O-ring
Seal
O-ring
Washer
O-ring
Seal
Seal
Plug
O-ring
Tubeline
Grease Fitting
Oil Seal
TS-1688b
17
12
9
1
15
10
16
14
11
15
14
2
13
7
4
5
18
18
17
TS-1688a
TS-1060a
20-21-5
139 of 1035
PE1520S
Figure 20-21-13
Disassembly
3
Use the following tools to disassemble the cylinder:
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].
2
3
P-48034
Use a seal pick to remove the seals (Item 3) [Figure 2021-12] on both sides of the pivot bushing.
Remove and replace bushing (Item 2) with a driver tool
and hammer [Figure 20-21-12].
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-21-12] from the cylinder case.
20-21-6
140 of 1035
Figure 20-21-16
Disassembly (Cont'd)
Figure 20-21-14
1
2
P-48040
P-48073
Figure 20-21-17
Figure 20-21-15
1
1
P-48042
P-48039
20-21-7
141 of 1035
Figure 20-21-19
Assembly
1
P-48073
Install the O-ring (Item 1) and seal (Item 2) [Figure 2021-19] on the cylinder piston.
P7424
P-48043
P7427
Install the rod seal on the rod seal tool [Figure 20-21-20].
NOTE: During installation the spring side of the seal
(Item 1) [Figure 20-21-20] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 2021-20].
20-21-8
142 of 1035
Figure 20-21-20
Figure 20-21-23
Assembly (Cont'd)
1
Figure 20-21-21
2
3
P-48071
P7425
Figure 20-21-22
P-48041
P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-2122].
P-48088
P-48089
20-21-9
143 of 1035
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-23].
P-48070
1
2
P-48034
20-21-10
144 of 1035
CYLINDER (BOB-TACH)
Figure 20-22-2
Testing
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.
1
P-31380
W-2072-0807
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
Figure 20-22-1
2
1
P-31381
20-22-1
145 of 1035
Figure 20-22-3
Figure 20-22-5
P-31382
P-31379
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
20-22-2
146 of 1035
8.
9.
10.
11.
12.
13.
Ring
O-ring
Head
Seal
Seal
Rod
1
2
2
3
4
5
6
1.
2.
3.
4.
5.
6.
7.
9
10
11
12
13
B-16207
20-22-3
147 of 1035
Figure 20-22-8
Disassembly
Figure 20-22-6
P16295
P16293
Figure 20-22-9
MEL1074 - O-ring Seal Hook
Spanner Wrench
2
1
Figure 20-22-7
4
N-20611
2
1
Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P16294
Figure 20-22-11
Assembly
Figure 20-22-10
P16295
NOTE: The piston center hole (Item 4) [Figure 20-2211] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
N-20612
Install the rod seal on the rod seal tool [Figure 20-22-12].
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
20-22-5
149 of 1035
P7424
Figure 20-22-15
Assembly (Cont'd)
Figure 20-22-13
1
2
3
P7422
Figure 20-22-14
Figure 20-22-16
P7425
P16294
Install the head (Item 1), and spacer (Item 2) [Figure 2022-16].
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do
not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 90 ft.-lb. (122 Nm) torque.
20-22-6
150 of 1035
P16293
20-22-7
151 of 1035
20-30-1
153 of 1035
Figure 20-30-1
Testing
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-37687
WARNING
W-2006-0284
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
20-30-2
154 of 1035
Testing (Contd)
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.
Figure 20-30-3
Right
Steering
Lever
Control
1
P-31833
Figure 20-30-4
SJC Option Only
Right
Steering
Lever
Control
P-26697
20-30-3
155 of 1035
P-37690
20-30-4
156 of 1035
Figure 20-30-7
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
P-37689
Figure 20-30-6
P-37690
20-30-5
157 of 1035
P-54236
20-40-1
159 of 1035
Figure 20-40-2
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
IMPORTANT
Raise the lift arms and install an approved lift arm support
device.
P-54569
Remove the lift arm bypass valve and mount from the
loader. (See Removal And Installation on Page 20-50-2.)
Clean area around control valve.
Open rear door.
20-40-2
160 of 1035
P-54497
Figure 20-40-6
P-54488
P-54500
Figure 20-40-5
4
1
1
2
P-68529
P-68526
Disconnect the harness connector (Item 1) [Figure 2040-5] from the auxiliary valve solenoid.
Disconnect the tubeline (Item 2) [Figure 20-40-5] that
goes from the control valve to the hydraulic cooler.
20-40-3
161 of 1035
Figure 20-40-10
Figure 20-40-8
P-68530
2
Install a chain hoist (Item 1) [Figure 20-40-10] to the
control valve, and support the control valve.
P-68528
P-68527
P-62618
20-40-4
162 of 1035
P-54495
P-62619
20-40-5
163 of 1035
C3
B3
D5
E3
E3
G2
G1
F2
A3
D3
B2
A2
C4
F4
E2
A1
D2
E1
F1
D1
F3
H3
B1
H2
MR
H1
C1
J3
MS1937
J1
ITEM
S220 LOADER
ITEM
S220 LOADER
A1
A2
A3
E1
E2
E3
F1
F2
F3
F4
G1
G2
H1
H2
H3
J1
J2
J3
J4
B1
B2
B3
C1
C2
C3
C4
D1
D2
D3
D4
D5
MR
20-40-6
164 of 1035
BICS Solenoid
Drain (Case)
Main Relief Valve 3300 PSI
D4
Figure 20-40-17
Figure 20-40-15
1
2
P-54238
Remove the lift load check valve (Item 1) [Figure 20-4017] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and
tighten to 55-65 ft.-lb. (75-88 Nm) torque.
P-68011
Figure 20-40-18
Remove the two mount bolts (Item 1) [Figure 20-40-15]
and lift eyes (Item 2) from the hydraulic control valve.
Remove the mount bracket (Item 3) from the hydraulic
control valve.
P-54237
20-40-7
165 of 1035
Figure 20-40-21
Figure 20-40-19
2
1
1
P-51692A
P-54243
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-19].
At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-40-19].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
Figure 20-40-20
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
4
Figure 20-40-22
1
3
P-51453
1
P-51693
Installation: Always use new O-ring (Item 1) [Figure 2040-22] on the anti-cavitation valve plug. Tighten the plug
to 38-45 ft.-lb. (52-61 Nm) torque.
20-40-8
166 of 1035
Figure 20-40-24
Figure 20-40-23
1
1
3
2
P-51692A
P-51453
Figure 20-40-25
1
P-51451
20-40-9
167 of 1035
Figure 20-40-28
Figure 20-40-26
1
1
P-51692A
P-51692A
Figure 20-40-29
Figure 20-40-27
1
1
P-51694
P-51454
20-40-10
168 of 1035
Figure 20-40-32
Figure 20-40-30
P-51696
P-51640
1
Installation: Always use new O-rings (Item 1) [Figure
20-40-33]. Tighten to 38-45 ft.-lb. (52-61 Nm) torque.
P-51695
20-40-11
169 of 1035
Figure 20-40-36
1
1
P-51461
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-34].
Figure 20-40-35
P-51462
1
P-51460A
20-40-12
170 of 1035
Figure 20-40-37
P-51506
P-51701
20-40-13
171 of 1035
Figure 20-40-42
2
1
P-51699A
Figure 20-40-41
Remove the rubber boots and retainer plate from the lift
and tilt spools.
Figure 20-40-43
1
P-68017
P-54245
20-40-14
172 of 1035
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-40] from the
end cap/spool lock block.
Figure 20-40-46
P-51511A
1
2
P-51514
2
1
P-51512
20-40-15
173 of 1035
Figure 20-40-49
P-51516
2
P-51515
Figure 20-40-50
Remove the screws (Item 1) [Figure 20-40-48] from the
detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-48].
Installation: Lubricate the screws and tighten to 90-100
in.-lb. (10-11,3 Nm) torque.
IMPORTANT
2
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
20-40-16
174 of 1035
P-51517
Figure 20-40-53
P-8988
Figure 20-40-54
P-51518
Figure 20-40-52
1
3
1
N-18915
P-51519
20-40-17
175 of 1035
Figure 20-40-57
1
N-19009
Figure 20-40-58
N-18916
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-58].
N-19004
20-40-18
176 of 1035
Figure 20-40-61
N-18961
N-18918
Remove the stud from the end of the spool [Figure 2040-59].
Figure 20-40-60
N-18920
N-18963
20-40-19
177 of 1035
Figure 20-40-65
3
2
N-18958
0.60 inch
(15,2 mm)
Install the stud and tighten until the other end of the stud
is out about 0.600 in. (15,2 mm) from the spool [Figure
20-40-63].
Figure 20-40-64
N-18968
N-18967
20-40-20
178 of 1035
Plastic
Plug
Figure 20-40-69
N-19005
Figure 20-40-68
N-18917
20-40-21
179 of 1035
N-19004
Figure 20-40-73
2
1
2
P-51515
2
1
N-19008
P-51514
20-40-22
180 of 1035
N-19007
Figure 20-40-77
2
1
P-51512
P-51511A
20-40-23
181 of 1035
Figure 20-40-78
P-54246
Figure 20-40-81
P-51701
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-79].
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Nm) torque.
Figure 20-40-80
P-68017
20-40-24
182 of 1035
Figure 20-40-84
Figure 20-40-82
1
P-68023
Installation: Replace the O-ring (Item 2) [Figure 20-4084] and lubricate the O-ring lightly with grease or oil
before installation of the end cap/spool lock block.
P-51521
Figure 20-40-85
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-82] from the tilt spool.
Figure 20-40-83
2
2
P-51544
1
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-40-85].
P-68019
20-40-25
183 of 1035
Remove the spool centering block (Item 1) [Figure 2040-84] from the control valve.
Figure 20-40-88
2
Figure 20-40-86
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-88].
N-18942
Put the linkage end of the spool in the vice [Figure 2040-86].
2
1
1
1
P-51545
N-18943
20-40-26
184 of 1035
Figure 20-40-89
Figure 20-40-92
1
2
3
1
1
P-51547A
2
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-92] from the auxiliary spool.
P-68019
2
1
Remove the spool centering block (Item 2) [Figure 2040-90] from the control valve.
Figure 20-40-91
P-51549A
2
1
P-51546A
20-40-27
185 of 1035
Figure 20-40-93
P-51550
P-51551
20-40-28
186 of 1035
Figure 20-40-98
1
1
P-51703
Figure 20-40-99
P-51702
1
2
2
P-51555
P-51553
20-40-29
187 of 1035
Figure 20-40-102
1
2
P-54249
Figure 20-40-103
P-54248
3
2
Figure 20-40-101
1
1
1
N-18694
20-40-30
188 of 1035
Figure 20-40-106
1
1
1
2
1
1
2
2
2
P-51564
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-104] is for the lift
circuit.
Figure 20-40-107
P-54250
Figure 20-40-105
P-51705
20-40-31
189 of 1035
Figure 20-40-110
1
1
1
1
2
2
2
P-51564
P-51697
P-51706
20-40-32
190 of 1035
P-51707
Figure 20-40-114
P-54252
Figure 20-40-112
1
1
P-51463
P-51437
20-40-33
191 of 1035
Figure 20-40-117
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40117] and tighten the fitting to 20-24 ft.-lb. (27-33 Nm)
torque.
P-68013
Figure 20-40-118
P-68870
P-68010
Remove the check valve fitting (Item 1) [Figure 20-40116] from the hydraulic control valve.
20-40-34
192 of 1035
P-54336
20-41-1
193 of 1035
Figure 20-41-2
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
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device.
Stop the engine. Raise the seat bar.
P-54569
20-41-2
194 of 1035
P-54497
Figure 20-41-6
Figure 20-41-4
1
2
2
P-68526
Disconnect the harness connector (Item 1) [Figure 2041-6] from the auxiliary valve solenoid.
P-54570
P-54564
P-68529
20-41-3
195 of 1035
Figure 20-41-10
Figure 20-41-8
P-68530
P-68527
P-62618
20-41-4
196 of 1035
2
P-54573
P-62619
20-41-5
197 of 1035
Figure 20-41-15
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-54587
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
P-54564
Unplug the actuator connectors (Item 1) [Figure 20-4114] from the loader harness.
20-41-6
198 of 1035
Figure 20-41-17
P-54568
2
Inspect the O-ring (Item 1) [Figure 20-41-17] on the face
of the actuator, and replace as needed.
P-54566
20-41-7
199 of 1035
Figure 20-41-20
1
1
P-54339
P-54337
Figure 20-41-21
P-54340
P-54338
Slide the actuator mount bracket (Item 1) [Figure 20-4119] away from the control valve.
Pull the actuator away from the control valve [Figure 2041-19].
20-41-8
200 of 1035
Figure 20-41-24
P-54343
1
P-54341
P-54340
P-54342
Slide the actuator mount bracket (Item 1) [Figure 20-4123] away from the control valve.
Pull the actuator away from the control valve [Figure 2041-23].
20-41-9
201 of 1035
2
3
P-51738
20-41-10
202 of 1035
C2
D5
J4
J2
C3
B3
E3
E3
G2
G1
D3
A3
B2
D4
C4
F2
E2
D1
A1
B1
H2
F1
MR
D2
E1
H3
C1
H1
J1
J3
MS1972
ITEM
S220 LOADER
ITEM
S220 LOADER
A1
A2
A3
B1
B2
B3
C1
C2
C3
C4
D1
E1
E2
E3
F1
F2
G1
G2
H1
H2
H3
J1
J2
J3
J4
D2
D3
D4
D5
MR
20-41-11
203 of 1035
A2
Figure 20-41-30
1
1
2
P-54355
Remove the lift load check valve (Item 1) [Figure 20-4130] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and
tighten to 55-65 ft.-lb. (75-88 Nm) torque.
P-68011
Figure 20-41-31
Remove the two mount bolts (Item 1) [Figure 20-41-28]
and lift eyes (Item 2) from the hydraulic control valve.
Remove the mount bracket (Item 3) [Figure 20-41-28]
from the hydraulic control valve.
P-54344
20-41-12
204 of 1035
Figure 20-41-34
Figure 20-41-32
2
1
P-51742A
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-32].
IMPORTANT
Figure 20-41-33
I-2003-0888
4
Figure 20-41-35
1
3
P-51453
P-51452
20-41-13
205 of 1035
P-54345
Figure 20-41-37
Figure 20-41-36
1
3
1
2
P-51742A
P-51453
Figure 20-41-38
P-51451
20-41-14
206 of 1035
Figure 20-41-41
Figure 20-41-39
1
1
P-51742A
P-51742A
Figure 20-41-42
Figure 20-41-40
1
1
P-51455
P-51454
20-41-15
207 of 1035
Figure 20-41-45
P-51743
P-51640
1
P-51801
20-41-16
208 of 1035
Figure 20-41-49
1
P-51461
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-47].
Figure 20-41-48
P-51462
1
P-51460A
20-41-17
209 of 1035
Figure 20-41-50
Figure 20-41-52
1
P-68041
P-68040
20-41-18
210 of 1035
Figure 20-41-55
Figure 20-41-53
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-55] from
the lift spool end cap.
P-68042
P-68044
1
P-68047
20-41-19
211 of 1035
Figure 20-41-59
P-51772
Figure 20-41-60
Figure 20-41-58
1
P-51773
P-68046
20-41-20
212 of 1035
P-68045
Figure 20-41-63
1
1
N-18920
Figure 20-41-62
Figure 20-41-64
3
2
4
2
1
P-51776
P-74183
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-62].
20-41-21
213 of 1035
Drill a hole all the way through the plug using a 7/64 in.
tap drill
N-190146
Figure 20-41-67
Figure 20-41-65
2
3
P-68044
Install the plastic plug and O-ring in the spool [Figure 2041-65].
Figure 20-41-66
P-68046
P-51775
20-41-22
214 of 1035
P-74184
Figure 20-41-70
Figure 20-41-68
P-68042
P-68048
Figure 20-41-71
1
Figure 20-41-69
3
2
1
P-68040
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-41-71].
P-68049
20-41-23
215 of 1035
Figure 20-41-74
1
P-68051
Installation: Replace the O-ring (Item 2) [Figure 20-4174] and lubricate lightly with oil/grease before installation
of the end cap block.
P-68049
Figure 20-41-75
Figure 20-41-73
P-68052
P-68050
20-41-24
216 of 1035
Remove the spool centering block (Item 1) [Figure 2041-74] from the control valve.
Figure 20-41-78
2
Figure 20-41-76
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-78].
N-18942
Put the linkage end of the spool in the vice [Figure 2041-76].
2
1
1
1
P-51545
N-18943
20-41-25
217 of 1035
Figure 20-41-79
Figure 20-41-82
P-68054
2
P-68050
Figure 20-41-81
P-68076
1
P-68053
20-41-26
218 of 1035
Figure 20-41-83
1
2
P-68077
P-68078
20-41-27
219 of 1035
Figure 20-41-88
1
P-54350
Figure 20-41-89
P-51552
1
2
2
P-51555
P-51553
20-41-28
220 of 1035
Figure 20-41-92
2
P-54352
Figure 20-41-93
P-54351
3
2
Figure 20-41-91
1
1
1
N-18694
20-41-29
221 of 1035
Figure 20-41-96
1
1
1
2
1
2
2
2
P-51564
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-41-94] is for the lift circuit.
Figure 20-41-97
P-54353
Figure 20-41-95
P-51792
P-54354
20-41-30
222 of 1035
1
1
1
1
2
2
2
P-51564
20-41-31
223 of 1035
1
1
P-51794
Figure 20-41-102
P-54344
Figure 20-41-100
1
1
P-51463
P-51437
20-41-32
224 of 1035
Figure 20-41-105
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41105] and tighten the fitting to 20-24 ft.-lb. (27-33 Nm)
torque.
P-68013
Figure 20-41-106
P-68870
P-68010
Remove the check valve fitting (Item 1) [Figure 20-41104] from the hydraulic control valve.
20-41-33
225 of 1035
Testing
Description
Figure 20-50-1
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob clockwise
1/4 turn. Then pull up and hold the Lift Arm Bypass
Control Knob until the lift arms slowly lower.
20-50-1
227 of 1035
P-66407
Figure 20-50-3
WARNING
P-66408
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 20-50-2
1
3
1
2
4
P-69012
P-66407
20-50-2
228 of 1035
W-2059-0598
P13656
20-50-3
229 of 1035
20-60-1
231 of 1035
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control clockwise on the tester so it reads about a 1000
PSI (69 bar).
Figure 20-60-1
P-16903
P-37687
20-60-2
232 of 1035
Figure 20-60-2
WARNING
W-2017-0286
P-66409
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING
P-34851
W-2059-0598
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-60-3
233 of 1035
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
X 100
20-60-4
234 of 1035
Figure 20-60-5
1
P-43640
W-2017-0286
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
4
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-39250
W-2059-0598
20-60-5
235 of 1035
WARNING
Figure 20-60-9
P-66413
Figure 20-60-10
Figure 20-60-8
1
1
P-39249
P-39248
20-60-6
236 of 1035
Figure 20-60-13
P-39253
Install the elbow fitting 17KB 1212 (Item 1) [Figure 2060-11] into the OUTLET of the charge pump.
Figure 20-60-14
P-39251
Figure 20-60-12
1
P-39254
P-39252
20-60-7
237 of 1035
P-39255A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-60-15].
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control (Item 1) on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. Refer
to Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%=
X 100
20-60-8
238 of 1035
Figure 20-60-16
WARNING
P-43934
Disconnect and cap the hose from the outlet fitting (Item
1) [Figure 20-60-16] of the hydraulic pump.
Disconnect and cap the hose from the outlet fitting (Item
2) [Figure 20-60-16] of the hydraulic charge pump.
W-2059-0598
Figure 20-60-17
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Stop the engine. Raise the seat bar.
Lift and block the loader. (See Procedure on Page 10-101.)
1
1
P-66410
Disconnect the two inlet hoses (Item 1) [Figure 20-6017] from the front of the hydraulic pump.
20-60-9
239 of 1035
Figure 20-60-19
1
1
P-43938B
2
Remove the hydraulic pump from the hydrostatic pump
[Figure 20-60-19].
P-66553
20-60-10
240 of 1035
Figure 20-60-22
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-59356
20-60-11
241 of 1035
P-31281
18
12
6
11
13
15
17
14
2
3
7
10
16
1
P-66540
20-60-12
242 of 1035
20-60-13
243 of 1035
IMPORTANT
20-61-1
245 of 1035
Figure 20-61-1
1
P-37687
20-61-2
246 of 1035
With the engine running at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Figure 20-61-2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-66409
Raise the lift arms and install an approved lift arm support
device. (See Installing 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
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-34851
20-61-3
247 of 1035
%=
IMPORTANT
X 100
I-2024-0284
Figure 20-61-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
20-61-4
248 of 1035
Figure 20-61-5
1
P-43640
Figure 20-61-6
2
W-2017-0286
4
1
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING
P-39250
W-2059-0598
20-61-5
249 of 1035
WARNING
Figure 20-61-9
P-66413
P-39247
Figure 20-61-10
Figure 20-61-8
1
1
P-39249
P-39248
20-61-6
250 of 1035
Figure 20-61-13
P-39253
Install the elbow fitting 17KB 1212 (Item 1) [Figure 2061-11] into the OUTLET of the charge pump.
Figure 20-61-14
P-39251
Figure 20-61-12
1
P-39254
P-39252
20-61-7
251 of 1035
P-39255A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-61-15].
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control (Item 1) on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. Refer
to Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%=
X 100
20-61-8
252 of 1035
Figure 20-61-17
WARNING
W-2017-0286
P-43954
Figure 20-61-16
1
P-34847
P-34851
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
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
%=
Figure 20-61-19
EXAMPLE: TESTER
CONNECTION
X 100
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
20-61-10
254 of 1035
Figure 20-61-21
WARNING
W-2017-0286
P-43954
Figure 20-61-20
1
2
P-34847
P-34851
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 20-61-24
1
2
P-45443
P-45457
20-61-12
256 of 1035
1
P-45445
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control clockwise on the tester to about 1000 PSI (69
bar).
20-61-13
257 of 1035
Figure 20-61-27
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-45443
Figure 20-61-28
3
P-45457
2
Remove the right rear tire. (See Mounting on Page 10160-2.).
Remove the gear pump access cover (Item 1) [Figure
20-61-26].
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and washer (Item 2) [Figure 20-61-28].
If the relief valve is bad, it must be replaced as a
complete unit.
Remove the plug (Item 3) and inspect the O-ring [Figure
20-61-28] damage and replace as needed.
20-61-14
258 of 1035
Installation: Tighten the relief valve to 30-35 ft.-lb. (4147 Nm) torque.
Figure 20-61-31
2
1
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-6131] for proper installation of the solenoid
valve cartridge.
P-43958
Figure 20-61-30
1
2
2
P-45462
P-45460
20-61-15
259 of 1035
Figure 20-61-33
P-45446
WARNING
Figure 20-61-34
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
1
1
1
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10120-2.)
P-66497
20-61-16
260 of 1035
Figure 20-61-36
2
1
P-66553
Remove the two mounting bolts (Item 1) [Figure 20-6136] from the hydraulic pump.
20-61-17
261 of 1035
P-43958
Figure 20-61-39
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-59356
20-61-18
262 of 1035
P-31281
16
11 5
24
19
21
2
20
17
18
12
6
11
5
5
15
13
14
10
8
25
2
1
P-66547
20-61-20
264 of 1035
IMPORTANT
20-61-21
265 of 1035
20-70-1
267 of 1035
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control clockwise on the tester so it reads about a 1000
PSI (69 bar).
Figure 20-70-41
P-16903
P-37687
20-70-2
268 of 1035
Figure 20-70-42
WARNING
W-2017-0286
P-66409
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
2
WARNING
P-34851
W-2059-0598
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-70-3
269 of 1035
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
X 100
20-70-4
270 of 1035
Figure 20-70-45
1
P-43640
W-2017-0286
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
4
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-39250
W-2059-0598
20-70-5
271 of 1035
WARNING
Figure 20-70-49
P-66413
P-39247
Figure 20-70-48
1
1
P-39249
P-39248
20-70-6
272 of 1035
Figure 20-70-50
Determine the proper direction of oil flow through the filter
housing (Item 1) [Figure 20-70-47] and [Figure 20-7048].
Figure 20-70-53
P-39253
Install the elbow fitting 17KB 1212 (Item 1) [Figure 2070-51] into the OUTLET of the charge pump.
Figure 20-70-54
P-39251
Figure 20-70-52
1
P-39254
P-39252
20-70-7
273 of 1035
P-39255A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-70-55].
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control (Item 1) on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. Refer
to Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%=
X 100
20-70-8
274 of 1035
Figure 20-70-56
WARNING
P-43640
W-2059-0598
1
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
P-43934
Disconnect and cap the hose from the outlet fitting (Item
1) [Figure 20-70-57] of the hydraulic pump.
Disconnect and cap the hose from the outlet fitting (Item
2) [Figure 20-70-57] of the hydraulic charge pump.
20-70-9
275 of 1035
Figure 20-70-59
1
1
1
2
P-66553
Disconnect the two inlet hoses (Item 1) [Figure 20-7058] from the front of the hydraulic pump.
20-70-10
276 of 1035
P-66410A
Figure 20-70-62
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-59356
20-70-11
277 of 1035
P-31281
18
12
11
17
13
15
5
14
2
3
7
10
16
1
P-66540
20-70-12
278 of 1035
20-70-13
279 of 1035
IMPORTANT
20-71-1
281 of 1035
With the engine running at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control on the tester to about 1000 PSI (69 bar).
P-16903
P-37687
20-71-2
282 of 1035
Figure 20-71-65
WARNING
W-2017-0286
P-66409
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
2
WARNING
20-71-3
283 of 1035
%=
X 100
IMPORTANT
A low percentage may indicate a failed pump.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Figure 20-71-67
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
20-71-4
284 of 1035
Figure 20-71-68
1
P-43640
W-2017-0286
Raise the lift arms and install an approved lift arm support
device.(See Installing on Page 10-20-1.)
4
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-39250
W-2059-0598
20-71-5
285 of 1035
WARNING
Figure 20-71-72
P-66413
P-39247
Figure 20-71-71
1
1
P-39249
P-39248
20-71-6
286 of 1035
Figure 20-71-73
Determine the proper direction of oil flow through the filter
housing (Item 1) [Figure 20-71-70] and [Figure 20-7171].
Figure 20-71-76
P-39253
Install the elbow fitting 17KB 1212 (Item 1) [Figure 2071-74] into the OUTLET of the charge pump.
Figure 20-71-77
P-39251
Figure 20-71-75
1
P-39254
P-39252
20-71-7
287 of 1035
P-39255A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-71-78].
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control (Item 1) on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. Refer
to Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%=
X 100
20-71-8
288 of 1035
Figure 20-71-80
WARNING
P-43954
Figure 20-71-81
Figure 20-71-79
1
P-34847
P-34851
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
20-71-9
289 of 1035
IMPORTANT
I-2024-0284
Figure 20-71-82
%=
X 100
EXAMPLE: TESTER
CONNECTION
A low percentage may indicate a failed pump.
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
BH-196
20-71-10
290 of 1035
Figure 20-71-84
WARNING
P-43954
Figure 20-71-85
Figure 20-71-83
P-34847
P-34851
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
20-71-11
291 of 1035
Figure 20-71-87
1
1
P-45443
20-71-12
292 of 1035
Figure 20-71-88
1
P-45445
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor
control clockwise on the tester to about 1000 PSI (69
bar).
20-71-13
293 of 1035
Figure 20-71-90
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-45443
Figure 20-71-89
Figure 20-71-91
1
3
2
P-45457
Inspect the relief valve and replace the two O-rings (Item
1) and washer (Item 2) [Figure 20-71-91].
If the relief valve is bad, it must be replaced as a
complete unit.
Remove the plug (Item 3) and inspect the O-ring [Figure
20-71-91] damage and replace as needed.
20-71-14
294 of 1035
Installation: Tighten the relief valve to 30-35 ft.-lb. (4147 Nm) torque.
Figure 20-71-94
Figure 20-71-92
1
P-45461
Figure 20-71-93
1
2
2
P-45462
P-45460
20-71-15
295 of 1035
NOTE: Mark the pump housing (Item 1) [Figure 20-7194] for proper installation of the solenoid
valve cartridge.
P-43958
Figure 20-71-96
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
1
1
20-71-16
296 of 1035
P-45446
Figure 20-71-99
1
1
2
P-66553
Remove the two mounting bolts (Item 1) [Figure 20-7199] from the hydraulic pump.
20-71-17
297 of 1035
P-43958
Figure 20-71-102
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-59356
20-71-18
298 of 1035
P-31281
23
22
5
6
16
11 5
24
19
21
2
20
17
18
12
6
11
5
5
15
13
14
10
8
25
2
1
P-66547
20-71-20
300 of 1035
20-71-21
301 of 1035
IMPORTANT
HYDRAULIC/HYDROSTATIC FILTERS
Description
The hydraulic/hydrostatic filters help to remove
contaminants from the fluid when the hydraulic/
hydrostatic systems are operating.
The hydraulic/hydrostatic filter system consists of one
main filter and one charge filter.
The main filter removes contaminants after the oil cooler.
The charge pressure filter removes contaminants after
the fan motor before the oil enters the hydrostatic pumps.
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 20-80-1
P-37094
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Disconnect the electrical connector (Item 1) [Figure 2080-1] from the filter sender.
Loosen the nut (Item 2) [Figure 20-80-1] and disconnect
the tubeline from the filter block.
20-80-1
303 of 1035
Figure 20-80-4
1
1
P-37097
P-37095
P-37096
N-19609
20-80-2
304 of 1035
Figure 20-80-8
Figure 20-80-6
2
P-66603
Figure 20-80-9
Figure 20-80-7
1
1
2
P-66609
P-66574
20-80-3
305 of 1035
Description
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
P-34063
20-90-1
307 of 1035
Figure 20-90-4
1
P-34066
P-66621
Figure 20-90-5
1
1
P-37885
P-34065
20-90-2
308 of 1035
Figure 20-90-8
P-37914
P-37913
Figure 20-90-9
1
P-37915
20-90-3
309 of 1035
P-66621
P-66622
Remove the hydraulic fluid screen (Item 1) [Figure 2090-11] from the reservoir.
Wash the screen in clean solvent and air dry, before
replacing.
20-90-4
310 of 1035
OIL COOLER
Description
The oil cooler is used to cool the loaders hydraulic and
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced around the passages cooling the
oil.
The oil cooler is located underneath the rear grill between
the A/C condenser (if so equipped) and the radiator.
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 20-100-1
P-37017
20-100-1
311 of 1035
Figure 20-100-4
1
1
P-37020
Lift the oil cooler from the mount and remove it from the
loader.
Install tool MEL1613 or MEL1640 (Item 1) [Figure 20100-2] to the outside of the rubber sleeve.
NOTE: MEL1613 is used on standard machines. MEL
1640 is used on machines equipped with the
high flow option or machines equipped with
the SJC option.
Slide the rubber sleeve in toward the radiator.
Figure 20-100-3
P-37019
20-110-1
313 of 1035
Figure 20-110-2
2
P-34205
Figure 20-110-3
P-26912
20-110-2
314 of 1035
P-34204
Solenoid Testing
Figure 20-110-5
Figure 20-110-4
1
P-34204
P9175
Use a test meter to measure coil resistance [Figure 20110-4]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
2
1
P-34206
20-110-3
315 of 1035
Figure 20-110-9
1
1
N-19072
Figure 20-110-10
Figure 20-110-8
N-19041
N-19070
20-110-4
316 of 1035
N-19069
Figure 20-110-13
2
N-19045
1
Remove the plug [Figure 20-110-13].
N-18339
Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-110-11].
Figure 20-110-14
Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.
Installation: Tighten the plug to 56-64 ft.-lb. (76-86,7
Nm) torque.
3
Figure 20-110-12
1
N-19046
Check all parts and replace as needed. Install a new Oring on the plug before installing.
3
N-19042
20-110-5
317 of 1035
Solenoid Testing
Description
Figure 20-120-1
Use a test meter to measure coil resistance [Figure 20120-1]. Coil wires do not have polarity. Correct resistance
is 8.6-9.5 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
20-120-1
319 of 1035
P9137
Figure 20-120-4
1
1
3
P-43678
P-43681
P-43711
20-120-2
320 of 1035
P-48199
Figure 20-120-8
P-43708
P-43711
P-43693
20-120-3
321 of 1035
Figure 20-120-10
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.
1
1
I-2003-0888
P-76791
There are 11 #4 SAE hex head plugs (Item 1) [Figure 20120-10] located on all sides of the diverter valve and can
be removed for clean out purposes.
Assembly: Put oil on O-rings. Tighten to 10 ft.-lb. (13,6
Nm) torque.
Figure 20-120-11
1
P-76747
P-48752
20-120-4
322 of 1035
Figure 20-120-9
Figure 20-120-14
1
1
P-76789A
Figure 20-120-15
P-76789A
Figure 20-120-13
2
1
P-48757
P-48756
20-120-5
323 of 1035
Figure 20-120-18
P-76794
Figure 20-120-17
1
2
2
1
P-76796
P-48754
20-120-6
324 of 1035
P-48753
Figure 20-120-22
1
1
P-48761
Figure 20-120-23
Figure 20-120-21
1
1
P-48762
P-48764
20-120-7
325 of 1035
P-48763A
Figure 20-120-26
P-48752
2
Inspect O-ring (Item 1) [Figure 20-120-26].
P-76833
1
P-48766
Remove and inspect the orifice (Item 1) [Figure 20-12027] for dirt and debris.
P-48765
20-120-8
326 of 1035
Figure 20-120-30
Figure 20-120-28
P-76798
Assembly: Tighten the #4 SAE hex head plug to 10 ft.lb. (13,6 Nm) torque.
Assembly: Tighten the #6 SAE hex head plugs to 14 ft.lb. (19 Nm) torque.
Figure 20-120-31
Figure 20-120-29
1
1
P-48752
P-48786
20-120-9
327 of 1035
P-48765
Description
WARNING
W-2059-0598
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
20-130-1
329 of 1035
Figure 20-130-2
Figure 20-130-1
1
P-48590
Disconnect and cap the outlet hose (Item 1) [Figure 20130-2] from block.
P-26244
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
P-48591
20-130-2
330 of 1035
Figure 20-130-5
1
4
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
spool (Item 3) [Figure 20-130-5].
P-48115
Figure 20-130-6
IMPORTANT
P-48116
20-130-3
331 of 1035
Figure 20-130-9
1
1
P-48122
Figure 20-130-8
1
2
1
P-48384
3
Remove the plug (Item 1) [Figure 20-130-10], inspect
the O-ring and replace as needed.
P-48119
Installation: Tighten the plug (Item 1) [Figure 20-13010] to 12-14 ft.-lb. (16,3-19 Nm) torque.
20-130-4
332 of 1035
Figure 20-130-13
Figure 20-130-11
2
1
P-48106A
P-48664
Figure 20-130-14
Installation: Tighten the orifice screw (Item 2) [Figure
20-130-11] to 6-8 ft.-lb. (8,1-10,8 Nm) torque.
Figure 20-130-12
1
1
2
P-48386
20-130-5
333 of 1035
Figure 20-130-17
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20130-17].
P-48175
Figure 20-130-18
Figure 20-130-16
3
2
2
1
1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20130-18] for damage replace as needed. If the screened
orifice plug is blocked replace with a new plug.
Check the O-ring (Item 2) [Figure 20-130-18] and
replace as needed.
20-130-6
334 of 1035
Description
The front auxiliary hydraulic coupler block is the
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of
the left side lift arm.
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 20-140-1
P-31242
20-140-1
335 of 1035
Figure 20-140-3
4
5
2
4
P-34760
20-140-2
336 of 1035
Figure 20-140-6
Figure 20-140-4
1
2
P-34665
Figure 20-140-5
2
P-34664
20-140-3
337 of 1035
Figure 20-140-7
HYDROSTATIC SYSTEM
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
30-40-1
30-40-5
30-40-1
30-40-4
30-40-2
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt Shield Removal And Installation . . . . . . . . . . . . . . . .
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . .
Tensioner Pulley Tension Spring Removal And Installation . . . .
30-60-1
30-60-2
30-60-2
30-60-1
30-60-1
30-60-3
30-60-5
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-20-1
30-20-1
30-20-5
30-20-4
30-20-2
30-30-1
30-30-5
30-30-1
30-30-4
30-30-3
30-30-2
30-31-1
30-31-6
30-31-1
30-31-4
30-31-3
30-31-2
HYDROSTATIC
SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sender Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-01
339 of 1035
30-02
340 of 1035
WARNING
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
1, 2
2, 3, 4, 5
2, 3, 5, 6, 7, 10
8, 9
30-10-1
341 of 1035
30-10-2
342 of 1035
HYDROSTATIC MOTOR
Description
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps.
In this system there is a case drain filter for filtering the
excess low pressure oil before the oil enters the hydraulic
reservoir.
The hydrostatic motors do not have an internal brake.
Inside the endcap of the hydrostatic motor, there is a
shuttle valve. The shuttle valve helps to keep the motor
cool by mixing case drain oil with cooled low pressure oil
from the charge circuit. The shuttle valve is shifted by the
high pressure oil coming from the hydrostatic pumps. If
the shuttle valve sticks, a delay or lack of drive may or
may not be felt in the controls and/or an overheated
hydrostatic motor will result.
30-20-1
343 of 1035
Figure 30-20-1
1
2
WARNING
N-17874
W-2059-0598
IMPORTANT
Figure 30-20-2
I-2003-0888
1
1
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
N-17876
30-20-2
344 of 1035
P5405
Remove the piston/roller section (Item 1) [Figure 30-203] from the loader, if it was not removed with the motor/
cam ring.
To remove the motor carrier. (See Removal and
Installation on Page 30-30-2.)
30-20-3
345 of 1035
Distributor
Spring
Seal
O-ring
Plug
O-ring
Spring
Washer
Spool
Spring
Rear Housing
Plug
O-ring
O-ring
Stop Pin
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Bolt
Plug
O-ring
Spring
Shim
Poppet
O-ring
Seal
O-ring
Seal
O-ring
Cam
Roller
Piston
Block
3
2
4
4
10
6
8 7
11
12
13
23
25
15
28
14
29
16
16
22
24
21
20
19
18
26
17
27
30
B-17125
30-20-4
346 of 1035
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Figure 30-20-5
IMPORTANT
Figure 30-20-4
N-17861
Remove the piston/roller section (Item 1) [Figure 30-204] from the motor.
30-20-5
347 of 1035
Figure 30-20-8
1
2
Figure 30-20-6
N-17864
N-17860
Figure 30-20-9
Assembly: Install the two cam ring mounting bolts (Item
1) [Figure 30-20-6] and tighten to 50 ft.-lb. (67,8 Nm)
torque.
Figure 30-20-7
1
1
4
2
N-17868
N-17863
Assembly: Install the distributor (Item 2) [Figure 30-209] into the housing.
Assembly: Align the distributor hole (Item 3) [Figure 3020-9] with the stop pin. When aligned correctly, the
distributor can be depressed slightly.
Assembly: Install and lightly smear grease on the O-ring
(Item 4) [Figure 30-20-9].
30-20-6
348 of 1035
Figure 30-20-12
5
2
1
N-17872
Inspect the distributor and springs (Item 2) [Figure 3020-10] for damage or surface scratches.
Figure 30-20-13
Figure 30-20-11
1
N-17871
N-17866
30-20-7
349 of 1035
N-17869
30-21-1
351 of 1035
Figure 30-21-1
WARNING
N-22483
W-2059-0598
Figure 30-21-2
IMPORTANT
3
I-2003-0888
N-22484
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Drain the hydraulic reservoir. (See Removal And
Installation on Page 20-90-1.)
30-21-2
352 of 1035
Figure 30-21-5
N-22488
N-22485
Figure 30-21-6
Figure 30-21-4
1
2
1
2
N-22487
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 3021-6] from the motor.
N-22486
30-21-3
353 of 1035
N-22535
30-21-4
354 of 1035
Installation: Replace the O-ring (Item 1) [Figure 30-217] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lb. (149
Nm) torque.
8
7
1
2
3
6
5
36
34
35
5
33
32
27
25
26
28
24
31
30
29
24
22
23
16
17
18
19
39
38
37
50
40
51
41
49
20
42
48
47
21
46
45
44
43
MS1467S
30-21-5
355 of 1035
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48
49.
50.
51.
Roller
Piston
Ring
Clamp
Ring
Block
Cam
Quad Ring
Distributor
Spring
Seal/O-ring
Seal/O-ring
Seal/O-ring
Seal/O-ring
Seal/O-ring
Poppet
Spool
Spring
O-ring
Plug
Pin
Plug
Housing
Spring
Spool
Washer
O-ring
Plug
Quad Ring
Bushing
Shaft
Dowel
Housing
Bolt
Shim
Brake Disc
O-ring
Snap Ring
Washer
Spring
Spool
Bolt
Seal
O-ring
Clamp
Piston
O-ring
Spring
Gasket
Cover
Bolt
30-21-6
356 of 1035
Figure 30-21-10
Disassembly
Figure 30-21-8
N-22491
N-22489
Figure 30-21-9
N-22493
N-22490
Remove the twelve mounting bolts (Item 1) [Figure 3021-9] from the brake cover plate.
Check the brake piston for damage and replace the seal.
Figure 30-21-14
Disassembly (Cont'd)
1
Figure 30-21-12
2
P-69985
Remove the five mounting bolts (Item 1) [Figure 30-2112] from the brake housing.
Figure 30-21-15
1
2
Figure 30-21-13
P-69978
Remove and discard the o-rings (Item 2) [Figure 30-2114] on the housing.
P-73062
30-21-8
358 of 1035
P-69973
Figure 30-21-18
Disassembly (Cont'd)
Figure 30-21-16
1
1
P-73057
4
3
Remove the flushing spool assembly (Item 1) [Figure 3021-18] from the housing.
N-22501
1
2
Figure 30-21-17
1
N-22504
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-2117] from the housing.
Installation: Tighten the plug to 22 ft.-lb. (30 Nm)
torque.
NOTE: Current motor housings are provided with
break off plugs (Item 2) [Figure 30-21-17] on
the side of the flushing spool housing. Earlier
motors were equipped with threaded plugs.
30-21-9
359 of 1035
Figure 30-21-19
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-16].
Figure 30-21-22
Disassembly (Cont'd)
Figure 30-21-20
1
3
2
N-22507
Figure 30-21-23
P-69981
Figure 30-21-21
P-73058
P-69982
30-21-10
360 of 1035
Figure 30-21-26
Disassembly (Cont'd)
Figure 30-21-24
N-22511
Figure 30-21-25
Figure 30-21-27
N-22509
P-73059
30-21-11
361 of 1035
N-22510
Figure 30-21-30
Disassembly (Cont'd)
1
Figure 30-21-28
1
N-22523
P-69984
Figure 30-21-29
1
2
N-22519
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-21-31].
N-22521
30-21-12
362 of 1035
Figure 30-21-31
NOTE: The distributor removal is best accomplished
by lifting the housing (Item 1) [Figure 30-2128] 2-3 inches above a wooden surface, and
dropping the housing [Figure 30-21-28].
Figure 30-21-34
Assembly
N-22525
Figure 30-21-33
P-73060
N-22518
30-21-13
363 of 1035
N-22511
Figure 30-21-38
Assembly (Cont'd)
1
Figure 30-21-36
N-22509
Figure 30-21-37
Figure 30-21-39
1
P-73061
P-69983
The pin in the distributor must align with the hole in the
housing (Item 1) [Figure 30-21-37]. Use a hand press to
push the distributor in place.
30-21-14
364 of 1035
N-22515
Figure 30-21-42
Assembly (Cont'd)
Figure 30-21-40
2
1
2
P-69986
Figure 30-21-43
P-73064
N-18347
30-21-15
365 of 1035
P-69978
Figure 30-21-46
Assembly (Cont'd)
1
Figure 30-21-44
1
3
N-22493
2
Install the brake seal (Item 1) [Figure 30-21-44].
NOTE: Install the seal with the metal case end
towards the brake pack.
Install the snap ring (Item 2) [Figure 30-21-44] to secure
the seal in the brake housing.
Install a new o-ring (Item 3) [Figure 30-21-44] in the
seal.
N-22492
Figure 30-21-45
Install the brake spring (Item 1) [Figure 30-21-47].
Install the end plate gasket (Item 2) [Figure 30-21-47].
Figure 30-21-48
1
1
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-45].
N-22490
30-21-16
366 of 1035
30-30-1
367 of 1035
Figure 30-30-1
1
1
WARNING
P5467A
W-2059-0598
Slide the motor carrier toward the rear and remove the
rear drive chain.
Figure 30-30-2
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the brake disc. (Single speed loaders only) (See
Disc Removal And Installation on Page 40-10-2.)
Remove the front axle sprocket. (See Axle, Sprocket And
Bearings Removal And Installation on Page 40-20-4.)
P5489A
30-30-2
368 of 1035
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
2
3
5
6
7
8*
9
30-30-3
369 of 1035
Figure 30-30-5
Disassembly
Figure 30-30-3
1
P-76544
Figure 30-30-4
Figure 30-30-6
P5766
P5768
30-30-4
370 of 1035
P5760
Assembly
Disassembly (Contd)
Figure 30-30-9
Figure 30-30-7
2
1
P5764
P5761
Figure 30-30-8
Use the tool (Item 2) [Figure 30-30-9] as shown in the
figure.
Figure 30-30-10
2
1
P5763
P5762
30-30-5
371 of 1035
Figure 30-30-12
Assembly (Contd)
Figure 30-30-11
P5769
30-30-6
372 of 1035
P5767
30-31-1
373 of 1035
Figure 30-31-1
1
1
WARNING
P5467A
W-2059-0598
Figure 30-31-2
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the brake disc. (Single speed loaders only) (See
Axle, Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
Remove the front axle sprocket. (See Axle, Sprocket And
Bearings Removal And Installation on Page 40-20-4.)
If the motor carrier is removed from the right side,
remove the lift arm bypass valve, (See Removal And
Installation on Page 20-50-2.) and remove the control
panel. (See Removal And Installation on Page 50-100-2.)
P5489A
Slide the motor carrier toward the rear and remove the
rear drive chain.
NOTE: For easier access for the motor carrier
coming out and going into the chaincase, tie
the front drive chain to the chaincase with a
wire [Figure 30-31-2].
Slide the motor carrier out of the chaincase far enough to
install a chain and chain hoist to the carrier [Figure 3031-2].
NOTE: When installing the motor carrier into the
loader, use caution to protect the wheel speed
washer from damage.
30-31-2
374 of 1035
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
Snap Ring
Washer*
Bearing
Race
Seal
Housing
Speed Washer
Shaft
Cover
7
3
4
5
30-31-3
375 of 1035
2* 1
PE3328S
Figure 30-31-5
Disassembly
Figure 30-31-3
1
P-76544
Figure 30-31-4
Figure 30-31-6
P-76540
P5766
30-31-4
376 of 1035
P5760
Figure 30-31-9
Disassembly (Contd)
Figure 30-31-7
2
P-28158
P-76462
Figure 30-31-8
1
1
P-76464
Remove the wheel speed washer (Item 1) [Figure 30-3110] from the shaft.
P-28157
30-31-5
377 of 1035
Figure 30-31-10
NOTE: The bearing (Item 1) [Figure 30-31-7] and the
wheel speed washer (Item 2) [Figure 30-31-7],
must both be replaced, due to damage to the
wheel speed washer from removing the
bearing.
Assembly
Disassembly (Contd)
Figure 30-31-12
Figure 30-31-11
2
2
1
P5764
P-28164
P5762
30-31-6
378 of 1035
Figure 30-31-15
Assembly (Cont'd)
Figure 30-31-14
2
1
P-76542
30-31-7
379 of 1035
P-76541
Figure 30-31-17
Assembly (Cont'd)
2
Figure 30-31-16
1
1
P-76539
P-5769
30-31-8
380 of 1035
CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor internal leakage
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is obtained from the dedicated section
of the hydraulic gear pump.
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary, lift and tilt spools
in the main hydraulic control valve.
30-40-1
381 of 1035
Figure 30-40-2
Testing
1
Figure 30-40-1
P-43197
P-43196
2
1
Figure 30-40-3
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-66572
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
30-40-2
382 of 1035
1
3
2
P-66570
30-40-3
383 of 1035
P-66419
30-40-4
384 of 1035
Figure 30-40-7
Adjusting
Non SJC Machines
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.
N-17231
I-2003-0888
Figure 30-40-8
P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-40-6].
Always use a new O-ring. Tighten the plug to 30-50 ft.-lb.
(41-68 Nm) torque.
N-19568
30-40-5
385 of 1035
Figure 30-40-10
Adjusting (Contd)
SJC Machines
IMPORTANT
1
P-64435
I-2003-0888
30-40-6
386 of 1035
HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bidirectional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The
function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
30-50-1
387 of 1035
Figure 30-50-3
1
2
P-66648
1
Remove the nut and washer (Item 1) [Figure 30-50-3]
from the hydrostatic pump drive shaft.
N-15337
Figure 30-50-4
Remove the belt shield clips (Item 1) and belt shield (Item
2) [Figure 30-50-1].
Figure 30-50-2
N-15340
Install the nut on the end of the pump drive shaft (without
washer).
P-37270
30-50-2
388 of 1035
Figure 30-50-7
P-66553
P5658
Figure 30-50-6
P-37274
Remove the two mounting bolts (Item 1) [Figure 30-505] and nuts (Item 1) [Figure 30-50-6].
Installation: Tighten the mounting bolts and nuts to 6570 ft.-lb. (88-95 Nm) torque. Make sure the key (Item 2)
[Figure 30-50-5] is installed.
30-50-3
389 of 1035
30-50-4
390 of 1035
Figure 30-50-9
Figure 30-50-8
1
2
P-66670
30-50-5
391 of 1035
11
4
10
5
8
3 4
1
3
7
9
26
9
9
12
10
11
14
16
13
2
17
2
15
12
17
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Snap Ring
Washer
Seal
Bearing
Key
Shaft
Housing
Plug
O-ring
Cover
Bolt
Pin
Swash Plate
Wear Plate
Piston Assembly
Piston Retainer
Retainer
Block
Spring
Valve Plate
Gasket
Poppet
Shim
Replenishing/High
Pressure Relief Valve
Coupler
Dust Seal
25.
26.
2
20
18
19
17
12
23
19
21
22
24
42
9
9
8
12
25
12
24
9
11
30-50-6
392 of 1035
D-2428C
1.
2.
3.
4.
5.
Bolt
End Cap
Plug
O-ring
Replenishing/High
Pressure Relief Valve
Gasket
Bearing
Pin
Valve Plate
Washer
Spring
Block
Retainer
Piston Assembly
Wear Plate
Swash Plate
Housing
Seal
Cover
Shaft
Snap Ring
Dust Seal
Piston Retainer
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
3
4
5
3
4
2
1
1
4
3
10
10
Ref.
8
13
11
13
10
23
12
8
15
13
14
22
16
3
4
7
17
4
8
19
18
7
21
21
19
4
20
3
1
21
D-2427B
30-50-7
393 of 1035
Figure 30-50-12
Disassembly
Figure 30-50-10
3
1
1
1
N-19571
Figure 30-50-11
Figure 30-50-13
N-19570
N-19550
30-50-8
394 of 1035
Figure 30-50-16
Disassembly (Contd)
2
Figure 30-50-14
1
N-17194
2
Check the valve plate locating pin (Item 1) [Figure 30-5016] for wear and replace if needed.
N-19551
Figure 30-50-17
Remove the gasket (Item 2) [Figure 30-50-14].
Figure 30-50-15
1
N-17197
N-17193
30-50-9
395 of 1035
Figure 30-50-20
Disassembly (Contd)
3
Figure 30-50-18
1
3
2
N-17200
Figure 30-50-19
Figure 30-50-21
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-5019] from the cylinder block.
30-50-10
396 of 1035
N-17198
Figure 30-50-24
Disassembly (Contd)
Figure 30-50-22
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-24] from
the pump housing and remove the driveshaft and bearing
from the housing.
Figure 30-50-25
N-17481
Figure 30-50-23
N-17241
N-17239
30-50-11
397 of 1035
Figure 30-50-28
Disassembly (Contd)
Figure 30-50-26
2
1
N-17244
N-17242
Figure 30-50-29
Figure 30-50-27
1
N-17245
1
Check the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-50-29] for wear and replace as needed.
N-17243
30-50-12
398 of 1035
Figure 30-50-32
Disassembly (Contd)
Figure 30-50-30
1
2
1
N-17250
N-17246
Figure 30-50-33
Remove the four mount bolts (Item 1) from the pump
housing and remove the linkage bracket (Item 2) [Figure
30-50-30].
Figure 30-50-31
1
2
N-17248
N-17247
30-50-13
399 of 1035
Figure 30-50-36
Disassembly (Contd)
1
Figure 30-50-34
1
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-50-36] and
remove the swash plate and lower bearing from the
pump housing.
N-17249
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-50-35] from
the swash plate shaft.
30-50-14
400 of 1035
Figure 30-50-39
Assembly
Figure 30-50-37
1
1
2
3
N-17249
N-17253
Figure 30-50-40
Figure 30-50-38
N-17248
Install the bearing race (Item 2) [Figure 30-50-39] and Oring (Item 3) [Figure 30-50-39] as shown in [Figure 3050-40].
N-17252
30-50-15
401 of 1035
Figure 30-50-43
Assembly (Contd)
Figure 30-50-41
1
N-17245
Figure 30-50-44
N-17247
Figure 30-50-42
1
N-17244
Install the bearing race (Item 1) [Figure 30-50-43] and Oring (Item 2) [Figure 30-50-43] at the lower trunnion as
shown in [Figure 30-50-44].
N-17246
30-50-16
402 of 1035
Figure 30-50-47
Assembly (Contd)
Figure 30-50-45
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-5047] on the pump shaft.
N-17243
Figure 30-50-48
N-17240
Install the pump shaft into the pump housing [Figure 3050-48].
Install the snap ring (Item 1) [Figure 30-50-48].
N-17242
30-50-17
403 of 1035
Figure 30-50-51
Assembly (Contd)
Figure 30-50-49
1
1
1
1
N-17198
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
Figure 30-50-52
Figure 30-50-50
1
N-17197
N-17199
30-50-18
404 of 1035
N-17200
Figure 30-50-55
Assembly (Contd)
Figure 30-50-53
1
1
N-17193
Figure 30-50-54
1
1
N-19551
N-17196
The valve plate locating spring pin (Item 2) [Figure 3050-54] will protrude from 0.165 - 0.185 in. (4,19 - 4,70
mm) from the surface of the charge pump.
30-50-19
405 of 1035
N-17194
Figure 30-50-59
Assembly (Contd)
Figure 30-50-57
1
N-19570
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-50-57] to 35-45 ft.lb. (47-61 Nm) torque.
Figure 30-50-58
1
1
3
P-43858
1
N-19571
30-50-20
406 of 1035
Figure 30-50-60
Figure 30-51-1
P-64943
A,B
T1
MA
MB
MG
30-51-1
407 of 1035
Figure 30-51-3
P-64460
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
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 30-51-2
1
Figure 30-51-4
P-64425
Locate the two hydraulic controllers (Item 1) [Figure 3051-2] on the hydrostatic pumps.
P-64426
30-51-2
408 of 1035
Removal:
Figure 30-51-7
Figure 30-51-5
2
1
P-64427
2
3
P-64427
Installation:
Figure 30-51-6
1
P-64978
P-64444
30-51-3
409 of 1035
Figure 30-51-10
IMPORTANT
P-37270
I-2003-0888
Figure 30-51-9
2
1
1
N-15337
P-66648
30-51-4
410 of 1035
Figure 30-51-14
P-64337
P-64338
1
Remove the two mounting bolts (Item 1) [Figure 30-5113] and nuts (Item 1) [Figure 30-51-14].
Install the nut on the end of the pump drive shaft (without
washer).
Installation: Tighten the mounting bolts and nuts to 6570 ft.-lb. (88-95 Nm) torque.
Make sure the key (Item 2) [Figure 30-51-13] is installed.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.
Figure 30-51-13
P-64458
1
Remove the air bleed plugs (Item 1) [Figure 30-51-15].
P-64348
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 18 ft.-lb. (25 Nm) torque.
30-51-5
411 of 1035
N-15340
30-51-6
412 of 1035
3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
O-ring
Bolt
End Housing
O-ring
Right Rotating Assembly
Timing Pin
Bearing
Spacer/Coupler
Pin
Positioning Pin
O-ring
Snap Ring
Position Sensor
Washer
Bolt
7
8
10
11
12
13
14
15
16
25
20
21
23 22
26
17
19
18
26
18
27
32
29
19
31
7
30
4
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
28
Steel Cover
Bolt
Hydraulic Controller
High Pressure Relief
Case Housing
Bolt
Plug
Screen
Plug
Orifice
Dowel Pin
Charge Pressure Relief
Left Servo
Right Servo
Left Rotating Assembly
Key
End Housing
B25010
30-51-7
413 of 1035
24
Figure 30-51-18
1
2
1
1
P-64437
Figure 30-51-17
P-64436
30-51-8
414 of 1035
P-64431
Figure 30-51-21
Figure 30-51-19
P-64435
Figure 30-51-20
P-64435
30-51-9
415 of 1035
P-64431
Figure 30-51-24
Figure 30-51-22
1
1
P-64439
Remove the hydraulic controllers (Item 1) [Figure 30-5122]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.)
Figure 30-51-25
P-64458
Figure 30-51-23
2
1
P-64440
30-51-10
416 of 1035
Figure 30-51-28
P-64442
P-64441
P-64453
30-51-11
417 of 1035
Figure 30-51-31
2
P-64464
Pull the end housings from the case housing [Figure 3051-31].
P-64445
1
P-64447
30-51-12
418 of 1035
Figure 30-51-34
1
1
P-64463
P-64465
P-64466
30-51-13
419 of 1035
2
P-64454
Figure 30-51-36
LEFT SIDE
P-64501
30-51-14
420 of 1035
Figure 30-51-39
RIGHT SIDE
Figure 30-51-37
1
2
RIGHT SIDE
P-64456
2
Figure 30-51-40
P-64455
LEFT SIDE
Figure 30-51-38
LEFT SIDE
P-64503
1
2
P-64502
Assembly: Align the timing pin (Item 1) [Figure 30-5137] and [Figure 30-51-38] in the case housing with the
notch (Item 1) [Figure 30-51-39] and [Figure 30-51-40]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure
30-51-37] and [Figure 30-51-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-39] and [Figure
30-51-40].
NOTE: Valve plate should sit FLUSH with the case
housing when properly installed.
30-51-15
421 of 1035
1
2
Figure 30-51-43
P-64469
Figure 30-51-44
Figure 30-51-42
P-64475
B25011
30-51-16
422 of 1035
Figure 30-51-47
P-64471
P-64476
Figure 30-51-46
P-64472
30-51-17
423 of 1035
Figure 30-51-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-45] in the
slippers, are not plugged.
Figure 30-51-51
P-64479
Figure 30-51-50
Figure 30-51-52
1
2
1
P-64478
P-64480
30-51-18
424 of 1035
P-64474
Figure 30-51-55
2
Figure 30-51-53
P-64483
Figure 30-51-54
P-64482
30-51-19
425 of 1035
P-64481
Figure 30-51-58
LEFT SIDE
P-64486
Figure 30-51-59
P-64484
RIGHT SIDE
1
P-64523
P-64524
Figure 30-51-62
2
1
P-64488
The drive shaft can be tapped out of the end housing with
a rubber mallet.
B25013
P-64489
30-51-21
427 of 1035
Figure 30-51-66
P-64492
P-64490
P-64491
30-51-22
428 of 1035
Figure 30-51-69
1
2
1
2
P-64493
P-64467
Figure 30-51-70
1
1
2
3
P-64494
P-64466
30-51-23
429 of 1035
Figure 30-51-68
Figure 30-51-73
1
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-73] from the
servo piston.
P-64495
1
2
P-64498
P-64496
30-51-24
430 of 1035
Figure 30-51-74
Remove the lock nut (Item 1) [Figure 30-51-71] from the
servo piston.
Figure 30-51-77
3
P-64499
Remove the plug (Item 1) from the top center of the case
housing. Replace O-ring (Item 2) [Figure 30-51-75].
Figure 30-51-76
P-64500
30-51-25
431 of 1035
P-64461
2
1
P-64502
30-51-26
432 of 1035
Figure 30-51-80
1
WARNING
P-64973
W-2017-0286
1
1
P-64425
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
30-51-27
433 of 1035
Figure 30-51-84
1
P-64457
Start the loader using the remote start tool and run at an
idle.
WARNING
Figure 30-51-83
Figure 30-51-85
1
P-64977
1
P-64457
30-51-28
434 of 1035
P-64438
Figure 30-51-88
1
P-64457
Figure 30-51-87
P-64457
30-51-29
435 of 1035
P-64457
Figure 30-51-89
P-64460
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-64458
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
30-51-30
436 of 1035
Figure 30-51-93
2
P-64459
Figure 30-51-94
P-64975
Figure 30-51-92
1
1
P-64459
P-64459
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
30-51-31
437 of 1035
Figure 30-51-96
P-64459
30-51-32
438 of 1035
P-64459
DRIVE BELT
Figure 30-60-2
Description
1
1
1
P-76107
P-76104
30-60-1
439 of 1035
Figure 30-60-3
Adjusting
Figure 30-60-4
The drive belt does not need adjustment. The belt has a
spring loaded idler which is constantly adjusted.
1
2
P-34915
P-34914
30-60-2
440 of 1035
Figure 30-60-8
2
1
P-34917
P-34915
Figure 30-60-9
P-34918
P-34916
30-60-3
441 of 1035
Figure 30-60-12
2
P5561
Figure 30-60-13
P5559
30-60-4
442 of 1035
Remove the pulley/arm assembly (Item 1) [Figure 30-6010] from the engine housing.
Figure 30-60-16
P5563
Figure 30-60-15
P5551A
30-60-5
443 of 1035
Check the spring for wear and etc. Replace the spring as
needed.
Figure 30-70-3
Description
The case drain filter is an external filter assembly in the
case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.
P-76218
1
1
P-76212
Figure 30-70-2
P-76216
The larger taper spring (Item 1) slides over the end of the
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-70-4] slides into the filter element.
P-76214
30-70-1
445 of 1035
DRIVE SYSTEM
BRAKE (S/N 530714318 & BELOW AND 530811605 & BELOW) . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
BRAKE (S/N 530714319 & ABOVE AND 530811606 & ABOVE). . .40-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-11-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .40-11-2
40-12-1
40-12-4
40-12-2
40-12-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Cover Removal And Installation. . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . .
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . .
40-30-1
40-30-2
40-30-1
40-30-1
40-30-3
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . .
Axle, Sprocket And Bearings Removal And Installation. . . . . . .
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40-20-1
40-20-2
40-20-4
40-20-9
40-20-1
DRIVE
SYSTEM
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . .
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40-01
447 of 1035
1
P-21944A
40-10-1
449 of 1035
Figure 40-10-3
P-34232
WARNING
Figure 40-10-2
1
2
1
2
P-34233
P-34230
Raise the lift arms and install an approved lift arm support
device. (See Procedure on Page 10-10-1.)
Raise the operator cab. (See Installing on Page 10-20-1.)
Disconnect the wiring connector (Item 1) [Figure 40-102] at the traction lock solenoid.
Remove the two mount bolts (Item 2) [Figure 40-10-2]
from the traction lock mount, and remove the traction lock
solenoid and mount bracket from the loader.
Remove the crossbar linkage. (See Linkage Removal
And Installation on Page 50-90-3.)
40-10-2
450 of 1035
2.)
Figure 40-10-7
P7801
Figure 40-10-8
Figure 40-10-6
P7800
A snap ring pliers with 905 tips are needed for removing
the brake disc snap ring.
Pull the disc away from snap ring.
Remove the snap ring (Item 1) [Figure 40-10-8] from the
end of the carrier shaft.
P7799
40-10-3
451 of 1035
P-34234A
P7865
3
3
P13003
40-10-4
452 of 1035
1
P-21944A
40-11-1
453 of 1035
Figure 40-11-3
P-34232
WARNING
Raise the lift arms and install an approved lift arm support
device. (See Procedure on Page 10-10-1.)
1
Raise the operator cab.
Figure 40-11-2
P-34233
P-34230
Disconnect the wiring connector (Item 1) [Figure 40-112] at the traction lock solenoid.
Remove the two mount bolts (Item 2) [Figure 40-11-2]
from the traction lock mount, and remove the traction lock
solenoid and mount bracket from the loader.
Remove the crossbar linkage. (See Linkage Removal
And Installation on Page 50-90-3.)
40-11-2
454 of 1035
Figure 40-11-7
P-76575
1
Snap ring pliers with 90 tips are needed for removing the
brake disc snap ring.
P-34234A
Figure 40-11-8
Figure 40-11-6
2
P-76574
1
P-76576
Using a snap ring pliers move the inside snap ring (Item
1) [Figure 40-11-6] towards the motor carrier.
Remove the outside snap ring and slide the disk off the
shaft.
BRAKE (TWO-SPEED)
Description
Figure 40-12-1
1
P-21944A
40-12-1
457 of 1035
Figure 40-12-4
P-34092
Disconnect the two hydraulic hoses (Item 1) [Figure 4012-4] from the brake/two speed block.
P-34096
Figure 40-12-5
P-34093
1
Disconnect the wire harness connector (Item 1) [Figure
40-12-5] from the brake solenoid.
Disconnect the wire harness connector (Item 2) [Figure
40-12-5] from the two speed solenoid.
P-34091
Disconnect the four hydraulic hoses (Item 1) [Figure 4012-3] from the brake/two speed block.
40-12-2
458 of 1035
P-34094
P-34095
Remove the two mounting bolts (Item 1) [Figure 40-127] from the valve.
Remove the brake/two-speed block from the loader.
40-12-3
459 of 1035
Figure 40-12-10
Figure 40-12-8
1
1
N-22580
1
1
Figure 40-12-11
2
P-34099
Loosen the electrical solenoid nut (Item 1) [Figure 40-1211] from the make-up valve solenoid.
Remove the brake solenoid nut (Item 2) [Figure 40-1211] from the brake solenoid.
P-34098
NOTE: The check valves (Items 1 & 2) [Figure 40-129] are interchangeable.
40-12-4
460 of 1035
P-34097
Figure 40-12-14
1
P-34101
P-34112
Figure 40-12-15
The resistance value for the solenoid coil can be found
on the electrical schematic.
Figure 40-12-13
N-22584
P-34111
40-12-5
461 of 1035
Figure 40-12-18
P-34103
P-34105A
Figure 40-12-19
P-34104
P-34102
40-12-6
462 of 1035
N-22610
N-22611
40-12-7
463 of 1035
DRIVE COMPONENTS
P-66933A
40-20-1
465 of 1035
Description
Figure 40-20-2
P4849
Figure 40-20-3
1
1
2
P4850
P4848
40-20-2
466 of 1035
WARNING
P4817
P4814
40-20-3
467 of 1035
Figure 40-20-6
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-101.)
P-4158A
40-20-4
468 of 1035
Installation: Tighten the axle sprocket bolt to 515-535 ft.lb. (699-726 Nm) torque.
Figure 40-20-9
Figure 40-20-8
1
2
P-4170
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)
[Figure 40-20-8].
P-4171
Press the splined end of the axle free from the bearing
[Figure 40-20-10].
40-20-5
469 of 1035
P5406A
Figure 40-20-12
1
1
P4812
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it
will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 4020-11] that contacts inner race of the bearing only.
Bearing Cup
Tool
Recess
MC-2164
40-20-6
470 of 1035
P-4175
Figure 40-20-16
2
1
Figure 40-20-14
P5468A
Use the bearing cup installation tool (Item 1) [Figure 4020-16] and (Item 1) [Figure 40-20-17].
P5637
Figure 40-20-15
Figure 40-20-17
P4816
P4811
40-20-7
471 of 1035
P4813
40-20-8
472 of 1035
Figure 40-20-19
Rear Drive
Chain
WARNING
Front Drive
Chain
P-68194
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front
Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
Remove the brake disc. (See Disc Removal And
Installation on Page 40-10-2.)
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
40-20-9
473 of 1035
P-66933A
40-20-10
474 of 1035
Description
Figure 40-20-2
P4849
Figure 40-20-3
1
1
2
P4850
P4848
40-20-11
475 of 1035
WARNING
P4817
P4814
40-20-12
476 of 1035
Figure 40-20-6
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-101.)
P-4158A
40-20-13
477 of 1035
Installation: Tighten the axle sprocket bolt to 515-535 ft.lb. (699-726 Nm) torque.
Figure 40-20-9
Figure 40-20-8
1
2
P-4170
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)
[Figure 40-20-8].
P-4171
Press the splined end of the axle free from the bearing
[Figure 40-20-10].
40-20-14
478 of 1035
P5406A
Figure 40-20-12
1
1
P4812
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it
will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 4020-11] that contacts inner race of the bearing only.
Bearing Cup
Tool
Recess
MC-2164
40-20-15
479 of 1035
P-4175
Figure 40-20-16
2
1
Figure 40-20-14
P5468A
Use the bearing cup installation tool (Item 1) [Figure 4020-16] and (Item 1) [Figure 40-20-17].
P5637
Figure 40-20-15
Figure 40-20-17
P4816
P4811
40-20-16
480 of 1035
P4813
40-20-17
481 of 1035
Figure 40-20-19
Rear Drive
Chain
WARNING
Front Drive
Chain
P-68194
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front
Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
Remove the brake disc. (See Disc Removal And
Installation on Page 40-10-2.)
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
40-20-18
482 of 1035
B-13504A
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
40-20-19
483 of 1035
CHAINCASE
Description
Figure 40-30-1
P-68217
40-30-1
485 of 1035
Clean the area around the cover to keep dirt and debris
from entering the chaincase area.
CHAINCASE (CONTD)
Figure 40-30-2
WARNING
P-68253
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Clean the area around the cover to keep dirt and debris
from entering the chaincase area.
Remove the crossbar linkage (Item 1) [Figure 40-30-2].
(See Linkage Removal And Installation on Page 50-903.)
Disconnect the brake solenoid connector (Item 2)
[Figure 40-30-2].
Remove the twelve mounting bolts (Item 3) [Figure 4030-2] from the center chaincase cover.
40-30-2
486 of 1035
CHAINCASE (CONTD)
Figure 40-30-3
WARNING
P-68255
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Clean the area around the cover to keep dirt and debris
from entering the chaincase area.
Remove the case drain filter (Item 1) [Figure 40-30-3]
from the top of the cover.
Remove the twelve mounting bolts (Item 2) [Figure 4030-3] from the rear chaincase cover.
Remove the cover.
NOTE: There are machined recesses (Item 3) [Figure
40-30-1] on the bottom side of the cover to
help pry the covers off.
Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage. Tighten the mounting
screws to 15 - 20 ft.-lb. (20 - 27 Nm) torque.
40-30-3
487 of 1035
MAIN FRAME
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . 50-121-2
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . 50-40-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . 50-40-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
MAIN FRAME
50-111-1
50-111-7
50-111-1
50-111-5
50-111-4
50-111-1
50-111-6
50-01
489 of 1035
CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW) . . . . . 50-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-15
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW) (SJC) 50-102-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-2
CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE) (SJC). 50-103-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103-2
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . 50-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Foot Pedal Linkage Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-4
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Continued On Next Page
50-02
490 of 1035
CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE) . . . . . . 50-101-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-11
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-6
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-15
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-4
50-03
491 of 1035
50-04
492 of 1035
SEAT BAR
Description
Figure 50-10-4
N-19225
Figure 50-10-5
N-18463
50-10-1
493 of 1035
Figure 50-10-8
N-18572
Remove the seat bar mounting nuts (Item 1) [Figure 5010-8] (both sides).
P-31289
Figure 50-10-7
N-19224
P-43750
50-10-2
494 of 1035
P-31288
Figure 50-10-10
Figure 50-10-12
5
7
3
1
10
1
N-19383
N-19340
Figure 50-10-11
8
4
6
3
2
5
6
7
10
1
7
1
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-10] & [Figure 50-1011].
Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-12] & [Figure 50-1013].
Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure
50-10-12] & [Figure 50-10-13] to 25 - 28 ft.-lb. (33,9 - 38
Nm) torque.
50-10-3
495 of 1035
Figure 50-10-13
Figure 50-10-15
Figure 50-10-14
1
5
4
3
2
1
Turn the bolt (Item 1) [Figure 50-10-14] & [Figure 50-1015] out of the clevis.
Assembly: Apply Loctite #518 adhesive to the bolt
threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
NOTE: For procedures requiring the use of Loctite
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite #518.
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Bushing (Item 4)
Clevis (Item 5)
Retaining Pin (Item 6)
Bushing (Item 7)
Pin (Item 8)
50-10-4
N-19222
496 of 1035
N-19384
OPERATOR CAB
Figure 50-20-2
P-43839
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-3
Figure 50-20-1
2
1
1
P-43444
P-31545
50-20-1
497 of 1035
Figure 50-20-6
2
1
P-31548
N-19719
50-20-2
498 of 1035
P-31549
Figure 50-20-9
1
2
1
P1008
Figure 50-20-10
Remove the retaining pins (Item 1) [Figure 50-20-7] from
the cab pivot pins.
Figure 50-20-8
P1006
1
P-43354
50-20-3
499 of 1035
Figure 50-20-13
Figure 50-20-11
P-66834
P-66833
50-20-4
500 of 1035
Figure 50-20-16
2
1
P-31545
Figure 50-20-15
P-43843
P-43842
50-20-5
501 of 1035
P-43839
2
1
P-43844
50-20-6
502 of 1035
OPERATOR SEAT
Figure 50-30-3
Figure 50-30-1
1
2
1
N-20729
N-20729
2
N-20655
P-31288
P-31289
50-30-1
503 of 1035
Figure 50-31-3
1
1
2
N-20974
N-20647
Figure 50-31-4
Remove the four seat mounting nuts (Item 1) [Figure 5031-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
Nm) torque.
Figure 50-31-2
N-20973
P-31288
P-31289
50-31-1
505 of 1035
Figure 50-31-6
Figure 50-31-5
1
1
1
2
2
1
1
N-20974
1
N-18587
(See
Removal
And
Installation: Tighten the mounting nuts to 58 to 62 ft.-lb.
(78.6 to 84 Nm) torque.
50-31-2
506 of 1035
Figure 50-31-9
N-18580
P-43120
Lift and remove the seat cushion (Item 1) [Figure 50-318] from the seat frame.
50-31-3
507 of 1035
Figure 50-31-12
Figure 50-31-10
1
1
1
2
P-43118
N-18583
Figure 50-31-11
Removal
And
N-18578
Remove the two mounting screws (Item 1) [Figure 5031-11] from the seat back and remove the back.
Reverse the removal procedure to install the operator
seat back.
50-31-4
508 of 1035
(See
Figure 50-31-15
(See
Removal
And
Figure 50-31-13
2
OUTSIDE OF CAB
P16131
P16285
2
P16126
P16128
Installation: Be sure tether strap (Item 3) [Figure 50-3114] is on the seat belt stud behind the seat belt retractor.
3
Remove the mounting bolt (Item 1) [Figure 50-31-15]
P16284
50-31-5
509 of 1035
Description
Figure 50-40-1
P-31400
1
P-31401
50-40-1
511 of 1035
Figure 50-40-5
1
1
P-31405
P-31402
Figure 50-40-6
Figure 50-40-4
P-31403
Remove the nut (Item 1) [Figure 50-40-6] from the BobTach pivot pin retaining bolt (both sides).
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
Installation: Tighten the retainer nut and bolt to 190 ft.lb. (258 Nm) torque.
50-40-2
512 of 1035
P-31406
1
P-31407
50-40-3
513 of 1035
Figure 50-40-11
1
2
P-31410
Remove the nut (Item 1) [Figure 50-40-9] from the BobTach lever pivot bolt.
NOTE: Removal procedure is shown for the left side.
Right side procedure is the same.
1
Figure 50-40-10
P-31411
2
3
50-40-4
514 of 1035
P-31408
Figure 50-40-14
Figure 50-40-13
N-18557
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) are damaged, put the assembly in a
vise [Figure 50-40-13].
Remove the bolt and replace the damaged parts as
needed,
Use a seal pick to remove seal (Item 1) [Figure 50-4014] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-14]
with a driver tool and hammer.
50-40-5
515 of 1035
P5345
Description
Figure 50-41-1
P-31400
Remove the retainer nut and bolt (Item 1) [Figure 50-412] from the tilt cylinder rod end pin (both sides).
50-41-1
517 of 1035
P-31379
Figure 50-41-5
1
P-31404
1
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
Figure 50-41-6
P-31401
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Figure 50-41-4
1
P-31405
1
Check and replace the O-ring (Item 1) [Figure 50-41-6]
on the grease plug.
P-31402
50-41-2
518 of 1035
Figure 50-41-9
P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the BobTach pivot pin retaining bolt (both sides).
P-31403
Installation: Tighten the retainer nut and bolt to 190 ft.lb. (258 Nm) torque.
Figure 50-41-8
P-31406
50-41-3
519 of 1035
Figure 50-41-12
P-31409
P-31379
Figure 50-41-11
2
P-31410
Remove the washers and bolts (Item 1) [Figure 50-4110] (both ends of the cylinder).
50-41-4
520 of 1035
P-31411
2
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise [Figure 50-41-15].
Remove the bolt and replace the damaged parts as
needed.
50-41-5
521 of 1035
N-18557
50-41-6
522 of 1035
LIFT ARMS
Figure 50-50-3
1
1
3
P-45015
P-43901
Figure 50-50-2
Figure 50-50-4
P-31565
P-45016
Pull the hose up and out of the upright to allow for lift arm
removal.
50-50-1
523 of 1035
Figure 50-50-7
P-43780
Remove the retainer bolt and nut (Item 1) [Figure 50-507] from the right side, rod end, lift cylinder pin.
At the right side of the loader, mark the two tilt hoses for
proper installation.
P-43846
Remove the retainer bolt and nut (Item 1) [Figure 50-508]. (Both sides.)
P-43845
Remove the retainer bolt and nut (Item 1) [Figure 50-506] from the left side, rod end lift cylinder.
50-50-2
524 of 1035
P-45017
Figure 50-50-11
1
P-43848
P-31561
P-43847
50-50-3
525 of 1035
REAR GRILL
Figure 50-60-3
P-43827
Lift and pull the rear grill and remove it from the loader
[Figure 50-60-3].
P-43825
Figure 50-60-4
Figure 50-60-2
2
1
P-31559
P-43826
50-60-1
527 of 1035
REAR DOOR
Figure 50-70-3
Figure 50-70-1
1
P-43360
NOTE: Install the door stop (Item 2) and the door stop
retainer (Item 3) [Figure 50-70-3] in the top
hinge as shown.
Installation: Tighten the mounting bolts and nuts to 2528 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.
Installation: Reverse the removal procedure to install
the rear door.
2
P-34588
N-19674
Figure 50-70-5
Figure 50-70-4
2
2
3
1
1
P-31320
P-31126
50-70-2
530 of 1035
WARNING
AVOID INJURY OR DEATH
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
P-31126
50-70-3
531 of 1035
Figure 50-70-9
P-31128
P-31125
1
P-31127
50-70-4
532 of 1035
FUEL TANK
Figure 50-80-3
P-51908
1
P-51907
50-80-1
533 of 1035
P1616
Figure 50-80-7
P-39517
P-39113
Installation: Tighten the main frame mount bolts to 300 330 ft.-lb. (407-447 Nm) torque.
1
2
P-39113
P-37359
Remove the two mounting bolts (Item 1) [Figure 50-806] from the battery hold down plate mounting bracket.
Lift the fuel tank and remove it from the loader frame.
NOTE: When installing the fuel tank, avoid striking
the tank with heavy objects to prevent
damage.
50-80-2
534 of 1035
P-37358
Figure 50-80-10
Figure 50-80-9
1
1
P-64954
P-37363
P-64955
50-80-3
535 of 1035
50-90-1
537 of 1035
Figure 50-90-2
P-31715
WARNING
Raise the lift arms and install an approved lift arm support
device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-1.)
Figure 50-90-1
P-31714
50-90-2
538 of 1035
Figure 50-90-5
Figure 50-90-3
P-54488
P-68138
1
1
P-24759
P-68139
50-90-3
539 of 1035
Pedal (Adjusting)
Figure 50-90-7
2
1
P-26008
P-26008
50-90-4
540 of 1035
50-91-1
541 of 1035
Figure 50-91-3
P-21936
P-21927
P-21938
Figure 50-91-4
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
Figure 50-91-2
2
1
P-21924
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Remove the foot pedal and sensor assembly from the
loader.
50-91-2
542 of 1035
1
P-21940
3
P-21935
P-21934
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.
50-91-3
543 of 1035
2
1
P-21931
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) [Figure 50-91-8] from the foot pedal.
50-91-4
544 of 1035
Figure 50-100-1
P-54658
50-100-1
545 of 1035
Figure 50-100-2
P-37789
WARNING
Loosen the jam nut (Item 1) from the lift arm bypass
control knob (Item 2) [Figure 50-100-2].
W-2059-0598
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
Figure 50-100-3
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-76485
50-100-2
546 of 1035
Figure 50-100-6
1
2
1
1
2
P-37875
Figure 50-100-7
P-76491
1
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-4] which are connected to the
steering shaft on the control panel.
P-37876
Figure 50-100-5
P-37878
50-100-3
547 of 1035
Figure 50-100-9
1
4
P-48275
P-48278
Remove Control Handle / Lever (Item 1) [Figure 50-1009]. (See Lever Removal And Installation on Page 50-1101.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50100-9] from both sides of the control panel.
Remove the steering linkage mounting bolts (Item 3)
[Figure 50-100-9] from both sides.
Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38
Nm) torque.
Remove the steering shaft from the control panel.
50-100-4
548 of 1035
Figure 50-100-12
Figure 50-100-10
1
2
1
P-26331
N-17640
2
P13773
50-100-5
549 of 1035
Figure 50-100-13
WARNING
W-2059-0598
P-51130
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
50-100-6
550 of 1035
Figure 50-100-16
Figure 50-100-14
2
P-48630
P-48631
DESCRIPTION
Bolt
Bushings
Washer
Bushing Spacer
Spring
Lock Nut
Figure 50-100-15
Centering Plate
Guide Bushings
ITEM
P-48632
50-100-7
551 of 1035
Figure 50-100-18
2
3
1
1
P-54617
2
Remove the bolts and washers (Item 1) [Figure 50-10018] from the pintle.
P-48629
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Figure 50-100-19
2
4
3
2
1
P-48624
50-100-8
552 of 1035
Figure 50-100-21
2
2
3
1
P-48659
P-54615
50-100-9
553 of 1035
Figure 50-100-23
Figure 50-100-22
4
4
3
2
P-54626
3
Remove the base pintle (Item 1) [Figure 50-100-23] from
the pump shaft.
1
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-22].
Figure 50-100-24
3
P-48619
50-100-10
554 of 1035
P-54624
Figure 50-100-26
Figure 50-100-25
2
P-48450A
P-54612
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
50-100-11
555 of 1035
Figure 50-100-27
WARNING
Figure 50-100-28
W-2017-0286
1
2
P-48451
50-100-12
556 of 1035
Figure 50-100-31
P-54610
P-48632
50-100-13
557 of 1035
P-48632
50-100-14
558 of 1035
Figure 50-100-33
WARNING
P-48448
W-2059-0598
Figure 50-100-34
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
50-100-15
559 of 1035
Figure 50-100-37
P-51132
P-37574
2
4
1
3
1
P-51131
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3)
[Figure 50-100-36].
50-100-16
560 of 1035
Figure 50-100-41
P-51132
Figure 50-100-42
Loosen the two bolts and nuts (Item 1) [Figure 50-10039] on each steering linkage bar.
Figure 50-100-40
P-54613
50-100-17
561 of 1035
Figure 50-100-44
Figure 50-100-43
P-37574
Tighten the two bolts and nuts (Items 1 & 2) [Figure 50100-43] to 35-40 ft.-lb. (47,5-54,2 Nm) torque at the
steering bell cranks.
NOTE: After removal, installation, and adjusting of
the linkage, the Back-up Alarm must be
inspected. (See Inspecting on Page 60-210-1.)
50-100-18
562 of 1035
P-48448
P-54658A
50-101-1
563 of 1035
Figure 50-101-1
Figure 50-101-2
1
3
P-48462A
WARNING
Loosen the jam nut (Item 1) from the lift arm bypass
control knob (Item 2) [Figure 50-101-2].
W-2059-0598
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-101-2].
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
Figure 50-101-3
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-76490
50-101-2
564 of 1035
Figure 50-101-6
2
1
2
P-76489
Figure 50-101-7
Figure 50-101-5
NOTE: Install the bottom bolts (Item 2) [Figure 50-1016] & [Figure 50-101-7] through the hole in the
control panel, do not install them in the
slotted area.
P-76486
50-101-3
565 of 1035
P-76491
1
2
2
P-48275
1
1
P-76487
50-101-4
566 of 1035
P-26328A
1
3
Figure 50-101-11
3
2
P-76484
2
P-48278
Remove Control Handle / Lever (Item 1) [Figure 50-10111]. (See Lever Removal And Installation on Page 50110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50101-11] from both sides of the control panel.
1
P-26331
Figure 50-101-14
WARNING
W-2059-0598
P-51130
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
50-101-6
568 of 1035
Figure 50-101-17
Figure 50-101-15
2
P-48630
P-48631
DESCRIPTION
Bolt
Bushings
Washer
Bushing Spacer
Spring
Lock Nut
Figure 50-101-16
Centering Plate
Guide Bushings
ITEM
P-48632
50-101-7
569 of 1035
Figure 50-101-19
2
3
1
1
P-54617
2
Remove the bolts and washers (Item 1) [Figure 50-10119] from the pintle.
P-48629
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-19].
Figure 50-101-20
2
4
3
2
1
P-48624
50-101-8
570 of 1035
Figure 50-101-22
2
2
3
1
P-48659
P-54615
50-101-9
571 of 1035
Figure 50-101-24
Figure 50-101-23
4
4
3
2
P-54626
3
Remove the base pintle (Item 1) [Figure 50-101-24] from
the pump shaft.
1
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-101-23].
Figure 50-101-25
3
P-48619
50-101-10
572 of 1035
P-54624
Figure 50-101-27
P-76492
Figure 50-101-26
2
P-48450A
P-54612
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
50-101-11
573 of 1035
Figure 50-101-28
WARNING
Figure 50-101-29
W-2017-0286
1
2
P-48451
50-101-12
574 of 1035
Figure 50-101-32
P-54610
P-48632
50-101-13
575 of 1035
P-48632
50-101-14
576 of 1035
Figure 50-101-34
WARNING
P-76492
W-2059-0598
Figure 50-101-35
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
50-101-15
577 of 1035
Figure 50-101-38
P-51132
P-37574
2
4
1
3
1
P-51131
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3)
[Figure 50-101-37].
50-101-16
578 of 1035
Figure 50-101-42
P-51132
Figure 50-101-43
Loosen the two bolts and nuts (Item 1) [Figure 50-10140] on each steering linkage bar.
Figure 50-101-41
P-54613
50-101-17
579 of 1035
Figure 50-101-45
Figure 50-101-44
P-37574
Tighten the two bolts and nuts (Items 1) [Figure 50-10144] to 35-40 ft.-lb. (47,5-54,2 Nm) torque at the steering
bell cranks.
NOTE: After removal, installation, and adjusting of
the linkage, the Back-up Alarm must be
inspected. (See Inspecting on Page 60-210-1.)
50-101-18
580 of 1035
P-76492
50-102-1
581 of 1035
Figure 50-102-1
WARNING
WARNING
Figure 50-102-2
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
P-26234
50-102-2
582 of 1035
Figure 50-102-5
P-26237
P-26235
1
2
P-26227
P-26236
Remove the control panel mount bolt (Item1) [Figure 50102-4] from the left side of the control panel.
Remove the two side panel mount bolts (Item 2) [Figure
50-102-4], to allow clearance for the removal of the
control panel.
Installation: Tighten the control panel mounting bolts to
20 ft.-lb. (27 Nm) torque.
50-102-3
583 of 1035
P-26238
P-26239
50-102-4
584 of 1035
50-103-1
585 of 1035
Figure 50-103-1
WARNING
2
1
WARNING
Figure 50-103-2
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
P-26234A
50-103-2
586 of 1035
Figure 50-103-5
P-26237A
P-76486A
Figure 50-103-6
NOTE: Install the bottom bolts (Item 2) [Figure 50-1033] through the hole in the control panel, do not
install them in the slotted area.
Remove the fuse cover.
Figure 50-103-4
1
1
P-26227
P-76487
50-103-3
587 of 1035
P-26238
50-103-4
588 of 1035
Description
Figure 50-110-1
2
P-26798
50-110-1
589 of 1035
Disconnect the electrical connectors (Item 1) [Figure 50110-1] from the control lever.
2
1
P-26797
50-110-2
590 of 1035
Description
Figure 50-111-2
Figure 50-111-1
1
1
P-21864
P-21837
50-111-1
591 of 1035
P-21879
Figure 50-111-6
P-21860
P-21836
Figure 50-111-7
Disconnect the harness connector (Item 2) [Figure 50111-4] from the handle lock solenoid connector.
Figure 50-111-5
5
1
2
4
3
1
P-21861
50-111-2
592 of 1035
P-21862
Figure 50-111-10
Figure 50-111-8
2
1
P-21878
Figure 50-111-11
1
P-21880
4
3
6
2
5
P-21882
50-111-3
593 of 1035
Figure 50-111-14
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50111-14] from the handle.
P-21879
Figure 50-111-13
2
2
N-17385
P16534
50-111-4
594 of 1035
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
2
1
N-17394
N-22796
50-111-5
595 of 1035
Figure 50-111-20
1
1
1
18.25
1
N-18417
Disconnect the electrical connectors (Item 1) [Figure 50111-18] from the control lever switch handle.
Remove the electrical connectors from the control lever
switch handle [Figure 50-111-18].
Figure 50-111-19
Remove the control lever from the cross shaft and control
panel.
Figure 50-111-21
2
1
N-22658
P13734
50-111-6
596 of 1035
N-22667
1
N-22659
50-111-7
597 of 1035
JOYSTICK CONTROL
Description (Earlier Models And Later Models)
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There is no mechanical
linkages connecting to the hydrostatic pumps or the
control valve.
50-112-1
599 of 1035
Figure 50-112-3
3
1
P-28312
Figure 50-112-2
The voltage should be between 2.45 and 2.55 volts.
Figure 50-112-4
P-28311
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
P-28310
50-112-2
600 of 1035
P-28301
Figure 50-112-7
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 50-112-5
P-26222
P-26220
P-26223
P-26221
50-112-3
601 of 1035
Figure 50-112-8
Figure 50-112-11
1
1
1
P-73248
P-26224
Figure 50-112-12
P-73240
Disconnect the joystick connector (Item 1) [Figure 50112-12] from the harness connector.
P-73247
50-112-4
602 of 1035
Disconnect the electrical harness (Item 1) [Figure 50112-9] from the joystick.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
P-26227
P-26225
Figure 50-112-15
Remove the joystick boot from the control lever assembly
[Figure 50-112-13].
1
P-26230
50-112-5
603 of 1035
Figure 50-112-17
Figure 50-112-16
1
P-73245
P-64308
1
1
P-73246
50-112-6
604 of 1035
Figure 50-120-3
Figure 50-120-1
1
1
1
1
P-37470
P-37102
Remove the four mounting bolts (Item 1) [Figure 50-1201] from the front access panel.
Figure 50-120-4
Remove the four mounting bolts (Item 1) [Figure 50-1203] from the front access panel.
Figure 50-120-2
1
1
1
1
1
P-37471
P-37103
50-120-1
605 of 1035
Figure 50-121-3
2
1
1
P-34653
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the three mounting bolts (Item 1) [Figure 50121-1], from the left foot rest.
Remove the foot rest from the loader.
Figure 50-121-2
P-34652
50-121-1
607 of 1035
P-34651
Figure 50-121-6
1
1
1
P-34546
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 50-121-7
Remove the three mounting bolts (Item 1) [Figure 50121-4], from the right side foot rest.
Remove the foot rest, from the loader.
Figure 50-121-5
1
1
2
P-34547
P-34545
50-121-2
608 of 1035
P-34544
Figure 50-121-10
1
2
P-34553
Lift the speed control pin (Item 1) from the notch (Item 2)
[Figure 50-121-10] in throttle cable.
P-73451
Figure 50-121-11
Figure 50-121-9
P-34549
P-34551
50-121-3
609 of 1035
Figure 50-121-14
1
1
2
1
1
2
P-34554
Remove the mount bolt and nut (Item 1) [Figure 50-12112] from the speed control linkage arm.
Remove the speed control linkage arm (Item 1) [Figure
50-121-12] from the access panel.
Figure 50-121-13
P-34555
50-121-4
610 of 1035
P-34550
WINDOW (REAR)
Installation
Removal
Figure 50-130-1
Figure 50-130-2
P-64994
Using gloves, push the rear window out the rear of the
operator cab.
If replacing the rubber molding (Item 1) [Figure 50-1302] cut off the excess molding.
Figure 50-130-3
P16015A
50-130-1
611 of 1035
P16014
Figure 50-130-6
Installation (Contd)
Figure 50-130-4
P16013
P-64998
50-130-2
612 of 1035
P-64997
WINDOW (TOP)
Removal And Installation
Figure 50-131-1
P-24378
1
1
1
N-20950
50-131-1
613 of 1035
WINDOW (SIDE)
Figure 50-132-3
2
1
N-20814
Move the window slide rail using the two thumb pads
(Item 2) [Figure 50-132-2] and [Figure 50-132-3]
towards the rear of the operator cab and then down
towards the bottom of the operator cab.
Figure 50-132-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
window is secure and does not fall. Make sure
the slide rails are in alignment and the window
is positioned in the top track during
installation.
P-66019
50-132-1
615 of 1035
P-66024
P-66021
P-66020
50-132-2
616 of 1035
Figure 50-133-3
3
2
P-24472
N-20171
50-133-1
617 of 1035
P-66051
Figure 50-133-6
P-66059
If replacing the rubber molding (Item 1) [Figure 50-1334] cut off the excess molding.
Figure 50-133-5
Figure 50-133-7
1
1
1
P-66651
P-66050
50-133-2
618 of 1035
P-66058
P-66049A
P-66051
50-133-3
619 of 1035
Figure 50-133-10
glazing
under
the
following
P-66101
50-133-4
620 of 1035
Lexan
CAB DOOR
Description
Figure 50-140-1
3
2
4
1
P-76520
P-76526
50-140-1
621 of 1035
Aligning
Figure 50-140-4
WRONG
WRONG
Figure 50-140-3
1
1
P-76523A
P-76524A
Figure 50-140-5
1
Remove the four bolts and nuts (Item 2) [Figure 50-1403] from the cab.
Remove the hinges (Item 1) [Figure 50-140-3] from the
cab.
Installation: Install the hinges (Item 1) on the cab and
use the bolts and nuts (Item 2) [Figure 50-140-3] to
secure the hinges. Tighten to 7-7.9 ft.-lb. (9,6-10,7 Nm)
torque.
P-76522A
P-76525A
50-140-2
622 of 1035
CORRECT
CORRECT
Adjusting
Checking Operation
Figure 50-140-6
Figure 50-140-8
4
B-15551G
N-18409
P-76516
50-140-3
623 of 1035
P-76521
60-210-1
60-210-2
60-210-5
60-210-1
60-210-1
60-210-5
60-210-4
60-210-3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . .
60-20-1
60-20-1
60-20-2
60-20-2
60-71-1
60-71-2
60-71-1
60-71-3
60-70-1
60-70-2
60-70-1
60-70-4
60-72-1
60-72-2
60-72-1
60-72-4
ELECTRICAL
SYSTEM &
ANALYSIS
60-01
625 of 1035
60-30-1
60-30-3
60-30-1
60-30-2
60-30-4
60-30-3
60-20-6
60-30-5
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . 60-160-7
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-3
Lift And Tilt Calibration (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Attachment Control Information (Keyless) . . . . . . . . . . . . . . . . . . . 60-180-2
Right Panel Setup (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Actuator Connector Disassembly And Assembly. . . . . . . . . . . . . . 60-130-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . 60-130-11
Handle Lock Solenoid Disassembly And Assembly. . . . . . . . . . . 60-130-11
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . 60-130-10
Handle Sensor Connector Disassembly And Assembly . . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . 60-140-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . 60-141-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Continued On Next Page
60-02
626 of 1035
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . .
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-200-1
60-200-1
60-200-6
60-200-2
60-190-1
60-190-2
60-190-1
60-190-3
60-110-1
60-110-5
60-110-1
60-110-4
60-110-3
60-110-2
60-03
627 of 1035
60-04
628 of 1035
629 of 1035
630 of 1035
631 of 1035
632 of 1035
633 of 1035
WIRING SCHEMATIC
STD CAB HARNESS
S220 (S/N 530711001 AND ABOVE)
(S/N 530811001 AND ABOVE)
(PRINTED MAY 2007)
V-0898
C479
LEFT PANEL CONN
C479
LEFT PANEL CONN
C480
RIGHT PANEL CONN
PROTECTED POWER
SYSTEM Tx
COMPUTER POWER
SYSTEM Rx
GROUND
RUN/ENTER SW
DATA
CLOCK/LATCH
1210
1920
9120
9220
9350
2920
9300
9310
9330
S2
BUZZER (-)
2920
2770
9220
9120
1920
1210
C212
POWER
PLUG
6100
6100
6120
2760
A
B
A
B
C434
LEFT
HEADLIGHT
C435
RIGHT
HEADLIGHT
SW1
BRAKE
SWITCH
45
46
44
12
34
33
27
24
13
30
17
9
10
22
16
28
20
14
25
47
15
19
18
6
11
38
21
26
23
43
32
3
5
2
36
29
45
46
44
12
34
33
27
24
13
30
17
9
10
22
16
28
20
14
25
47
15
19
18
6
11
38
21
26
23
43
32
3
5
2
36
29
3910
3920
3900
2910
2930
2920
2770
2900
9210
9200
9110
9100
1910
1900
1220
1200
9200
9100
1900
1200
4500
A
B
C
A GND
B SIG
C PWR
9220
9120
1920
1210
C482
SEATBAR
SENSOR
1
2
2795
1160
2730
2790
2710
A
B
1_
2
+
A
B
C212
POWER
PLUG
C209
DOME LIGHT
SWITCH
2765
2765
2750
6110
B
A
B
A
6100
6100
6120
2760
A
B
A
B
C434
LEFT
HEADLIGHT
C435
RIGHT
HEADLIGHT
1770
1100
1770
1700
2730
1700
1170
1770
1100
1770
9340
2900
9350
2770
B
A
39
31
40
35
8
1
7
37
41
48
42
4
4500
B
A
2770
2750
6110
4500
2765
39
31
40
35
8
1
7
37
41
48
42
4
1100
C209
DOME LIGHT
SWITCH
2765
634 of 1035
9330
2910
2930
2710
A
B
9310
9300
S1
BUZZER (+)
C482
SEATBAR
SENSOR
A
B
9340
9210
9110
1910
1220
2910
9320
1210
1920
9120
9220
9350
2920
9300
9310
9330
2790
OPEN
B A G D K H F E
1200
4500
1_
2
+
START
B A G D K H F E
1900
1
2
START
9100
2795
1100
DATA
9200
A GND
B SIG
C PWR
HEADLIGHTS
C G E F H K D A B
2900
A
B
C
CLOCK/LATCH
C G E F H K D A B
B A G D K H F E
9330
3910
3920
3900
STSTEM Tx
B A G D K H F E
9310
9300
45
46
44
12
34
33
27
24
13
30
17
9
10
22
16
28
20
14
25
47
15
19
18
6
11
38
21
26
23
43
32
3
5
2
36
29
SYSTEM Rx
9340
9210
9110
1910
1220
2910
9320
45
46
44
12
34
33
27
24
13
30
17
9
10
22
16
28
20
14
25
47
15
19
18
6
11
38
21
26
23
43
32
3
5
2
36
29
COMPUTER POWER
9210
9200
9110
9100
1910
1900
1220
1200
1100
9340
2900
9350
PROTECTED POWER
BUZZER
C G E F H K D A B
S2
BUZZER (-)
39
31
40
35
8
1
7
37
41
48
42
4
GROUND
PROTECTED POWER
SYSTEM Tx
COMPUTER POWER
SYSTEM Rx
GROUND
RUN/ENTER SW
CLOCK/LATCH
DATA
OPEN
START
DATA
START
HEADLIGHTS
CLOCK/LATCH
STSTEM Tx
SYSTEM Rx
COMPUTER POWER
PROTECTED POWER
BUZZER
GROUND
C G E F H K D A B
S1
BUZZER (+)
39
31
40
35
8
1
7
37
41
48
42
4
C480
RIGHT PANEL CONN
A B C
A B C
C129
ACCESSORY
CONNECTOR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
WIRES CONNECT BY
LETTER ACROSS
CONNECTORS
B
A
A
B
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
V-0898 (4-9-07)
SW1
BRAKE
SWITCH
635 of 1035
636 of 1035
637 of 1035
638 of 1035
639 of 1035
640 of 1035
6500
6200
2600
6310
6200
2600
D
F
C
E
B
A
G
KEY "RUN"
UNSW POWER
CAN SHIELD
2620
2610
6320
2640
6330
2620
6340
2610
6610
6320
2640
6330
6620
V-0781
CAN LOW
CAN HIGH
GROUND
E F C A B D
F E D C B A
C604
C605
E F C A B D
F E D C B A
2630
6210
REGISTRATION
LAMP
LEFT WORK
RIGHT WORK
1 2
2 1
C604
C605
1 2
2 1
2630
Connector
on Loader
Boom
6210
LEFT WORK
RIGHT WORK
DELUXE TAILGATE
HARNESS - 7109404
3120
3100
STOP
TURN
TAIL
STOP
LEFT TAILLIGHT
7030
2360
TAIL
RIGHT TAILLIGHT
LEFT TAILLIGHT
E OUTPUT
F OUTPUT
G OUTPUT
TURN
H OUTPUT
RIGHT TAILLIGHT
7020
C OUTPUT
D OUTPUT
REAR BASE
TO HORN
CONNECTOR
2750
2320
1 2
1 2
1 2
C416
C417
C413
C414
2770
1 2
1 2
2750
4440
2 1
7010
1 2
TO OPTIONS
(DELUXE ACCESSORY)
2760
C411
2440
2430
2470
4475
4460
4455
7000
2450
7000
2460
4460
4471
4451
E
D
C
6410
6000
6510
2780
6410
85
87
86
30
4430
3 2
30
ID (K TO L)
ID (K TO P)
C506
2760
Connector
on Loader
Boom
ADDITIONAL POWER
CONNECTOR
1740
6020
B
A
PUR
1730
RNG
9620
PUR
9520
PUR
9710
1720
B
A
H
F
B
E
D
C
A
G
J1 - 8-PIN
GROUND
CAN SHIELD
ACD
Machine
Connector to
Engine
Compartment
SW POWER
CAN LOW
CAN HIGH
OPEN
OPEN
OPEN
1740
C703
2740
5100
5100
5350
5350
5400
5400
5050
5050
5300
5300
5150
5150
5250
5250
5200
5200
5910
5000
12
5510
5450
C
H
J
B
G
D
E OUTPUT
F
E
A
K
A OUTPUT
J
A
B
C
D
E
F
G
H
K
ID #1
J2 - 10-PIN BLACK
F OUTPUT
G OUTPUT
H OUTPUT
C OUTPUT
D OUTPUT
ACD
Output
Connector to
Engine
Compartment
B OUTPUT
J OUTPUT
K OUTPUT
11
14-PIN
ATTACHMENT
CONNECTOR
C704
5900
5500
6010
TO MAINFRAME
2720
9510
13
BLK
Rev. none
C497
9610
14
6515
B C A
1720
DELUXE ATTACHMENT
CONTROL HARNESS 6732730
TO AWS
CONTROLS
2710
C705
2720
BOOM-MOUNTED
ACD CONNECTORS
A
M
L
P
A OUTPUT
M OUTPUT
7200
6415
RIGHT BLINKER
RELAY
85
87
86
2740
J3 - 10-PIN GRAY
ID #2
ID #3
ID #4
ID #0
OPEN
OPEN
ACD
Input
Connector to
Engine
Compartment
OPEN
OPEN
OPEN
4440
4470
2460
4450
30
87A
87A
3120
3100
86
85
87
87A
2790
6510
3120
3100
1730
HORN RELAY
2 1
4430
2770
7010
B
A
C412
REAR ROD
C490
RELIEF VALVE
C489
C401or
C402
DIVERTER VALVE
2350
RED/WHT
9710
2730
7-PIN
J
N
K
B
E
F
G
H
C
D
GROUND
STANDARD TAILGATE
HARNESS - 7109403
PUR
1160
To Mainframe
Harness
C666 ATTACHMENT
CONNECTOR
SW POWER
3120
3100
9800
9600
BACK-UP
ALARM
SW POWER
C426
D F C E A B G
9500
6310
SSL 7-PIN
CAN CONNECTOR
1710
6400
C
F
G
E
A
D
H
B
9800
6600
BACK-UP
ALARM
C103
OPTIONS
TO MAINFRAME
7100
2650
1160
C
F
G
E
A
D
H
B
9700
TO MAINFRAME
7100
2650
C103
WIRING SCHEMATIC
RIGHT TAILLIGHT
BACK-UP
ALARM
C605
2550
OPEN
6610
OPEN
6710
6510
6230
6240
2510
2520
6250
A B C D E F
6200
6400
OPEN
6500
OPEN
7100
2500
6310
7100
2520
2530
A B C D E F G H
6600
1730
2730
A B C D E F
RIGHT WORK
C103
A B C
1740
B A
2720
1720
6240
2540
2530
A B
OPEN
OPEN
2540
6640
6810
STOP LIGHT
ACCESSORY
A B C D E F
6410
TO ENGINE OR
MAINFRAME
REGISTRATION
LEFT WORK
C604
6370
A B C D E F
6430
6730
2660
OPEN
HARNESS 6713993
A
B
HARNESS 6713994
C
B
A
6430
6730
2660
OPEN
HARNESS 6713993
6430
2630
D
E
F
D
E
F
A
B
HARNESS 6713994
OPEN
2640
6330
2630
6830
6630
OPEN
6330
2630
2660
To Engine Ground
30
2670
TO OLDER
MODEL ATTACHMENTS
87A
85
87
86
87A
85
30
30
A B
HARNESS 6726430
ROAD LIGHTS
M
FRONT WIPER
BOTTLE AND TANK
TO
MAINFRAME
FRONT WIPER
MOTOR
V
M
TO OPTIONS
(DELUXE ACCESSORY)
ADDITIONAL POWER
CONNECTOR
1740
B
A
C667
YEL
2765 or BRN
L X
C491
GD
RT
RED
C623
DBL
G
H
L
K
BACK-UP ALARM
SWITCHES HARNESS 7107544
A
B
C402
1730
2720
S
LT
TM
CENTER
C622
TO
MAINFRAME
1720
3
2
7310
5
1
6
4
7160
2735
2755
7210
7180
4710
WIPER HARNESS
7117322
STROBE OR
BEACON
B
C
A
2
1
C610
7110
TO OLDER
MODEL ATTACHMENTS
PARK
BACK-UP ALARM
SWITCHES
B
C
A
DOOR SENSOR
7180
2
1
4720
2 2
1 1
DOOR HARNESS
7104465
2 1
SSL 7-PIN
CAN CONNECTOR
TO
STROBE/BEACON
KEY "RUN"
6540
4 WAY
FLASHER
641
of 1035
HARNESS - 6718873
2
1
3
2785
6700
2780
6440
6540
E
A
C
D
F
B
C668 OR C670
2785
1
2
3
TO OPTIONS
(4 WAY FLASHER)
C669
6440
C669
2795
TO OPTIONS
(EXTERIOR CAB)
2775
TO OPTIONS
UNSW POWER
CAN SHIELD
SW POWER
CAN LOW
CAN HIGH
GROUND
Connector
on Loader
Boom
D
2
C
9800
1
B
A
3
1710
D
F
C
E
A
B
G
1160
9700
9600
9500
2700
7-PIN
ATTACHMENT
CONNECTOR
C426
C666
CONTROL HARNESS - 6718426
A
B
4460
2460
A
B
C415
C609
A
B
7.5 ohm
12V
HF HARNESS
6733137
To Mainframe
Harness
DOME LIGHT
SWITCH
TO OPTIONS
C608
RIGHT
FLASHER
LIGHT
C415
2 1
LEFT
FLASHER
LIGHT
2790
C506
B
A
2745
7100
C404
TO ATTACHMENT
B
J
N
P
BLK
85
A B
1010
RNG
BRN
86
6310
6350
A B
M
C
D
A
E
F
87
RNG
86
7200 or YEL
YEL
30
87
HIGH
BLK
DBL
RED
85
1020
BRN
87A
2730
1020
S
LT
TM
CENTER
GD
RT
WHT
86
1320
M
A
D
C
E
F
G
H
L
87
2650
C623
C506
87A
2640
2610
2640
2620
TO ATTACHMENT
B
J
N
P
1370
6800
HARNESS 6731239
1320
42
A
B
A
B
C
1020
40
A
B
C
OPEN
6320
HARNESS 6731239
7150 or DGN
C
B
A
2620
2650
40
6330
6620
6210
41
OPEN
6720
6360
46
2640
6520
1370
42
A
B
A
B
C
D
E
F
2660
40
2630
A
B
C
D
E
F
6700
C
B
A
6340
40
1320
41
2670
46
A
B
RED
BLK
DOME LIGHT
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
WIRES CONNECT BY
LETTER ACROSS
CONNECTORS
A
B
A
B
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
V-0781 (4-9-07)
DESCRIPTION
COMPONENTS
CONNECTIONS
A
3500
3520
C
B
C
B
3520
C
107
3500
3510
3510
C107
A
C
B
3500
3520
3510
A
C
B
3500
3520
3510
DESCRIPTION
LIGHT -
COMPONENTS
SWITCH - Single Pole - Double
Throw (ON-OFF-ON) - This switch
can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
when released.)
POTENTIOMETER
resistance - Provides
resistance.
Variable
variable
60-10-1
642 of 1035
SYMBOL
SYMBOL
DESCRIPTION
DESCRIPTION
COMPONENTS
I
B
ST
0.5 ohm
HOLD PULL
15 ohm
B
A
SOLENOID - Fuel and Traction Lock Dual solenoids. (The ohm rating of
the solenoid coils are listed next to
the component [if available]). The pull
solenoid is energized for a short time.
HORN - Audible alarm. Sound is
activated manually by a switch to
warn personnel.
START
R U N
O FF
3
4
L
M
H
GRD
87A 87
30
86
GRD
PARK
85
3
7
0
0
HIGH
25A
3
7
1
0
3
1
1
0
V
M
2
7.7 ohm
A
B
7.5 ohm
12V
60-10-2
643 of 1035
PUMP - FUEL
DESCRIPTION
SENDERS AND SENSORS
A
C
+
-
0.5 - 7.5 V
B
A
to
B
A
500-3000ohm
A
B
B
A
30-270 ohm
C
B
A
A
C
A
B
60-10-3
644 of 1035
C 212
SW9
SW8
SW7
C670
C 483
S3
S4
C 611
C 630
C 635
C 209
C 40
T2
C 40
T1
C 480
C 435
C 408
C 434
C 479
S1
S2
C 482
408
*C 129
T5
T6
T3
SW1
SW2
SW3
SW4
SW5
SW6
MS2441
C 426
408
C 106
C 109
T4
T5
T 14
T 15
T1
T6
T8
C 405
408
C 408
136
C 40
T3
C 350
408
C 101
C 408
C 104
408
C 407
C 478
C 489
C 443
C 632
C 103
408
C 40
T12
C 102
C 135
C 446
C 107
C 110
T 11
C 423
C 362
408
C 419
J1
J2
C 126
C 409
C 418
C 420
C 421
C 422
C 437
C 492
C 404
C 410
C 411
C 412
C 425
C 441
MS2180
60-10-5
646 of 1035
Figure 60-10-2
Description
Figure 60-10-1
1
P-37100
Figure 60-10-3
P-37101
The fuse holder (Item 1) [Figure 60-10-2] & [Figure 6010-3] is located in the engine compartment, below the air
cleaner.
60-10-7
648 of 1035
P-13848A
N-19659
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
Figure 60-10-5
1
N-19661
60-10-8
649 of 1035
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
CAUSE
1, 2, 3, 4, 5
1, 2, 5
2, 3, 4, 6, 7, 8, 9
60-10-9
650 of 1035
PROBLEM
The fuse location and sizes are shown in [Figure 60-106] & [Figure 60-10-7].
Figure 60-10-6
Ref Description
F1
F2
F3
F4
F5
F6
F7
F8
Heater
Front & Marker Lights
Rear Lights
Bobcat Controller
Traction
Fuel Shutoff
Not Used
Not Used
25
15
15
25
30
30
---
F9
F10
F11
F12
Amp.
Unswitched Attch.
25
Switched Attach.
25
Alternator & Kits
25
ACS/SJC/AWS Power 25
Ref Description
Ref Description
B
C
D
E
F
G
H
J
Switch Power
Rear Lights
Front & Marker Lights
Not Used
Glow Plugs
Fuel Shutoff
Traction
Starter
N-19660
6718774
Figure 60-10-7
1
N-19661
60-10-10
651 of 1035
P9175
Use a test meter to measure coil resistance [Figure 6010-8]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
60-10-11
652 of 1035
BATTERY
Figure 60-20-2
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.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
W-2065-0807
P-09590
Figure 60-20-1
4
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.
P-37344
60-20-1
654 of 1035
P-09589
BATTERY (CONT'D)
BATTERY (CONT'D)
Servicing
Figure 60-20-3
WARNING
P-09590
The battery cables must be clean and tight [Figure 6020-3]. Check electrolyte level in the battery. Add distilled
water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Battery Saver (6664458) or grease on the battery
terminals and cable ends to prevent corrosion.
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.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
W-2065-0807
60-20-2
655 of 1035
P-09589
Figure 60-20-4
2
4
P-34873
P-31292
Connect the end of the first cable (Item 1) [Figure 60-204] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Connect the end of the second cable (Item 3) [Figure 6020-4] to the negative terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
60-20-3
656 of 1035
ALTERNATOR
Belt Adjustment
Figure 60-30-1
1
P-34952
60-30-1
658 of 1035
ALTERNATOR (CONT'D)
Figure 60-30-2
WARNING
P-34951
W-2065-0807
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.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F (16C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-0705
Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair/replace. If fuse is in
doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)
Verify the charge of the battery. Make sure battery is fully
charged.
Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect a test light between the
negative battery post and the disconnected negative
cable clamp.
IMPORTANT
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Below.)
60-30-2
659 of 1035
ALTERNATOR (CONT'D)
Figure 60-30-4
Figure 60-30-3
P-34951
P-34953
Figure 60-30-5
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-3].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70 F (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the
following high voltage test.
P-34954
60-30-3
660 of 1035
ALTERNATOR (CONT'D)
High Voltage Testing
Figure 60-30-6
2
1
P-34955
60-30-4
661 of 1035
ALTERNATOR (CONT'D)
Figure 60-30-8
2
3
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
1
P-34952
I-2023-1285
Figure 60-30-7
P-34951
60-30-5
662 of 1035
ALTERNATOR (CONT'D)
Parts Identification
Figure 60-30-9
Alternator
Nut
Pulley
Spacer
Bolt
Bracket
Bolt
Bearing
Retainer
Rotor
11.
12.
13.
14.
15.
16.
17.
18.
19.
Bearing
Stator
Bracket
Sleeve
Regulator
Rectifier
Cover
Spacer
Nut
7
6
1
4 7
3
12
2
10
8
13
14
5
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
18
19
17
15
16
C-3529B
60-30-6
663 of 1035
Figure 60-40-2
STARTER
Testing
Bat
S
M
Figure 60-40-1
Bat
S
M
Cranking
Motor
Cranking
Motor
A-1991
60-40-1
664 of 1035
A-1992
STARTER (CONT'D)
Figure 60-40-5
1
1
P-34958
P-34956
P-34957
60-40-2
665 of 1035
STARTER (CONT'D)
Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
30
Starter
Shaft
Gear
Washer
Shaft
Stop Ring
Lever
Holder
Spring
Spring
Plate
Seal
33
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
34
13
36
8
10
11
Lever
Gear
Bracket
Spring
Gear
Stop
Stop Ring
Ball
Armature
Washer
Seal
31
7
32
21
15
12
19 18
16
37
14
17
20
5
14
6
1
29
4
3
28
2
27
35
22
23
25
23
24
26
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Yoke
Holder
Bracket
Ring
Bolt
Bolt
Switch
Seal
Bolt
Washer
Nut
Boot
Bracket
Bearing
B-19824
60-40-3
666 of 1035
INSTRUMENT PANELS
Left Panel
The table below shows the DESCRIPTION and
FUNCTION / OPERATION for each of the components of
the left panel.
Figure 60-50-1
2
1
3
4
13
10
14
11
12
B-15551
DESCRIPTION
FUNCTION / OPERATION
TEMPERATURE GAUGE
HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
relating to the loader monitoring system. ENGINE PREHEAT COUNTDOWN - Preheat time remaining.
FUEL GAUGE
LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2).
(CODES* show only when there is an error found by loader monitoring system.)
Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold two seconds
to view [SHTDN] and Operational Code Number in HOURMETER / CODE DISPLAY.
MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM
FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast
movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary
functions.) MAXIMUM FLOW allows for only fast movement.]
Rear Auxiliary Only - With key ON and engine running, press to shut down engine and relieve rear auxiliary
hydraulic pressure. (See Relieve Hydraulic Pressure - Loader and Attachment Page OI-23 for front auxiliary
pressure release.)
Press to activate BICS when the Seat Bar is down and operator is seated in operating position.
10
SEAT BAR
11
The light comes ON when the seat bar is down and the PRESS TO OPERATE button is pressed. The lift and tilt
functions can be operated when the light is ON.
12
TRACTION
The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can
be moved forward or backward when the light is ON.
13
(Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to
use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader
service. (See TRACTION LOCK OVERRIDE Page OI-12). Press a second time to lock the brakes.
14
ALARM
* See SYSTEM SETUP & ANALYSIS, (See DIAGNOSTIC SERVICE CODES on Page 60-90-1) for further description of
SERVICE CODES.
60-50-1
668 of 1035
REF.
NO
Figure 60-50-2
1
9 11 13
10 12 14
15
B-15552G
FUNCTION
ICON/
LIGHT
ALARM
Advanced
1 Control System
(ACS)
ON
Attachment
2 Control
Device (ACD)
ON
--FLASHING 3 Beeps
3 Beeps
General
Warning
ON
3 Beeps
ON
3 Beeps
FLASHING Continuous
NOT USED
---
Fuel
Level
ON
3 Beeps
FLASHING 3 Beeps
Engine Preheat
ON
--FLASHING 3 Beeps
---
CODE
*
CONDITION
Error
--- ---
DESCRIPTION
Error with Advanced Control System (ACS).
Error
*
**
Error
Error with one or more engine or hydraulic functions.
WARNING
Engine speed high or in shutdown.
SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
---
---
---
Error
WARNING
4
5
6
*
*
--- --*
Error
WARNING
---
System Voltage
ON
3 Beeps
Seat Belt
ON
---
Engine
Oil Pressure
ON
3 Beeps
ON
3 Beeps
FLASHING Continuous
*
*
*
Error
Engine oil pressure sender out of range.
WARNING
Engine oil level low.
SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic
Charge
Pressure
ON
3 Beeps
ON
3 Beeps
FLASHING Continuous
*
*
*
Error
Hydraulic oil pressure sender out of range.
WARNING
Hydraulic oil pressure low.
SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine
Coolant
11
Temperature
ON
3 Beeps
ON
3 Beeps
FLASHING Continuous
*
*
*
Error
Engine coolant sender out of range.
WARNING
Engine coolant temperature high.
SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic
Oil
Temperature
ON
3 Beeps
ON
3 Beeps
FLASHING Continuous
*
*
Error
Hydraulic oil temperature out of range.
WARNING
Hydraulic oil temperature high.
SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
ON
3 Beeps
FLASHING 3 Beeps
*
*
Error
WARNING
ON
3 Beeps
FLASHING 3 Beeps
*
*
Error
WARNING
---
7
---
8
9
10
12
Engine
13 Air Filter
14
Hydraulic
Filter
15 Key Switch
---
---
---
60-50-2
669 of 1035
REF.
Figure 60-50-4
ENTER PASSWARD
3
LANGUAGES
2
B-16165
B-15553H
the Display
Key Switch
when the
associated
60-50-3
670 of 1035
The first screen you will see on your new loader will be as
shown in [Figure 60-50-4].
B-16655
60-50-4
671 of 1035
Figure 60-50-7
FRONT PANEL
3
4
5
6
Figure 60-50-6
SIDE PANEL
OR
B-15993B
B-15993H
P16000
1
2
3
5
6
7
DESCRIPTION
REF.
NO.
FUNCTION / OPERATION
POWER PLUG
(Option)
NOT USED
FRONT WIPER
(Option)
2
3
6
7
60-50-5
672 of 1035
DESCRIPTION
ADVANCED
CONTROL
SYSTEM (ACS)
(Option)
NOT USED
POWER
BOB-TACH (Option)
PARKING BRAKE
(Standard on all
Loaders)
TURN SIGNAL
INDICATORS
(Option)
HAZARD LIGHTS
(Option)
ROTATING
BEACON (Option)
SELECTABLE
JOYSTICK
CONTROL (SJC)
(Option)
FUNCTION / OPERATION
Press the top to select Hand
Controls; bottom to select Foot
Controls.
--Press and hold the up arrow to
disengage the Bob-Tach wedges.
Press and hold the down arrow to
engage the wedges into the
mounting frame holes.
Press the top to engage the
PARKING BRAKE; bottom to
disengage.
Indicates left or right TURN
SIGNALS are ON.
Press the top to turn the HAZARD
LIGHTS ON; bottom to turn OFF.
Press the top to turn the
ROTATING BEACON ON; bottom
to turn OFF.
Press the top to select ISO
Control Pattern; bottom to select
H Control Pattern.
Front Panel
[Figure 60-50-7]
Side Panel
[Figure 60-50-6]
REF.
NO.
Figure 60-50-10
1
N-20140
P-28360A
Figure 60-50-11
1
P-28360
N-20158
60-50-6
673 of 1035
Figure 60-50-14
N-20163
Figure 60-50-13
1
1
1
N-20142
N-20103
NOTE: The instrument panel (Item 1) [Figure 60-5015] must be replaced as a complete unit.
60-50-7
674 of 1035
N-20141
Figure 60-50-18
1
1
1
N-20144
3
1
2
N-20165
60-50-8
675 of 1035
Figure 60-50-21
N-20147
1
To install the bulbs, place them in the sockets and turn
clockwise [Figure 60-50-21].
N-20145
Remove the two light bulb covers (Item 1) [Figure 60-5019] from the back of the instrument panel.
Figure 60-50-20
N-20146
60-50-9
676 of 1035
Figure 60-50-24
N-20141
N-20140
P-28360
60-50-10
677 of 1035
Figure 60-50-26
1
1
P-26255
2
1
P-26251
60-50-11
678 of 1035
N-20144
LIGHTS
Figure 60-60-3
N-19351
Disconnect and remove the bulb (Item 1) [Figure 60-603] from the socket.
N-19348
N-19349
60-60-1
680 of 1035
LIGHTS (CONTD)
Figure 60-60-6
Figure 60-60-4
1
1
P-66221
P-66220
NOTE: The wires for the switch will hold the light
cover. Do not pull the light cover to far away
from the light housing to prevent damage to
the wires.
Move the light cover to allow access to the bulb.
Figure 60-60-7
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
60-60-2
681 of 1035
60-70-1
682 of 1035
41
31
50
40
30
20
10
21
11
1
9 8 7 6
41
31
21
11
1
50
40
30
20
10
9 8 7 6
5 4 3 2
J1
5 4 3 2
J2
Controller
50
50
41
40
31
21
30
21
30
11
20
11
20
41
J1
31
1 2 3 4
J2
1 2 3 4 5
7 8 9 10
40
6 7 8
9 10
V-171/V-172
60-70-2
683 of 1035
3420
7200
3520
8550
3500
2100
6320
8110
40
4730
4470
1120
4450
8210
30
9500
3400
6510
4200
4460
6210
8800
3430
4910
6410
8510
4110
9 10
8000
9800
31
8150
1130
9700
21
4150
3010
9600
8250
1110
11
J1
50
1400
20
41
4410
9410
4640
9340
3920
J2
3300
4840
2110
4940
40
30
31
4420
9350
3910
21
4340
4430
9400
1900
3900
4830
3100
4320
4930
9110
4440
1200
9200
4820
3700
4310
4920
4360
4330
2900
9100
4810
9210
3200
4300
3600
9 10
11
50
4500
20
V-172
60-70-3
684 of 1035
41
Figure 60-70-3
P-37104
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Installation: Tighten the connector mounting bolts to 3035 in.-lb. (3,39-3,96 Nm) torque.
Unplug the two harness connectors from the controller.
2
1
1
P-66928
Installation: Tighten the controller mounting bolts to 1214 ft.-lb. (16-19 Nm) torque.
Remove the eight panel mount bolts (Item 1) [Figure 6070-2] and remove the rear panel.
60-70-4
685 of 1035
P-37102
60-71-1
686 of 1035
G
F
H
J
K
E
D
A
B
C
J3
J1
H
J
K
G
F
F
E
D
E
D
G
H
A
B
C
J2
J3
J2
J1
C
J3
J2
P-21843
P/N
J1
Orange
Orange
Green
Purple
Purple
Purple
Black
Black
J2
Green
Green
Green
Green
Green
Green
PIN
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
J
K
DESCRIPTION
P/N
CONNECTOR, METRI-PACK
5V HALL EFFECT SUPPLY
SWITCHED AHC POWER
HAND/FOOT INPUT
CAN SIGNAL HIGH AHC
CAN SIGNAL LOW AHC
CAN SHIELD AHC
AHC GROUND
AHC GROUND
CONNECTOR, METRI-PACK
OPEN
OPEN
OPEN
OPEN
TILT SPOOL SIGNAL
LIFT HANDLE SIGNAL
TILT HANDLE SIGNAL
LIFT SPOOL SIGNAL
LIFT PEDAL SIGNAL
TILT PEDAL SIGNAL
J3
Red
Red/White
Red/White
Black
Green
Red
Green
Black
Black
Black
60-71-2
687 of 1035
PIN
A
B
C
D
E
F
G
H
J
K
DESCRIPTION
CONNECTOR, METRI-PACK
TILT ACTUATOR FORWARD
UNSWITCHED AHC POWER
UNSWITCHED AHC POWER
LIFT ACTUATOR REVERSE
HANDLE LOCK POWER
LIFT ACTUATOR FORWARD
PEDAL LOCK POWER
AHC GROUND
AHC GROUND
TILT ACTUATOR REVERSE
J1
Figure 60-71-3
1
P-45283
Remove the two mounting bolts (Item 1) [Figure 60-713] from the controller.
P-21839
Figure 60-71-2
P-21843
60-71-3
688 of 1035
Description
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the
drive functions.
The drive controller is located behind the right side
access panel near the operators right foot.
The drive controller monitors the position of the left
joystick, pump swash plate angles and the output of the
wheel speed sensors.
P-66836
60-72-1
690 of 1035
Connector Identification
P-64295
60-72-2
691 of 1035
P-64296
60-72-3
692 of 1035
Figure 60-72-2
WARNING
Figure 60-72-1
P-66927
60-72-4
693 of 1035
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
60-80-1
694 of 1035
Figure 60-80-3
Testing
2
Figure 60-80-1
P-28307
1
Figure 60-80-2
P-28309
1
Connect the speed sensor test harness (Item 1) [Figure
60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
P-28306
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
60-80-2
695 of 1035
P-28302
Figure 60-80-7
1
P-26290
2
P-26288
Figure 60-80-8
P-26291
P-26289
harness
60-80-3
696 of 1035
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 60-80-11
1
1
P-26292
P-26293
Figure 60-80-12
Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
1
2
1
P-26295
Installation: The alignment pin (Item 1) [Figure 60-8012] at the bottom of the speed sensor must be installed in
the hole (Item 2) [Figure 60-80-12] in the motor carrier.
P-26294
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1
2
3
4
Red
White
Black
Blue
60-80-4
697 of 1035
B-15551B
not
INPUT
CODE
60-90-1
698 of 1035
01-16
01-17
10-16
10-17
02-16
02-17
11-05
11-06
03-09
03-10
03-11
03-14
03-22
12-21
12-22
12-23
04-09
04-14
04-15
04-21
04-22
13-05
13-06
13-07
14-02
14-03
15-02
15-03
16-05
16-06
16-07
17-05
17-06
17-07
18-05
18-06
18-07
05-09
05-10
05-11
05-14
05-15
05-21
05-22
06-10
06-11
06-13
06-15
06-18
07-10
07-11
07-15
19-02
07-21
19-03
07-22
20-03
08-10
08-11
08-15
21-02
08-21
08-22
21-03
22-02
22-03
Starter error ON
Starter error OFF
23-02
23-03
09-09
09-21
09-22
60-90-2
699 of 1035
CODE
24-02
24-03
32-57
32-58
32-59
32-60
25-02
25-03
32-61
32-62
26-02
26-03
27-02
27-03
28-02
28-03
32-63
32-64
32-65
32-66
32-67
32-68
32-69
32-70
32-71
32-75
29-02
29-03
33-23
30-28
34-04
31-28
35-02
35-03
32-04
32-23
32-31
32-32
32-33
32-34
32-35
32-36
32-37
32-38
32-39
32-40
32-41
32-49
32-50
32-51
32-52
32-53
32-54
32-55
32-56
36-48
37-02
37-03
60-90-3
700 of 1035
CODE
38-04
38-05
38-06
38-07
38-08
38-09
38-11
38-12
38-13
38-14
38-15
38-16
38-17
38-18
38-19
38-20
38-21
38-22
38-23
38-24
38-25
38-53
38-54
38-55
38-56
38-57
38-58
38-59
38-60
38-61
38-62
38-63
38-64
38-65
38-66
38-67
38-68
38-69
38-70
38-71
38-72
38-73
38-26
38-27
38-28
38-29
38-30
38-31
38-32
38-33
38-34
38-35
38-36
38-37
38-38
38-39
38-40
38-41
38-42
38-43
38-44
38-45
38-46
38-47
38-48
38-49
38-50
38-51
38-74
38-75
38-76
38-77
38-78
38-79
38-80
38-81
38-82
38-83
38-84
38-85
38-86
38-87
38-88
38-89
38-90
38-91
38-92
38-93
38-94
38-95
38-96
38-98
38-99
38-52
60-90-4
701 of 1035
CODE
39-04
40-04
44-02
44-03
Horn error ON
Horn error OFF
45-02
45-03
46-02
46-03
47-21
47-22
48-02
48-03
49-02
49-03
50-01
50-02
50-03
50-04
50-05
50-06
50-07
50-08
50-09
50-10
50-11
50-12
50-13
50-14
50-15
50-24
50-27
50-28
50-29
50-30
50-31
50-33
50-34
50-35
50-36
50-37
50-38
50-39
50-41
50-42
50-43
50-44
50-45
50-46
50-47
50-48
50-49
50-50
50-51
50-52
50-53
50-54
50-55
50-56
50-57
50-59
50-60
50-63
50-66
50-67
50-68
50-69
50-70
50-99
60-21
60-22
60-23
62-04
63-05
63-06
Short to battery
Short to ground
64-02
64-03
60-90-5
702 of 1035
CODE
65-02
65-03
65-05
65-06
65-07
66-05
66-06
74-72
74-73
75-04
75-05
75-07
75-08
75-09
75-17
75-18
75-19
75-21
75-22
75-27
75-28
75-29
75-31
75-32
75-37
75-39
75-40
75-41
75-42
75-43
75-44
75-45
75-46
75-52
75-53
75-54
75-55
75-56
75-66
75-67
75-69
75-70
75-71
75-72
75-73
75-74
75-75
75-76
75-77
75-78
75-79
75-80
75-85
75-91
75-92
75-93
75-94
75-95
75-96
75-98
76-73
77-48
78-74
60-90-6
703 of 1035
CODE
80-02
80-03
81-02
81-03
82-02
82-03
83-02
83-03
84-02
84-03
85-02
85-03
86-02
86-03
87-02
87-03
90-02
90-03
91-02
91-03
92-02
92-03
93-02
93-03
CODE
60-90-7
704 of 1035
4
B-15551G
N-18409
60-100-1
706 of 1035
4
B-15551G
N-18409
WARNING
AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS) must
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394
60-100-2
707 of 1035
WARNING
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
PROBLEM
CAUSE
2, 3, 4
60-100-3
708 of 1035
Troubleshooting Chart
Light ON
Light OFF
SEAT BAR
No. of Service
Flashes Code
Causes
PRESS TO
OPERATE
LOADER Button
is pressed.
PRESS TO
OPERATE
LOADER Button
is not pressed.
----
----
Seat Bar is
down.
11-05
11-06
Control valve
Lift, tilt and
cannot be used. traction
functions will
not operate.
1
2
3
3
17-07
17-05
17-06
17-06
1
2
16-07
16-05
16-06
15-02
15-03
Control valve
can be used.
Loader can be
Loader cannot
moved forward & be moved
backward
forward and
backward.
Loader cannot
be moved
forward and
backward.
TRACTION
4
03-09
Flashing 03-10
Continuous
----
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.
60-100-4
709 of 1035
Indicator
Light
Effect on
Operation of
Loader When
Light is OFF
60-110-1
710 of 1035
WARNING
PROBLEM
CAUSE
1, 2, 3, 4, 5
60-110-2
711 of 1035
Figure 60-110-3
Testing
Figure 60-110-1
1
1
P-4698
N-18463
Figure 60-110-4
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
1
Figure 60-110-2
1
P-4699
N-19557
N-19558
If the above test fails, there is a problem with the seat bar
sensor.
Disconnect the Sensor Tester.
60-110-3
712 of 1035
Figure 60-110-7
2
1
Figure 60-110-5
N-19383
N-19224
IMPORTANT
Figure 60-110-6
N-19219
60-110-4
713 of 1035
Figure 60-110-9
Figure 60-110-8
1
P-4703
60-110-5
714 of 1035
N-18463
Figure 60-110-11
P-4699
The BICS seat bar indicator light (Item 1) [Figure 60-11010] should illuminate.
60-110-6
715 of 1035
TRACTION LOCK
Description
The Traction Lock Control System will lock the traction
drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS).
Two speed loaders dont have a wedge block brake in the
transmission chaincase. The brakes on the two speed
loaders are incorporated into the end of the hydrostatic
motor. The traction lock inspecting is still valid to the two
speed loaders because all loaders have an rpm sensor.
For more information on the two speed brakes (See
BRAKE (TWO-SPEED) on Page 40-12-1.) or (See
HYDROSTATIC MOTOR (TWO-SPEED) on Page 30-211.) for information on the two speed hydrostatic motor.
60-120-1
716 of 1035
WARNING
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
PROBLEM
CAUSE
1, 2, 3, 4, 5, 6, 7,11,12,13
8, 9, 10, 11
KEY TO CORRECT THE CAUSE
5. To test the solenoid, the pull coil should be about 0.3 ohms and the hold coil should be about 10.9 ohms.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel RPM sensor and wiring.
12. Check the Display Panel for an error code. (See Electrical System Service Manual)
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
60-120-2
717 of 1035
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See
Fuse And Relay Location / Identification on Page 60-10-10.)
Figure 60-120-2
WARNING
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat
Company parts if repair is necessary.
2
P-68141
W-2165-0100
Remove the traction lock assembly (Item 1) [Figure 60120-2] from the chaincase.
Figure 60-110-1
Figure 60-120-3
P-4712
P-68254
P-68143
60-120-3
718 of 1035
Figure 60-120-5
IMPORTANT
2
Figure 60-120-4
P-68142
4
Inspect the guides (Item 1) [Figure 60-120-5] for wear or
damage. Replace if necessary.
If replacement is necessary, remove the center
chaincase cover. Remove the screws (Item 2) [Figure
60-120-5] and pry the center cover off.
2
1
Figure 60-120-6
P-68144
P11331
60-120-4
719 of 1035
Figure 60-120-9
P11333
P11330
INCORRECT
CORRECT
Figure 60-120-8
1
1
N-19106
P11332
60-120-5
720 of 1035
N-19105
Figure 60-120-10
To remove the traction lock guides remove the four bolts
(Item 1) [Figure 60-120-7].
P11337
60-120-6
721 of 1035
Figure 60-120-13
P-34966
4
B-15551G
60-120-7
722 of 1035
N-18409
60-130-1
724 of 1035
General
Warning
Fuel Level
System
Voltage
Engine Oil
Pressure
Attachment
Control
Device
Two Speed
Glow Plugs
Seat belt
Hydraulic
Charge
Pressure
Engine
Coolant
Temperature
Hydraulic Oil
Temperature
Air Filter
Hydraulic
Filter
60-130-2
725 of 1035
Advanced
Control
System
Figure 60-130-3
P13733
Figure 60-130-2
1 1
1
P13725
P13725
P13732
60-130-3
726 of 1035
Figure 60-130-6
3
2
1
P13735
P-21879
Figure 60-130-7
Disconnect the harness connector (Item 1) [Figure 60130-4] from the handle sensor connector.
Disconnect the harness connector (Item 2) [Figure 60130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
1
P13725
P13732
1
P13725
P13732
60-130-4
727 of 1035
Figure 60-130-10
2
3
3
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-130-10] from the loader wiring harness
connectors.
Figure 60-130-11
P13735
Figure 60-130-9
1
2
N-22783
Roll the pistol grip handle cover (Item 1) [Figure 60-13011] down.
N-17779
60-130-5
728 of 1035
Figure 60-130-14
Figure 60-130-12
2
Tape back 1/2 of Wires
P-24233
P-21699
N-22784
Figure 60-130-13
P-24234
60-130-6
729 of 1035
Figure 60-130-15
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.
Route wire (Item 1) [Figure 60-130-15] through the
casting, along side the handle sensor and into the control
lever tube.
NOTE: Do not pull the wire harness tight, allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
returns to neutral position.
Figure 60-130-16
P-21700
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
E-Terminal - Blank
P-21695
Figure 60-130-19
1
1
3
2
P13735
1
Install the wires into the connectors as listed below:
Left and Right Control Lever Switch Handle [Figure 60130-19]
1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
Figure 60-130-18
Figure 60-130-20
1
N-17772
1
2
P13735
60-130-8
731 of 1035
N-17779
Figure 60-130-22
Figure 60-130-21
P-26842
P-21804
N-18940
60-130-9
732 of 1035
Figure 60-130-25
Figure 60-130-24
2
1
P-21836
Disconnect the harness connector (Item 1) [Figure 60130-25] from the handle sensor connector.
N-17741
Disconnect the harness connector (Item 2) [Figure 60130-25] from the handle lock solenoid connector.
Figure 60-130-26
1
P-21832
60-130-10
733 of 1035
N-17742
Figure 60-130-29
Figure 60-130-27
1
1
2
1
P-24269
P-21878A
Figure 60-130-28
4
3
2
1
1
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-13030].
P-21789
60-130-11
734 of 1035
P-24270
Figure 60-130-33
P-21790
P-21938
P-21939
60-130-12
735 of 1035
B-16447
Solenoid Number
Activated
RH
HFH
Attachment
Harness
Attachment Harness
Terminal
Connector
Activated
1, 8
1, 8
2, 3
6, 7
K, A, D
1, 3
5, 7
K, A, C
1, 3
5, 7
K, E
1, 3
5, 7
K, F
1, 3
5, 7
K, G
1, 3
5, 7
K, H
--
--
Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader.
Right Side
Control Handle
Switches
B-16449
B-16448
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
60-140-1
736 of 1035
Left Side
Control Handle
Switches
xxxxxxxxx
Switch
Number
3
4
5
Hydraulic
Coupler
Front
Female
(Rod)
Front
Male
(Base)
Diverter &
Bleed
Bleed - Rear
Male & Female
High Flow
on Pump
Wiring
Number
4330
4340
4450/4480
4430/4440
4460
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 4 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 5
at the gear pump.
60-140-2
737 of 1035
S220
RIGHT HAND
17
18
1
2
8
11
9
16
P-24802
1. Front Aux.
2. Front Aux.
3. Auxiliary Detent
8. Right Ski (Up)
9. Right Ski (Down)
10. Right Blink
11. Left Blink
16. Float (Yellow in Color)
17. Future Function
18. Future Function
P-28316
LEFT HAND
19
4
20
5
12
6
7
13
15
14
P-24820
P-28317
60-141-1
738 of 1035
10
Attachment
Harness
Terminal
Activated
STD
RH
HFH
HRH
1, 6
1, 6
1, 6
1, 6
3, 5
3, 5
K, A, D
3, 4
3, 4
K, A, C
3, 4
3, 4
K, E
3, 4
3, 4
K, F
3, 4
3, 4
K, G
9
1
3, 4
Attachment Harness Connector
3, 4
K, H
Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader.
Right Side
Control Handle
Switches
9
2
1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
HRH - Loaders with High Flow and Rear Hydraulics Option.
60-141-2
739 of 1035
xxxxxxxxx
Switch
Number
Left Side
Control Handle
Switches
3
4
5
Hydraulic
Coupler
Front
Female
(Rod)
Front
Male
(Base)
Diverter &
Bleed
Bleed - Rear
Male & Female
High Flow
on Pump
Wiring
Number
4330
4340
4450/4480
4430/4440
4460
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 4 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 5
at the gear pump.
60-141-3
740 of 1035
S220
Figure 60-150-2
Figure 60-150-1
2
3
P-76450
P16119
60-150-1
742 of 1035
CALIBRATION
Actuator Testing
Description
Figure 60-160-1
P-54336
60-160-1
744 of 1035
60-160-2
Figure 60-160-2
Run Actuator Test
Pass
Fail
Fail
Loosen Actuator
Pass
Column 1
Probable Cause
Misaligned Assembly
Pin
Contamination in Spool
Fail
Column 2
Probable Cause
Actuator
End Cap / Center Spring
Wire Harness
Controller
Contamination in Spool
745 of 1035
CALIBRATION (CONTD)
CALIBRATION (CONTD)
P-24826
60-160-3
746 of 1035
CALIBRATION (CONTD)
Figure 60-160-6
Figure 60-160-4
B-16626
With the seat bar down, turn the ignition key ON (keyless
panel press RUN/ENTER) [Figure 60-160-4].
Figure 60-160-7
NOTE: Do not start the engine.
Figure 60-160-5
1
2
B-16627
B-16627
60-160-4
747 of 1035
CALIBRATION (CONTD)
Figure 60-160-8
P-45240
B-19874
P-28063
60-160-5
748 of 1035
CALIBRATION (CONTD)
Figure 60-160-12
1
P-26477A
P-26475
Figure 60-160-11
P-26480
60-160-6
749 of 1035
CALIBRATION (CONT'D)
Figure 60-160-14
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-26475
Figure 60-160-15
1
1
2
P-26480
P-45238
60-160-7
750 of 1035
Figure 60-160-13
CALIBRATION (CONT'D)
Figure 60-160-18
1
P-26477A
The Control Pattern ISO Switch (Item 1) [Figure 60-16016] will start flashing.
Figure 60-160-17
B-19873
B-19873
P-26476
P-26476
60-160-8
751 of 1035
P-45238
CALIBRATION (CONT'D)
Figure 60-160-22
75-98
1
P-26477A
Three audible beeps will sound and the error code (Item
2) (75-98) will be displayed if the operator presses the
HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure
60-160-22].
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
Figure 60-160-21
Figure 60-160-23
P-26474
P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-16023] will stop flashing, and will remain ON for the rest of
the calibration procedure.
60-160-9
752 of 1035
P-26477A
CALIBRATION (CONT'D)
Figure 60-160-25
B-19873
1
P-26482
Figure 60-160-26
P-68134
WARNING
P-64321
60-160-10
753 of 1035
CALIBRATION (CONT'D)
B-19873
Move the left joystick to the reverse position [Figure 60160-27] and check for normal reverse wheel or track
rotation.
Figure 60-160-28
60-160-11
754 of 1035
P-26483
Description
Figure 60-160-1
STEERING DRIFT COMPENSATION
[S-L10]
[S----]
[S-r10]
B-23580B
60-161-1
756 of 1035
Figure 60-160-3
3
B-15551
B-15551F2
B-15551F3
B-15551F4
P-24820B
B-15551
B-15551F8
B-15551F9
P-24802B
OR
Press the PRESS TO OPERATE LOADER button to
disengage from steering drift compensation without
saving the current setting. [donE] (Item 4) will appear in
the display (Item 2) [Figure 60-160-3] and the upper left
and upper right buttons on the left joystick will no longer
make changes to steering drift compensation. The
current settings will remain in effect until the STOP button
is pressed (Keyless Panel) or the key is turned OFF (Key
Switch Panel). The machine will revert back to the last
saved settings the next time it is started.
60-161-2
757 of 1035
Right Joystick
Left Joystick
60-170-1
758 of 1035
Figure 60-170-2
Adjustment
1
Figure 60-170-1
1
2
P-43970
60-170-2
759 of 1035
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0.050 inch. (1,27 mm)
between the jam nut and the housing with a feeler gauge
(Item 1) [Figure 60-170-2].
P-43971
Examples
Figure 60-180-2
Icon Identification
Figure 60-180-1
Press
TOOL/SETUP
SELECTION
BUTTONS
EXAMPLE
Press
LOADER FEATURES
B-16162
ICON
DESCRIPTION
Press
DISPLAY OPTIONS
Press
ADJUST CONTRAST
EXIT
11:23
0.0
UP OR DOWN
Arrow to
change contrast.
Press EXIT to
return to
previous level
menu.
NEXT
INFO
B-16163/B16164/B-16161/B-16166/B-16167
60-180-1
760 of 1035
More Examples
Clocks
Figure 60-180-3
Press . . .
TOOL/SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
Press
TOOL/SETUP
SET CLOCK
Use the keypad to set time.
Press RUN/ENTER to set clock.
Press EXIT to return to previous level menu.
Press
LOADER FEATURES
Press
ATTACHMENTS
Press . . .
TOOL/SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN/ENTER.
Press EXIT to return to previous level menu.
Press
RUN / ENTER BUTTON
on keypad
Press
VITALS
Press SELECTION ARROW to select METRIC or
ENGLISH (M/E) readouts
UP OR DOWN
Arrow to
scroll through
attachments
Press
the keypad number
of a switch to view
a description of the
attachment function
of the switch
B-16163/B16164/B-16161/B-15753A/B-15754A/B-15755A
60-180-2
761 of 1035
Languages
60-190-1
762 of 1035
B-16163
B-24288
Keypad
B-24291
OWNER PASSWORD
USER PASSWORD
B-16171
B-16171
B-24292
B-24295
B-24293
B-24296
B-24294
B-24297
60-190-2
763 of 1035
ENTER
B-24290
Enter OWNER
PASSWORD
on Keypad
then press ENTER
to Continue.
Press
UNLOCK MACHINE
Press
EXIT
Machine is now
UNLOCKED and
can be started
without using a
password.
B-16163/P-76075/P-76076/P-76076A/P-76077
60-190-3
764 of 1035
MAINTENANCE CLOCK
Figure 60-200-3
Description
The Maintenance Clock alerts the operator when the next
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-200-1
1
B-16163A
B-15551
B-15551-3A
B-15551-3B
1
P-76122
60-200-1
766 of 1035
Figure 60-200-5
Setup
Figure 60-200-4
Controller Mounting Bolts
1
P-64243
P-76109
Figure 60-200-6
The easiest way to determine if a Bobcat controller is
recent enough to add the maintenance clock is to
measure the controller mounting bolt pattern on the left
side of the loader mainframe. Controllers with a bolt
pattern measuring 5.8 inches are maintenance clock
compatible. The previous controller pattern measures 7.0
inches (not maintenance clock compatible) [Figure 60200-4].
Using the remote start tool and service PC, connect and
upgrade the Bobcat controller to version 37 or greater
software. (See SERVICE PC (LAPTOP COMPUTER) on
Page 60-150-1.)
P-76110
60-200-2
767 of 1035
Figure 60-200-9
Setup (Contd)
1
Figure 60-200-7
P-76118
Figure 60-200-10
2
P-76115
P-76113
60-200-3
768 of 1035
P-76110
Figure 60-200-13
Setup (Contd)
Figure 60-200-11
1
2
P-76112
P-76114
NOTE: The Maintenance tab (Item 1) [Figure 60-20014] will not appear when servicing loaders
equipped with the older controller.
Figure 60-200-14
Figure 60-200-12
3
4
P-76111
60-200-4
769 of 1035
Figure 60-200-17
Setup (Contd)
Figure 60-200-15
1
1
P-76110
P-76111
P-64244
Figure 60-200-16
After the maintenance clock has been activated, the first
analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-18]. If past
the interval, the number will reflect negative hours.
1
P-76111
60-200-5
770 of 1035
Figure 60-200-18
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will
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 60-200-15].
P-76117
60-200-6
771 of 1035
Inspecting
Description
Figure 60-210-1
P-76108
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) in the reverse
position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear
door.
Figure 60-210-2
2
P-69346
60-210-1
772 of 1035
P-62915
60-210-2
773 of 1035
WARNING
PROBLEM
CAUSE
Back-up alarm will not sound when the operator moves both steering
1, 2, 3, 4, 5, 6, 7
levers in the reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7
60-210-3
774 of 1035
WARNING
Troubleshooting (Joystick)
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
Back-up alarm will not sound when the operator moves joystick(s) in the 1, 2, 3, 4, 5, 6
reverse position.
Back-up alarm sounds when joystick(s) in neutral / forward position.
5, 6
60-210-4
775 of 1035
Figure 60-210-4
1
1
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.
60-210-5
776 of 1035
P-69346
2
3
P-62917
60-210-6
777 of 1035
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-40-1
CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Idle Gear And Shaft Removal And Installation. . . . . . . . . . . . 70-100-5
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Timing Gearcase Cover Removal And Installation . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . 70-100-2
ENGINE
SERVICE
70-01
778 of 1035
70-02
779 of 1035
70-03
780 of 1035
70-04
781 of 1035
ENGINE INFORMATION
Description
The S220 has a Kubota direct injected V3300 Turbo
diesel engine with a displacement of 202.5 cu.in. (3,3
L).The engine is rated at (SAE Net) 71.7 HP (53,5 Kwh)
and has an open crankcase ventilation system.
The engine has 4 cylinders and the rotation is counterclockwise (viewed from the flywheel side). It is also
equipped with an air intake heater for assisting in cold
starts. Engine block heaters are also available from
Bobcat Parts.
The engine serial number is stamped on the engine and
is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
70-10-1
782 of 1035
Fuel System
Injection Timing
When the pressure is 16.67 MPa (170 kgf/cm, 2418 PSI), the
valve seat must be fuel tightness
Valves
0.06
0.09
60 1.047 rad.
45 0.785 rad.
0.2740 to 0.2764 in. (6.960 to 6.975 mm)
0.2768 to 0.2774 in. (7.030 to 7.045 mm)
0.0022 to 0.0033 in. (0.055 to 0.085 mm)
Valve Springs
Valve Spring (Intake)
Allowable Limit
Valve Spring (Exhaust)
Allowable Limit
Setting Load/Setting Length (Intake)
Allowable Limit
Setting Load/Setting Length (Exhaust)
Allowable Limit
Tilt - Allowable Limit
Valve Tappets
Clearance Between Tappet And Guide
Allowable Limit
Tappet O.D.
70-10-2
783 of 1035
Valve Timing
Intake Valve - Open
Closed
Exhaust Valve - Open
Closed
Rocker Arm
Allowable Limit
Camshaft
Clearance Between Tappet And Guide
Allowable Limit
Tappet O.D.
Timing Gear
Timing Gear Backlash
Crank Gear - Idler Gear
Allowable Limit
Idler Gear - Cam Gear
Allowable Limit
Idle Gear - Injection Pump Gear
Allowable Limit
Allowable Limit
70-10-3
784 of 1035
Cylinder Head
Cylinder Head Surface Flatness - Allowable Limit
Compression Pressure
498 to 526 PSI / 250 RPM 3.43 to 3.63 MPa / 250 RPM 35 to
37 kgf/cm / 250 RPM
Compression Ratio
19.3
10% or less
Firing Order
1-3-4-2
Connecting Rod
Connecting Rod Alignment - Allowable Limit
Clearance Between Piston Pin And Small End Bushing
Allowable Limit
Piston Pin O.D.
Small End Busing I.D.
Cylinder Bore
Cylinder Bore I.D.
Allowable Limit
Oversized Cylinder Liner I.D.
Allowable Limit
70-10-4
785 of 1035
Crankshaft
Crankshaft Alignment - Allowable Limit
Crankpin O.D.
Crankshaft Journal O.D.
Oil Clearance Between Crankshaft Journal And
Crankshaft Bearing
Allowable Limit
Oil Clearance Between Crank Pin And Pin Bearing
Allowable Limit
Crankshaft Side Clearance
Allowable Limit
Oil Pump
Allowable Limit
Engine Oil Pressure - At Rated Speed
Allowable Limit
Allowable Limit
Relief Valve Working Pressure
Thermostat
Thermostat Valve Opening Temperature
194F (90C)
Approximately 0.3
70-10-5
786 of 1035
Head Mark 7
Head Mark 10
M5 x 0.8
3 - 4 ft.-lb.
(4 - 5 Nm)
M6 x 1.0
6 - 7 ft.-lb.
(8 - 9 Nm)
6 - 9 ft.-lb.
(8 - 12 Nm)
M8 x 1.25
6 - 9 ft.-lb.
(8 - 12 Nm)
11 - 16 ft.-lb.
(15 - 22 Nm)
18 - 25 ft.-lb.
(24 - 34 Nm)
M10 x 1.25
13 - 18 ft.-lb.
(18 - 24 Nm)
22 - 30 ft.-lb.
(30 - 41 Nm)
36 - 50 ft.-lb.
(49 - 68 Nm)
M12 x 1.25
22 - 30 ft.-lb.
(30 - 41 Nm)
40 - 54 ft.-lb.
(54 - 73 Nm)
69 - 87 ft.-lb.
(94 - 118 Nm)
M14 x 1.5
36 - 50 ft.-lb.
(49 - 68 Nm)
58 - 80 ft.-lb.
(79 - 108 Nm)
Grade
Nominal Unit
Diameter
(4)
Nm
kgfm
ft-lb.
Nm
kgfm
ft-lb.
M6
7.9 to 9.3
0.80 to 0.95
5.8 to 6.9
9.8 to 11.3
1.00 to 1.15
7.23 to 8.32
M8
17.7 to 20.6
1.8 to 2.1
13.0 to 15.2
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
M10
39.2 to 45.1
4.0 to 4.6
28.9 to 33.3
49.0 to 55.9
5.0 to 5.7
36.2 to 41.2
M12
62.8 to 72.6
6.4 to 7.4
46.3 to 53.5
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads.
tightening, be sure to check out the numbers as shown below.
Punched number
None or 4
70-10-6
787 of 1035
Prior to
Thread Size
(Dia. x Pitch)
CAUSE
1, 2, 3
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29, 54
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
4, 31, 32, 33, 34, 35, 37, 38, 39, 52
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
22, 27, 29, 30, 40, 49
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
70-10-7
788 of 1035
PROBLEM
70-10-8
789 of 1035
WARNING
N-19999P
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 70-10-9
P-66571
70-10-9
790 of 1035
Figure 70-10-12
1
P-66410A
P-66671
Figure 70-10-11
1
P-28122
P-43934
Remove the engine mount bolt (Item 1) [Figure 70-1013] at the left front engine mount.
At the right side access hole, remove all hoses (Item 1)
[Figure 70-10-11] from the hydraulic gear pump outlet
side.
70-10-10
791 of 1035
Figure 70-10-16
P-66674
Remove the engine mount bolt (Item 1) [Figure 70-1014] at the right front engine mount.
Installation: Tighten the mounting bolt 61 - 69 ft.-lb. (83 94 Nm) torque.
Figure 70-10-15
Figure 70-10-17
4
2
3
4
1
5
2
P-66675
P-66672
Disconnect the positive (+) wires (Item 1) [Figure 70-1015] from the starter.
Disconnect the wire connector (Item 2) [Figure 70-10-15]
from the engine speed sensor.
Disconnect the wire connector (Item 3) [Figure 70-10-15]
from the starter solenoid wires.
P-28123
Figure 70-10-20
1
2
P-34967
P-48356
Figure 70-10-21
3
1
P-34969
P-66673
70-10-12
793 of 1035
Figure 70-10-23
P-37375
Install the engine removal bracket (Item 1) [Figure 7010-23] on the engine.
70-10-13
794 of 1035
P-34968
13.0
(330)
2.5
(64)
1-1/2 I.S. Dia.
2-1/2 O.S. Dia.
2.5 (64)
1-1/2 Square Tubing
1/4 (4)
Thick Gusset
1.0 (25)
1.0 (25)
0.5
(12,7)
28.0
(711)
0.375
(9,5)
4.25
(108)
0.5
(12,7)
2.0 (51)
0.6875
(17,5)
9.0
(229)
45
1.0
(25)
1.75
(44,5)
1.375
(35,0)
0.66 (16,8)
4.5
(114)
8,525
(218)
1.125
(28,6)
1.125
(28,6)
1.75
(44,5)
0.775
(19,7)
(2) 2 x 2 x 1/4
Gusset
17.750
9/16
Dia. Hole (2)
MC-1799B
70-10-14
795 of 1035
2.0
(51)
4.0
(102)
Figure 70-10-25
MS1522
70-10-15
796 of 1035
Figure 70-10-28
1
1
P-37373
Figure 70-10-29
Figure 70-10-27
P-37372
P-37369
Tighten the all bolts and nuts that hold the engine
removal bracket onto the engine.
70-10-16
797 of 1035
P-37374
Figure 70-10-32
1
1
P-37385
Check all bolts that attach the engine lift brackets (Item 1)
[Figure 70-10-32] to the engine and tighten as needed.
P-37370
Figure 70-10-33
2
2
P-37384
P-37368
70-10-17
798 of 1035
Figure 70-10-35
HEAVY DUTY
ENGINE
MOUNT
Engine
Mounting
Bracket
Washer
2
Loader
Frame
Engine
Mount
4
5
Snubbing
Washer
Spacer
TS-1520
MC-1771A
70-10-18
799 of 1035
Compression -Checking
Compression
pressure
Figure 70-10-36
Factory spec.
Allowable limit
Tightening
Torque
Nozzle holder
clamp nut
17.7 to 20.6
Nm
1.8 to 2.1 kgfm
13.0 to 15.2 ft.lb.
Overflow pipe
assembly
retaining screw
9.8 to 11.3 Nm
1.0 to 1.15
kgfm
7.23 to 8.32 ft.lb.
Cylinder head
cover screw
1.6 to 2.3 Nm
0.15 to 0.23
kgfm
1.15 to 1.66 ft.lb.
Injection pipe
retaining nut
22.6 to 36.3
Nm
2.3 to 3.7 kgfm
16.6 to 26.8 ft.lb.
P-37196
70-10-19
800 of 1035
Figure 70-20-3
P-66729
Raise the lift arms and install an approved lift arm device.
(See Installing on Page 10-20-1.)
N-19803
70-20-1
802 of 1035
N-19802
Figure 70-20-5
P-48353
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
P-66730
70-20-2
803 of 1035
Figure 70-21-3
1
1
1
P-34546
P-34544
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 70-211], from the right side foot rest.
Remove the foot rest, from the loader.
Figure 70-21-2
2
P-34550
P-34545
70-21-1
804 of 1035
Figure 70-21-7
1
P-34548
P-34549
Figure 70-21-8
P-34551
Slide the hand speed control lever (Item 1) [Figure 7021-8] forward and lift, and disconnect the assembly from
the speed control cable.
P-34654
The parts that go into the pivot arm (Item 1) are the bolt
(Item 2), washers (Items 3), fiber washers (Items 4),
spacer (Item 5) and nut (Item 6) [Figure 70-21-6].
70-21-2
805 of 1035
P-34553
70-21-3
806 of 1035
Figure 70-21-12
1
3
1
P-34657
P-34655
Figure 70-21-13
Figure 70-21-11
1
P-34658
P-34656
70-21-4
807 of 1035
P-34659
70-21-5
808 of 1035
Figure 70-21-16
2
1
1
P-48353
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
70-21-6
809 of 1035
P-66730
MUFFLER
Figure 70-30-3
Figure 70-30-1
1
1
1
P-34939
Remove the three bolts and nuts (Item 1) [Figure 70-303] from the muffler mounting bracket.
P-34937
P-34938
70-30-1
810 of 1035
AIR CLEANER
Figure 70-40-3
P-34910
P-34908
Remove the left side access panel behind the lift cylinder
from the loader.
P-34909
70-40-1
812 of 1035
Figure 70-40-5
1
1
P-34913
P-34912
70-40-2
813 of 1035
Figure 70-50-3
1
P-66742A
Remove the radiator hose clamp (Item 1) [Figure 70-503] and remove the right side radiator hose from the
radiator.
P-37021
Figure 70-50-4
P-76685A
P-66742
Remove the oil cooler mount bracket (Item 1) [Figure 7050-2]. (Both sides.)
70-50-1
814 of 1035
Figure 70-50-7
P-66741
Remove the radiator hose clamp (Item 1) [Figure 70-505] and remove the left side radiator hose.
Figure 70-50-6
1
P-37027
70-50-2
815 of 1035
Figure 70-50-8
Figure 70-50-11
1
P-66742A
Remove the radiator hose clamp (Item 1) [Figure 70-5011] and remove the right side radiator hose from the
radiator.
P-37021
Figure 70-50-12
P-76685A
P-66742
Remove the oil cooler mount bracket (Item 1) [Figure 7050-10]. (Both sides.)
70-50-3
816 of 1035
Figure 70-50-15
P-76686
At the left side access hole, remove the two nuts (Item 1)
and the chute (Item 2) [Figure 70-50-15].
P-37024
Remove the radiator hose clamp (Item 1) [Figure 70-5013] and remove the left side radiator hose.
Figure 70-50-14
1
1
2
P-76687
Remove the two bolts (Item 1) and the side access panel
(Item 2) [Figure 70-50-14].
Repeat for other side.
70-50-4
817 of 1035
Figure 70-50-16
Figure 70-50-18
Figure 70-50-17
1
P-51911
Figure 70-50-19
1
P-51912
Remove the two mounting bolts (Item 1) [Figure 70-5019] from the radiator and radiator mount bracket.
Installation: Tighten the bolts to 7.5-11.5 ft.-lb. (10,115,5 Nm) torque.
70-50-5
818 of 1035
Remove the two mounting bolts (Item 1) [Figure 70-5018] from the radiator and radiator mount bracket.
P-37027
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
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10120-2.)
Remove the hydraulic/hydrostatic filter housing. (See
Housing Removal And Installation on Page 20-80-1.)
Remove the fan motor filter housing. (See Charge Filter
Housing Removal And Installation on Page 20-80-3.)
70-50-6
819 of 1035
Figure 70-50-22
2
1
4
P-51908
Disconnect the fuel fill hose (Item 1) and the vent hose
(Item 2) [Figure 70-50-22].
P-66610
Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-50-20].
Figure 70-50-21
2
P-66611
P-66621
70-50-7
820 of 1035
Figure 70-50-23
Figure 70-50-25
Figure 70-50-24
P-54418
P-66649
1
P-54419
70-50-8
821 of 1035
Figure 70-50-28
Figure 70-50-27
2
1
1
P-68126
70-50-9
822 of 1035
P-54421A
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
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10120-2.)
Remove the hydraulic/hydrostatic filter housing. (See
Housing Removal And Installation on Page 20-80-1.)
Remove the charge filter housing. (See Charge Filter
Housing Removal And Installation on Page 20-80-3.)
70-50-10
823 of 1035
Figure 70-50-31
P-76703
4
Remove the fuel fill hose (Item 1) and the vent hose (Item
2) [Figure 70-50-31].
3
P-69841
Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-50-29].
Remove the fan case drain hose (Item 3) [Figure 70-5029].
Disconnect the electrical connector (Item 4) [Figure 7050-29].
Figure 70-50-30
2
1
P-66621
70-50-11
824 of 1035
Axial Fan Removal And Installation (S/N 530713066 530740000, 530811454 - 530840000)
Figure 70-50-34
Figure 70-50-32
1
P-69670
P-69676
P-69663
70-50-12
825 of 1035
P-69842A
Figure 70-50-37
Axial Fan Removal And Installation (S/N 530713066 530740000, 530811454 - 530840000) (Contd)
Figure 70-50-36
2
1
P-69666
70-50-13
826 of 1035
Figure 70-50-39
Figure 70-50-38
2
1
P-68126
70-50-14
827 of 1035
P-69659
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
3
1
I-2003-0888
2
P-76714
70-50-15
828 of 1035
Figure 70-50-43
2
2
1
P-76704
Remove tubeline (Item 1), the tie strap (Item 2), and the
hose clamp (Item 3) [Figure 70-50-41].
1
Figure 70-50-42
P-76705
P-76703
Remove the fuel fill hose (Item 1) and the vent hose (Item
2) [Figure 70-50-42].
70-50-16
829 of 1035
Figure 70-50-44
Figure 70-50-47
P-69663
P-76710
Remove and cap the case drain hose (Item 2) and fan
inlet hose (Item 3) [Figure 70-50-45].
Remove and cap the fan outlet hose (Item 4) and the pilot
pressure hose (Item 5) [Figure 70-50-45].
Figure 70-50-46
2
2
P-76708
70-50-17
830 of 1035
Figure 70-50-50
Figure 70-50-48
P-69827A
P-69670
P-69676
70-50-18
831 of 1035
Figure 70-50-52
Figure 70-50-51
1
1
P-76699
P-69666
P-69659A
Remove and discard the two bolts (Item 1) [Figure 7050-53] and the hydraulic fan motor from the mounting
plate.
Installation: Tighten the bolts to 5-9 ft.-lb. (6,78-12,20
Nm) torque.
NOTE: Always install new bolts, nuts, cotter pins,
and rubber gasket when installing the fan
motor.
70-50-19
832 of 1035
Remove and discard the two nuts and cotter pins (Item 1)
[Figure 70-50-52].
Figure 70-50-56
Figure 70-50-54
4
2
3
1
P-76716
Remove coil mounting nut (Item 1), the coil (Item 2), and
the coil valve stem (Item 3) [Figure 70-50-56].
P-76714
Figure 70-50-55
P-76637
P-76715
70-50-20
833 of 1035
Figure 70-50-60
Figure 70-50-58
1
3
2
4
1
P-66743
Figure 70-50-59
P-76726
70-50-21
834 of 1035
P-76717
Figure 70-50-63
Figure 70-50-62
2
1
P-37151
B-22926A
Figure 70-50-64
P-37152
70-50-22
835 of 1035
P-37172
Factory spec.
74.5 to 78.5C
166.1 to
173.3F
Temperature at
which thermostat
completely opens
Factory spec.
90C
194F
70-50-23
836 of 1035
LUBRICATION SYSTEM
Figure 70-60-3
P-37127
P-37125
Figure 70-60-2
Carefully apply the adhesive evenly.
NOTE: When mounting the adhesive-applied parts,
take care to fit them to the mating parts.
Assemble the adhesive-applied parts within
ten minutes.
To avoid uneven tightening, tighten mounting
screws in diagonal order from the center.
After cleaning the oil strainer, install it.
Attach the oil pan with its central drain plug
facing toward the air suction side.
P-37126
70-60-1
838 of 1035
Install the oil strainer, using care not to damage the Oring.
3EEABAC1P089A
70-60-2
839 of 1035
Figure 70-60-6
P-37218
Factory spec.
0.04 to 0.16 mm
0.0016 to 0.0063 in.
70-60-3
840 of 1035
Clearance
between outer
rotor and pump
body
Factory spec.
0.100 to 0.184
mm
0.0039 to 0.0072
in.
Allowable
limit
0.3 mm
0.0118 in.
P-37220
Relief Valve
Figure 70-60-8
Figure 70-60-7
3EEABAC1P107A
3EEABAB1P225A
Remove the relief valve (Item 2), the spring (Item 3) and
the packing (Item 4) [Figure 70-60-8].
Install the cover and tighten the screws with the specified
torque.
Remove the cover carefully, and measure the amount of
the flattening with the scale and get the clearance.
Tightening
torque
Relief valve
68.6 to 78.4 Nm
7.0 to 8.0 kgfm
50.6 to 57.9 ft.-lb.
Factory spec.
0.025 to 0.075 mm
0.0010 to 0.0030 in.
Allowable
limit
0.225 mm
0.0089 in.
Tightening
torque
Oil pump
cover screw
7.9 to 9.3 Nm
0.80 to 0.95 kgfm
5.8 to 6.9 ft.-lb.
70-60-4
841 of 1035
3EEABAC1P053B
Remove the joint bolt (Item 1) and take off the pipe (Item
2) [Figure 70-60-9].
Remove the bolts (Item 3) and release the clamp (Item 4)
[Figure 70-60-9].
Remove the oil pipe 2 (Item 5) [Figure 70-60-9].
Before installation pour fresh engine oil through the oil
supply port of the turbocharger.
Replace the gasket with new one.
Be careful not to allow dust, dirt and other foreign matters
in the oil pipes.
NOTE: Tape or plug all openings to prevent foreign
matters from damaging the oil cavities in the
turbocharger.
70-60-5
842 of 1035
Figure 70-60-12
3EEABAC1P092A
3EEABAC1P091A
Remove the oil cooler joint bolt (Item 3) [Figure 70-6011] & [Figure 70-60-12].
Installation: Tighten the oil cooler joint bolt to 29 - 32.5
ft.-lb. (39,2 - 44,1 Nm)
70-60-6
843 of 1035
P-37150
Allowable limit
0,49 bar
0.5 kgf/cm
7 PSI
At rated speed
Factory spec.
Allowable limit
1,47 bar
1.5 kgf/cm
21.3 PSI
70-60-7
844 of 1035
FUEL SYSTEM
Figure 70-70-3
3EEABAC1P028A
Fix the fuel camshaft with open end wrench (Item 3), and
remove the governor weight mounting nut and the
governor weight (Item 4) [Figure 70-70-3].
Figure 70-70-4
3EEABAB1P217A
Remove the fuel feed pump from the injection pump unit.
Remove the governor sleeve (Item 1) [Figure 70-70-1].
Figure 70-70-2
3EEABAB1P221B
70-70-1
846 of 1035
Figure 70-70-6
3EEABAB1P223B
After removing the bearings cir-clip (Item 8) [Figure 7070-5], press out the bearings.
Attach the O-ring and the cover and tighten the cover
mounting bolts.
70-70-2
847 of 1035
Tightening
torque
Fuel camshaft
stopper
mounting
screw
7.9 to 9.3 Nm
0.80 to 0.95 kgfm
5.8 to 6.9 ft.-lb.
Governor
weight
mounting
screw
62.8 to 72.6 Nm
6.4 to 7.4 kgfm
46.3 to 53.5 ft.-lb.
Fix the fuel camshaft with lock bolts as the key way to
fuel camshaft (Item 9) [Figure 70-70-6] is rightdownward.
3EEABAB1P222B
Figure 70-70-8
3EEABAB1P078B
Unhook the start spring (Item 4) from the rack pin (Item 5)
[Figure 70-70-8] of injection pump assembly.
3EEABAC1P077A
Figure 70-70-9
3EEABAB1P205A
Slide off the governor connecting rod (Item 7) [Figure 7070-9] from the rack pin of injection pump assembly.
For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod.
Remove the governor housing mounting bolts.
70-70-3
848 of 1035
Figure 70-70-11
3EEABAC1P079A
70-70-4
849 of 1035
Governor
housing
mounting bolt
9.8 to 11.3 Nm
1.00 to 1.15 kgfm
7.23 to 8.32 ft.-lb.
Anti-rotation
nut
3.43 Nm
0.35 kgfm
2.5 ft.-lb.
3EEABAC1P078A
Figure 70-70-14
3EEABAC1P082A
3EEABAC1P080A
Pull off the governor for lever shaft (Item 1) with the extra
bolt (Dia.: 4 mm, Pitch: 0.7 mm, Length: more than 25
mm) (Item 2) [Figure 70-70-12].
Figure 70-70-13
Speed Lever
Figure 70-70-15
3EEABAC1P081A
3EEABAC1P083A
70-70-5
850 of 1035
Stop Lever
Figure 70-70-18
Governor Fork
Figure 70-70-16
3EEABAC1P086A
3EEABAC1P085A
70-70-6
851 of 1035
3EEABAC1P084A
Figure 70-70-21
Figure 70-70-19
1
1
P-66788
P-66788
1
P-37522
Remove the two mounting bolts (Item 1) [Figure 70-7022] from the fuel stop solenoid. Remove the solenoid
from the injection pump.
P-66789
70-70-7
852 of 1035
Figure 70-70-25
Figure 70-70-23
2
P-37522
2
1
Figure 70-70-26
P-37520
P-37521
Disconnect the four injection lines (Item 1) [Figure 7070-24] at the injectors.
Remove the injection lines from the loader.
70-70-8
853 of 1035
Figure 70-70-29
Figure 70-70-27
P-37526
Disconnect the starter spring hook (Item 1) [Figure 7070-27]. (Be careful to not deform the starter spring.)
Figure 70-70-28
1
1
2
P-37528
70-70-9
854 of 1035
Figure 70-70-30
Figure 70-70-33
3EEABAC1P056D
Figure 70-70-32
P-37529
Align the pin on the injection pump (Item 1) [Figure 7070-32] with the notch in the housing.
Remove the injection pump from the injection pump
housing.
3EEABAB1P078A
Unhook the start spring (Item 6), and remove the antirotation nut (Item 8) [Figure 70-70-34].
70-70-10
855 of 1035
Figure 70-70-37
3EEABAB1P224A
3EEABAC1P029B
Figure 70-70-36
3EEABAB1P205A
Slide off the governor connecting rod (Item 7) [Figure 7070-36] from the rack pin of injection pump assembly.
3EEABAB1P224B
70-70-11
856 of 1035
Figure 70-70-41
3EEABAC1P110A
Figure 70-70-42
3EEABAC1P029C
3EEABAC1P111A
Place the jig (Item 3) [Figure 70-70-41] & [Figure 70-7042] in the stop solenoid mounting hole of the injection
pump unit.
3EEABAB1P205B
Hook the governor connecting rod (Item 2) [Figure 7070-40] to the rack pin of the injection pump assembly
(Item 1) [Figure 70-70-39].
70-70-12
857 of 1035
Figure 70-70-40
Figure 70-90-45
3EEABAC1P112A
Figure 70-90-44
3EEABAC1P113A
70-70-13
858 of 1035
3EEABAC1P114A
Figure 70-90-48
3EEABAC1P117A
Figure 70-70-49
Slightly tighten the anti-rotation nut (Item 4) [Figure 7070-46] of the governor connecting rod.
Holding down the jig by hand, tighten up the anti-rotation
nut to the specified torque.
Figure 70-70-47
3EEABAC1P119A
70-70-14
859 of 1035
3EEABAC1P116A
Anti-rotation nut
Bolt
23.5 to 27.5
Nm
2.4 to 2.8
kgfm
17.4 to 20.3 ft.lb.
Nut
17.7 to 20.6
Nm
1.8 to 2.1
kgfm
13.0 to 15.2 ft.lb.
3.43 Nm
0.35 kgfm
2.5 ft.-lb.
Tightenin
g torque
70-70-15
860 of 1035
Figure 70-70-51
1
2
P-37517
Look for a timing mark on the idler gear (Item 1), if one is
not present, mark the engaged tooth (Item 2) [Figure 7070-51] with a white marking pin to aid in reassembly.
P-37116
70-70-16
861 of 1035
Place the piston of the 4th cylinder at the top dead center
in the compression stroke. Fix the flywheel with the
flywheel stopper bolt.
Figure 70-70-54
P-37532
Figure 70-70-53
Do not over tighten the lock bolts when they have come
in contact with the cam shaft.
Figure 70-70-55
1
1
P-37555
P-37533
70-70-17
862 of 1035
P-37513
Figure 70-70-58
1
P-37537
P-37534
Figure 70-70-57
P-37540
Remove the two mounting bolts (Item 1) [Figure 70-7059] and move the fuel filter, to allow clearance for the
injection pump assembly to be removed.
P-37535
70-70-18
863 of 1035
Figure 70-70-59
Install two bolts (M10 X P1.25 X L80 mm) into the two
threaded holes (Item 1) [Figure 70-70-56] in the injection
pump cam gear.
P-37539
P-37541
70-70-19
864 of 1035
Figure 70-70-64
P-37533
3
Hand tighten the injection pump gear mounting nut (Item
1) [Figure 70-70-64]
P-37616
Figure 70-70-63
1
2
1
P-37541
Install the two rear mount bolts (Item 1) [Figure 70-7065] and tighten.
P-37534
70-70-20
865 of 1035
Figure 70-70-65
Place the injection pump gear (Item 1) back into the gear
case. Align the marks of the injection pump gear (Item 2)
and the idle gear (Item 3) [Figure 70-70-62].
Figure 70-70-68
1
1
1
P-37532
P-37539
Figure 70-70-67
1
1
P-37513
Tighten the injection pump gear nut (Item 1) [Figure 7070-67] to 54 - 62 ft.-lb. (74 - 83 Nm) torque.
70-70-21
866 of 1035
Figure 70-70-69
Install the three mounting flange nuts (Item 1) [Figure
70-70-66] and finger tighten. (Two on the front side and
one on the back side of the injection pump.)
Figure 70-70-72
Figure 70-70-70
P-37516
Figure 70-70-73
P-37538
Figure 70-70-71
P-37519
2
Remove the flywheel pin (Item 1) [Figure 70-70-73] from
the engine flywheel and flywheel casting.
P-37539
70-70-22
867 of 1035
Figure 70-70-76
P-37521
Disconnect the four injection lines (Item 1) [Figure 7070-76] from the injector.
P-37538
Figure 70-70-75
2
P-37522
Disconnect the electrical connector (Item 1) [Figure 7070-77] from the fuel shutoff solenoid.
P-37520
Disconnect the four injection lines (Item 1) [Figure 7070-75] from the injection pump.
70-70-23
868 of 1035
Figure 70-70-80
P-37543
Figure 70-70-81
P-37543
Figure 70-70-79
2
P-37543
After there is fuel rise seen in the plastic tube, rotate the
engine back (clockwise) at least 90 degrees.
P-37515
Disconnect the wiring connector (Item 1) [Figure 70-7079] from the engine speed control sensor.
70-70-24
869 of 1035
P-37544
P-37542
70-70-25
870 of 1035
Figure 70-70-86
P-37579
3EEABAC1P064A
Figure 70-70-87
Installation: Install new injection nozzle oil seals.
Installation: Tighten the valve cover bolts to 14-20 in.-lb.
(1.6 to 2.3 Nm) torque.
Figure 70-70-85
1
1
1
P-37580
Remove the nozzle holder clamps (Item 1) [Figure 7070-87] from the injector nozzle.
P-37578
70-70-26
871 of 1035
Figure 70-70-90
Figure 70-70-88
3EEABAC1P012A
P-37581
Figure 70-70-89
If the measurement is not within the factory
specifications, replace the injection nozzle assembly or
repair at Denso service shop.
1
Injection
pressure
Factor
y
spec.
1st
stage
18.63 to 19.61
MPa
190 to 200 kgf/
cm
2702 to 2845
PSI
P-37583
70-70-27
872 of 1035
Figure 70-70-92
Figure 70-70-91
3EEABAC1P014A
3EEABAC1P013A
Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
cm, 2418 PSI) for 10 seconds.
If any fuel leak is found, replace the injection nozzle
assembly or repair at Denso service Shop.
Valve seat
tightness
70-70-28
873 of 1035
Factory
spec.
CYLINDER HEAD
Figure 70-80-3
Figure 70-80-1
1
2
P-37559
P-37557
Figure 70-80-2
Installation: Tighten the bolts to 17-20 ft.-lb. (24-28 Nm)
torque.
Figure 70-80-4
2
1
1
P-37558
P-37560
Factory spec.
70-80-1
874 of 1035
the
the
are
the
Figure 70-80-6
and
P-37195
Valve
clearance
Factory spec.
0.23 to 0.27 mm
0.0091 to 0.0106 in.
Valve arrangement
Adjustment cylinder
Location of piston
When No. 1 piston is
compression top dead
center
70-80-2
EX.
1st
2nd
3rd
4th
When No. 1 piston is
overlap position
875 of 1035
IN.
1st
2nd
3rd
4th
Figure 70-80-9
1
2
2
1
P-37577
Any time the timing mark (Item 1) on the fuel cam gear is
meshed with the idler gear (Item 2) [Figure 70-80-9] the
engine is on top dead center of the compression stroke
on number four cylinder.
Figure 70-80-10
P-37516
Figure 70-80-8
P-37599
Install a.375 in. (9,525 mm) bolt through the hole in the
flywheel casting (Item 1) [Figure 70-80-10].
1
2
P-37576
70-80-3
876 of 1035
Figure 70-80-11
Figure 70-80-12
P-37519
P-37158
70-80-4
877 of 1035
P-37201
Figure 70-80-15
P-37266
Cylinder head
screw
98.1 to 107.9 Nm
10.0 to 11.0 kgfm
72.3 to 79.6 ft.-lb.
70-80-5
878 of 1035
P-37228A
Figure 70-80-18
3EEABAC1P026A
Make sure to not the notch (a), (b) or (c) of cylinder head
gasket (Item 1) [Figure 70-80-16] in advance.
Notc
h of
Cylin
der
Head
Gask
et
Thickness of
cylinder head
gasket
Before
tighten
ing
After
tighten
ing
2
notche
s (a)
0.90
mm
0.0354
in.
1
notch
(b)
Withou
t notch
(c)
Part
Cod
e
Piston Heads
recessing or
protrusion from
the level of
crankcase
cylinder face.
(average of 4
pistons)
0.80
mm
0.0315
in.
1C0
200331
0
-0.07 to +0.0490
mm
-0.0028 to
+0.0019 in.
1.00
mm
0.0394
in.
0.90
mm
0.0354
in.
1C0
200360
0
+0.050 to +0.149
mm
+0.0020 to
+0.0058 in.
1.05
mm
0.0413
in.
0.95
mm
0.0374
in.
1C0
200361
0
+0.150 to +0.20
mm
+0.0059 to
+0.0078 in.
P-37203
70-80-6
879 of 1035
P-37156
Figure 70-80-21
Figure 70-80-19
P-37212
P-37204
Figure 70-80-22
P-37162
P-37118
Install the valve spring [Figure 70-80-20] with its smallpitch end downward (at the head side).
Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.
70-80-7
880 of 1035
Figure 70-80-20
P-37197
Factory spec.
0.72 to 0.90 mm
0.0283 to 0.0354 in.
Tightening
torque
Cylinder head
screw
98.1 to 107.9 Nm
10.0 to 11.0 kgfm
72.3 to 79.6 ft.-lb.
70-80-8
881 of 1035
Figure 70-80-25
A
B
C
D
E
F
G
H
I
J
K
L
C1
C2
C0.3
P-37187
70-80-9
882 of 1035
P-37188
Clearance
between
valve stem
and guide
Valve stem
O.D.
Factory
spec.
Intake
valve
0.055 to 0.085
mm
0.0022 to 0.0033
in.
Exhau
st
valve
0.055 to 0.085
mm
0.0022 to 0.0033
in.
Allowabl
e limit
0.1 mm
0.0039 in.
Factory
spec.
Intake
valve
6.960 to 6.975
mm
0.2740 to 0.2746
in.
Exhaus
t valve
6.960 to 6.975
mm
0.2740 to 0.2746
in.
Intake
valve
7.030 to 7.045
mm
0.2768 to 0.2774
in.
Exhaus
t valve
7.030 to 7.045
mm
0.2768 to 0.2774
in.
P-37138
Figure 70-80-27
Factory
spec.
P-37139
70-80-10
883 of 1035
Figure 70-80-30
P-37257
P-37168
Figure 70-80-29
(30) valve
0.262 rad.
so that the
(2.12 mm,
P-37256
70-80-11
884 of 1035
Valve Lapping
Figure 70-80-32
Valve Recessing
Figure 70-80-31
P-37214
Factory
spec.
Allowable
limit
Intake
valve
(recessing)
0.6 to 0.8 mm
(0.0236 to
0.0315 in.)
Exhaust
valve
(recessing)
0.85 to 1.05 mm
(0.0335 to
0.0413 in.)
(recessing)
1.2 mm (0.0472 in.)
70-80-12
885 of 1035
P-37213
Figure 70-80-34
Valve Spring
Figure 70-80-33
P-37254
Setting
load/
setting
length
Factory
spec.
Intake
valve
Exhaus
t valve
Allowabl
e limit
Intake
valve
Exhaus
t valve
63.547 N / 31.5
mm
6.48 kgf / 31.5 mm
14.256 lb. / 1,2401
in.
Free length
(A)
63.547 N / 31.5
mm
6.48 kgf / 31.5 mm
14.256 lb. / 1,2401
in.
Allowabl
e limit
45.864 N / 31.5
mm
4.68 kgf / 31.5 mm
10.296 lb. / 1,2401
in.
Tilt (B)
Allowabl
e limit
Intake
valve
35.1 to 35.6 mm
1.3819 to 1.4016
in.
Exhau
st
valve
35.1 to 35.6 mm
1.3819 to 1.4016
in.
Intake
valve
34.6 mm
1.3622 in.
Exhau
st
valve
34.6 mm
1.3622 in.
1.0 mm
0.039 in.
45.864 N / 31.5
mm
4.68 kgf / 31.5 mm
10.296 lb. / 1,2401
in.
70-80-13
886 of 1035
Factory
spec.
P-37255
Figure 70-80-36
Valve Tappets
Figure 70-80-35
P-37174
70-80-14
887 of 1035
Oil clearance
between
tappet and
guide
Factory
spec.
0.020 to 0.062 mm
0.0008 to 0.0024 in.
Allowable
limit
0.07 mm
0.0028 in.
Tappet O.D.
Factory
spec.
23.959 to 23.980 mm
0.9433 to 0.9411 in.
Tappet guide
I.D.
Factory
spec.
24.000 to 24.021 mm
0.9449 to 0.9457 in.
P-37202
P-37173
Factory
spec.
0.016 to 0.045 mm
0.0006 to 0.0018 in.
Allowable
limit
0.15 mm
0.0059 in.
Rocker arm
shaft O.D.
Factory
spec.
15.973 to 15.984 mm
0.6289 to 0.6293 in.
Rocker arm
I.D. for shaft
Factory
spec.
16.000 to 16.018 mm
0.6299 to 0.6306 in.
70-80-15
888 of 1035
Figure 70-90-2
P-37159
Remove the connecting rod screws (Item 1) [Figure 7090-1] from connecting rod cap.
When using the existing crank pin metal again, put tally
marks on the crank pin metal and the connecting rod in
order to keep their positioning.
Fit the crank pin metal in place.
70-90-1
890 of 1035
Connecting rod
screw
78.5 to 83.4 Nm
8.0 to 8.5 kgfm
57.9 to 61.5 ft.-lb.
Turn the flywheel and set a piston to the top dead center.
Figure 70-90-3
P-37208
Figure 70-90-4
P-37233
Figure 70-90-5
Oil Ring
Gap
70-90-2
891 of 1035
When inserting the piston into the cylinder, face the mark
(Item 3) [Figure 70-90-4] on the connecting rod to the
injection pump.
07909-31661
Application:
Application
Range:
Figure 70-90-6
P-37189
(Press fit)
A
B
C
D
E
F
a
b
C1
C2
70-90-3
892 of 1035
Figure 70-90-9
P-37160
Figure 70-90-10
P-37210
P-37161
P-37211
When installing the oil ring onto the piston, place the
expander joint (Item 10) on the opposite side of the oil
ring gap (Item 11) [Figure 70-90-9].
The end faces of the oil ring are plated with hard chrome.
In putting the piston into the cylinder, be careful not to get
the oil ring scratched by the cylinder. Use the piston ring
fitter to tighten up the oil ring. If the rings planted is
scratched, it may get stuck on the cylinder wall, causing a
serious trouble.
NOTE: Mark the same number on the connecting rod
and the piston so as not to change the
combination.
70-90-4
893 of 1035
Figure 70-90-8
Figure 70-90-12
P-37178
Factory
spec.
30.000 to 30.013 mm
1.1811 to 1.1816 in.
Allowable
limit
30.05 mm
1.1831 in.
70-90-5
894 of 1035
Factory
spec.
0.020 to 0.040 mm
0.0008 to 0.0016 in.
Allowable
limit
0.15 mm
0.0059 in.
Factory
spec.
30.006 to 30.011 mm
1.1813 to 1.1815 in.
Small end
bushing I.D.
Factory
spec.
30.031 to 30.046 mm
1.1823 to 1.1829 in.
P-37253
Figure 70-90-15
Figure 70-90-13
P-37215
P-37179
Figure 70-90-14
Allowable limit
P-37142
Compression
ring 1
0.05 to 0.07 mm
0.0020 to 0.0028 in.
Compression
ring 2
0.093 to 0.120 mm
0.0037 to 0.0047 in.
Oil Ring
0.020 to 0.060 mm
0.0008 to 0.0023 in.
Compression
ring 1
0.15 mm
0.0059 in.
Compression
ring 2
0.20 mm
0.0079 in.
Oil ring
0.15 mm
0.0059 in.
70-90-6
895 of 1035
P-37180
Insert the piston ring into the lower part of the liner (the
least worn out part) with the piston.
Measure the ring gap with a feeler gauge [Figure 70-9016].
If the gap exceeds the allowable limit, replace the piston
ring.
Compression
ring 1, 2
Oil Ring
Factory spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
Factory spec.
0.25 to 0.45 mm
0.0098 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
70-90-7
896 of 1035
Figure 70-90-19
P-37164
Figure 70-90-18
Oversize
(+ 0.5 mm) Spec.
98.500 to 98.522 mm
3.8780 to 3.8788 in.
Maximum wear
Allowable limit
98.65 mm
3.8839 in.
Finishing
P-37163
Factory spec.
98.000 to 98.022 mm
3.8582 to 3.8591 in.
Allowable limit
98.15 mm
3.8642 in.
Part Code
Marking
Piston
1C050-21910
05 OS
1C020-21090
05 OS
70-90-8
897 of 1035
Part Name
P-37169
Figure 70-90-20
(See Piston And Connecting Rod - Servicing on Page 7090-3.) for the code to order this tool [Figure 70-90-20]
from the engine manufacturer.
B-3686
Allowable limit
0.05 mm
0.0020 in.
70-90-9
898 of 1035
P-37181
Figure 70-90-23
P-37130
70-90-10
899 of 1035
Bearing Case
Cover mounting
screw
23.5 to 27.5 Nm
2.4 to 2.8 kgfm
17.4 to 20.3 ft.-lb.
P-37131
Figure 70-90-26
3EEABAC1P096A
P-37231
Crankshaft
screw
Tightening
torque
255.0 to 274.6 Nm
26.0 to 28.0 kgfm
188.1 to 202.5 ft.-lb.
Crankcase 2
mounting screw
49.0 to 55.9 Nm
5.0 to 5.7 kgfm
36.2 to 41.3 ft.-lb.
Flywheel
housing screw
77.5 to 90.2 Nm
7.9 to 9.2 kgfm
57.1 to 66.5 ft.-lb.
Figure 70-90-27
Figure 70-90-25
P-37133
3EEABAB1P108B
70-90-11
900 of 1035
Figure 70-90-29
P-37136
Crankcase 2
mounting screw
49.0 to 55.9 Nm
5.0 to 5.7 kgfm
36.2 to 41.3 ft.-lb.
P-37137
70-90-12
901 of 1035
P-37134
Reassemble the thrust bearing (Item 2) [Figure 70-9031], with the oil groove facing outside, into both side of
the fourth main bearing case.
Apply oil to the bearing case screws and tighten them to
the specified torque.
Figure 70-90-31
Tightening
torque
Main bearing
case screw
137.3 to 147.1 Nm
14.0 to 15.0 kgfm
101.3 to 108.5 ft.-lb.
3EEABAC1P097A
Figure 70-90-32
3EEABAC1P098A
Figure 70-90-33
3EEABAC1P099A
70-90-13
902 of 1035
Figure 70-90-35
P-37114
P-37115
70-90-14
903 of 1035
Rmax = 12.5 S
94.5 to 95.0 mm (3.7205 to 3.7402 in.)
40 mm (1.5748 in.)
30 mm (1.1811 in.)
12 mm (0.4724 in.)
7.9 to 8.1 mm (0.3110 to 0.3189 in.)
20 mm (0.0787 in.)
130 mm (5.1181 in.)
99.4 to 99.6 mm (3.9134 to 3.9213 in.)
95.05 to 95.20 mm (3.7421 to 3.7480 in.)
3 mm dia. (0.1181 in. dia.)
15 mm (0.5905 in.)
10 mm (0.3937 in.)
90 mm (3.5433 in.)
115 mm (4.5275 in.)
16.9 to 17.1 mm (0.6654 to 0.6732 in.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 3.0 mm (0.1181 in.)
Chamfer 5.0 mm (0.1969 in.)
Chamfer 0.2 mm (0.0079 in.)
Chamfer 0.3 mm (0.0118 in.
Figure 70-90-34
3EEABAC1P115A
A
B
C
D
E
F
G
H
I
J
K
70-90-15
904 of 1035
Oversize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Thrust bearing
1 02
1C010-23951
020 OS
Thrust bearing
2 02
1C010-23971
020 OS
Thrust bearing
1 04
1C010-23961
040 OS
Thrust
bearing1 04
1C010-23981
040 OS
Figure 70-90-37
0.4 mm
0.016 in.
3EEABAC1P105A
Oversize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
29.20 to 29.25 mm
1.1496 to 1.1515 in.
29.40 to 29.45 mm
1.1574 to 1.1594 in.
Dimension B
169.1 to 169.15 mm
6.6575 to 6.6594 in.
169.2 to 169.25 mm
6.6614 to 6.6634 in.
Dimension C
(0.8-S)
The crankshaft journal must be fine-finished to higher than
Figure 70-90-38
Figure 70-90-39
P-37144
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
P-37182
70-90-16
905 of 1035
Allowable limit
0.02 mm
0.00079 in.
Figure 70-90-41
P-37147
ID
Color
Connecting rod
Large-end in.
dia.
Clas
s
Part
code
Blue
56.01 to 56.02
mm
2.2051 to 2.2055
in.
1C02022311
1.496 to 1.501
mm
0.0589 to 0.0591
in.
Yellow
or No
Color
56.00 to 56.01
mm
2.2047 to 2.2051
in.
1C02022331
1.491 to 1.496
mm
0.0587 to 0.0589
in.
Factory spec.
52.977 to 52.990 mm
2.0857 to 2.0862 in.
Oil clearance
between crank
pin and crank
pin bearing
Factory spec.
0.018 to 0.051 mm
0.0007 to 0.0020 in.
Allowable limit
0.20 mm
0.0079 in.
70-90-17
906 of 1035
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
1C020-22960
020 US
0.4 mm
0.016 in.
1C020-22970
040 US
P-37145
Figure 70-90-43
P-37149
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
Dimension B
Dimension C
52.777 to 52.790 mm
2.0778 to 2.0783 in.
52.577 to 52.590 mm
2.0700 to 2.0705 in.
(0.8-S)
The crank pin must be fine-finished to higher than
Factory spec.
74.977 to 74.990 mm
2.9518 to 2.9548 in.
Oil clearance
between
crankshaft
journal and
crankshaft
bearing
Factory spec.
0.018 to 0.062 mm
0.0007 to 0.0020 in.
Allowable limit
0.20 mm
0.0079 in.
70-90-18
907 of 1035
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankshaft
bearing 02
1C020-23910
020 US
0.4 mm
0.016 in.
Crankshaft
bearing 04
1C020-22920
040 US
Crankshaft Sleeve
Figure 70-90-45
Figure 70-90-44
P-37148
P-37269
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
Dimension B
Dimension C
74.777 to 74.790 mm
2.9440 to 2.9445 in.
74.577 to 74.590 mm
2.9361 to 2.9366 in.
(0.8-S)
The crank pin must be fine-finished to higher than
70-90-19
908 of 1035
Remove the used crankshaft sleeve (Item 1) [Figure 7090-45] using a special-use puller set (Code No.: 0791609032).
Figure 70-100-3
3EEABAC1P094A
3EEABAC1P089A
70-100-1
910 of 1035
3EEABAC1P093A
3EEABAC1P100A
Set a dial indicator (lever type) with its tip on the gear
tooth [Figure 70-100-4].
Move the gear to measure the backlash, holding its
mating gear.
If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
If the oil clearance is proper, replace the gear.
Crank gear
Idle gear
Factory
spec.
0.049 to 0.193 mm
0.0019 to 0.0076 in.
Allowable
limit
0.22 mm
0.0087 in.
Factory
spec.
0.049 to 0.189 mm
0.0019 to 0.0074 in.
Allowable
limit
0.22 mm
0.0087 in.
Idle gear 2
Factory
spec.
0.030 to 0.165 mm
0.0012 to 0.0065 in.
Injection
pump gear
Allowable
limit
0.22 mm
0.0087 in.
Idle gear
Cam gear
70-100-2
911 of 1035
Alignment
Camshaft - Servicing
Figure 70-100-6
Side Clearance
Figure 70-100-5
P-37175
Factory
spec.
0.07 to 0.22 mm
0.0028 to 0.0087 in.
Allowable
limit
0.03 mm
0.0118 in.
70-100-3
912 of 1035
Camshaft
alignment
Allowable
limit
0.01 mm
0.00039 in.
3EEABAC1P102A
Figure 70-100-8
3EEABAC1P103A
P-37176
Figure 70-100-9
Factory
spec.
Allowable
limit
Intake
valve
37.63 mm
1.4815 in.
Exhaust
valve
38.96 mm
1.5338 in.
Intake
valve
37.13 mm
1.4618 in.
Exhaust
valve
38.46 mm
1.5141 in.
P-37140
70-100-4
913 of 1035
Oil clearance
of camshaft
journal
Factory
spec.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
Allowable
limit
0.15 mm
0.0059 in.
Camshaft
journal O.D.
Factory
spec.
45.934 to 45.950 mm
1.8084 to 1.8091 in.
Camshaft
journal I.D.
Factory
spec.
46.000 to 46.025 mm
1.8110 to 1.8120 in.
3EEABAC1P095A
Remove three set screws of the idle gear and draw out
the idle gear 1, 2 [Figure 70-100-10].
Remove two set screws of the camshaft stopper and
draw out the camshaft.
Set the crankshaft at the top dead center of No. 1 and 4
cylinder and the camshaft key to the top position and
align the marks of idle gear and cam gear and crank gear
to assemble them [Figure 70-100-10].
70-100-5
914 of 1035
Side Clearance
Figure 70-100-12
Figure 70-100-11
3EEABAC1P101A
P-37189
70-100-6
915 of 1035
Factory
spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable
limit
0.9 mm
0.0354 in.
Set a dial indicator with its tip on the idle gear [Figure 70100-12].
Figure 70-100-14
P-37141
70-100-7
916 of 1035
Clearance
between idle
gear shaft
and idle gear
bushing
Factory
spec.
0.050 to 0.091 mm
0.0020 to 0.0036 in.
Allowable
limit
0.10 mm
0.0039 in.
Idle gear
bushing I.D.
Factory
spec.
45.025 to 45.050 mm
1.7726 to 1.7736 in.
Idle gear
shaft O.D.
Factory
spec.
44.959 to 44.945 mm
1.7700 to 1.7707 in.
3EEABAC1P104A
P-37177
70-100-8
917 of 1035
TURBOCHARGER
Testing
Description
Figure 70-110-1
Spin turbine by hand. Turbine should spin freely.
If the turbine is damaged replace the turbocharger.
Check the oil tubelines for leaks.
2
1
P-66824
internal
components
are
not
70-110-1
918 of 1035
TURBOCHARGER (CONTD)
Figure 70-110-3
WARNING
W-2257-1196
Figure 70-110-2
P-66823
2
1
2
P-66824
2
Remove the bolts (Item 1) and tubeline [Figure 70-1102].
2
1
1
1
3
P-66822
70-110-2
919 of 1035
Figure 70-120-1
The ring gear (Item 1) [Figure 70-120-2] on the flywheel
is an interference fit. Heat the ring gear enough to
expand it and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth
fit.
1
P-37364
P-37365
70-120-1
920 of 1035
Figure 70-120-4
1
1
1
1
P-37367
1
P-37366
70-120-2
921 of 1035
SAFETY &
MAINTENANCE
80-130-1
80-130-4
80-130-2
80-130-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . .
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-50-1
80-50-1
80-50-4
80-50-2
80-50-3
80-50-1
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
HVAC
80-70-1
80-70-2
80-70-2
80-70-1
80-70-3
80-01
922 of 1035
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-10-2
80-10-3
80-10-4
80-10-2
80-10-7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . 80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-12
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . 80-30-19
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . . . . . . . . 80-30-2
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . 80-30-20
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Insufficient Cooling Although Air Flow And Compressor Operation Are
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
The Compressor Does Not Operate At All, Or Operates Improperly 80-30-1
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
80-02
923 of 1035
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-3.) As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, lowpressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-3.) Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
80-10-2
925 of 1035
The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 80-10-3.) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-3.)
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
Compressor
Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3
Receiver Drier
Status of R134a
High Pressure Gas
80-10-3
926 of 1035
Figure 80-10-3
Components
Figure 80-10-1
N-22134
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-103] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.
P-39456
Figure 80-10-4
NOTE: The
A/C
system
(Compressor)
is
recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2
N-22206
80-10-4
927 of 1035
Figure 80-10-7
Components (Cont'd)
Figure 80-10-5
3
N-22087
Figure 80-10-6
Figure 80-10-8
N-22150
N-22100
80-10-5
928 of 1035
Evaporator Coil: The evaporator coil (Item 1) [Figure 8010-7] cools and dehumidifies the air before it enters the
cab.
N-22121
Figure 80-10-10
Components (Cont'd)
Figure 80-10-9
1
1
P-66919
3
Heater Valve: The heater valve (Item 1) [Figure 80-1010] is used to control the amount of engine coolant that
flows to the heater coil.
Figure 80-10-11
N-22261
A/C Switch: The rocker switch (Item 3) [Figure 80-109] will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure
80-10-9] controls the Heat Valve from fully Off to fully
On. This can be used in conjunction with the A/C for
defrost of the windows and temperature control.
N-22134
80-10-6
929 of 1035
WARNING
Safety Equipment
Figure 80-10-12
P16398
WARNING
P16399
80-10-7
930 of 1035
Figure 80-10-13
REGULAR MAINTENANCE
Figure 80-20-3
1
1
P-28820
P-28819
Remove the filter cover and filter (Item 1) [Figure 80-202] from the loader.
1
P-37674
Remove the two retaining knobs (Item 1) [Figure 80-204] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-20-4]
from the loader cab.
80-20-1
932 of 1035
P-28818
Figure 80-20-7
Figure 80-20-5
1
1
P-37883
P-37675
Remove the recirculating air filter (Item 1) [Figure 80-205] from the rear of the cab.
Figure 80-20-6
Figure 80-20-8
P-37677
P-39458
80-20-2
933 of 1035
Figure 80-20-11
Condenser
Figure 80-20-9
3
1
1
P-39462
2
P-39459
P-39460
80-20-3
934 of 1035
Machine Dealer:
Customer:
15 Minutes
30 Minutes
Notes
15 Minutes
30 Minutes
Notes
80-20-4
935 of 1035
1
1
P-39463
1
P-39464
With air or water clean the heater coil (Item 1) and the
evaporator coil (Item 2) [Figure 80-20-13].
80-20-5
936 of 1035
TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause
1. Blown fuse.
2. Broken wiring or bad
connection.
3. Fan motor malfunction.
4. Resistor malfunction.
5. Fan motor switch
malfunction.
Inspection
Solution
Replace Motor.
Replace Resistor.
Replace Fan Switch.
Inspection
Solution
2. Air leak.
Replace thermostat.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
Possible Cause
Inspection
2. Excessive refrigerant.
Solution
Repair any leaks and recharge
the refrigerant to the correct
level.
Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
Possible Cause
1. Loose drive belt.
2. Internal compressor
malfunction.
Inspection
The belt is vibrating or oscillating.
The compressor is locked up and the belt slips.
Solution
Adjust tension.
Replace compressor.
Clutch slips.
Clutch slips.
Clutch slips.
6. Open coil.
80-30-1
938 of 1035
Repair.
Check operation.
Possible Cause
1. Evaporator inlet obstruction.
TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
1. Expansion valve
opens too far.
2. Defective
compressor.
Low pressure side
Too low.
1. Low refrigerant
charge.
2. Clogged or closed
expansion valve.
3. Restriction between
drier and expansion
valve.
4. Thermostat
malfunction.
5. Restriction in
receiver drier.
High pressure side
Too high.
1. Poor condenser
performance.
2. Excessive
refrigerant.
Inspection
The low pressure side pressure normally becomes too
high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
Frost is present on the suction hose.
Replace compressor.
4. Air in system.
5. Restriction in drier,
condenser or high
pressure line.
80-30-2
939 of 1035
Solution
Adjust thermostats
temperature setting or probe
placement or replace
thermostat.
Replace receiver drier.
Possible Cause
TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)
Possible Cause
Inspection
Replace compressor.
Solution
80-30-3
940 of 1035
TROUBLESHOOTING (CONT'D)
Troubleshooting Tree
B-21491
80-30-4
941 of 1035
TROUBLESHOOTING (CONT'D)
B-21491A
80-30-5
942 of 1035
TROUBLESHOOTING (CONT'D)
B-21492
80-30-6
943 of 1035
TROUBLESHOOTING (CONT'D)
B-21493
80-30-7
944 of 1035
TROUBLESHOOTING (CONT'D)
Temperature / Pressure Chart
NORMAL CONDENSER RANGE
TEMP F.
PSIG
TEMP F.
PSIG
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
45
50
55
60
65
70
75
80
85
90
91
92
15.69
17.04
18.43
19.87
21.35
22.88
24.47
26.10
27.79
29.52
31.32
33.17
35.07
37.03
39.05
40.09
45.48
51.27
57.47
64.10
71.19
78.75
86.80
95.40
104.40
106.30
108.20
93
94
95
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
135
140
145
150
155
160
165
170
110.20
112.10
114.10
124.30
128.50
132.90
137.30
141.90
146.50
151.30
156.10
161.10
166.10
171.30
176.60
182.00
187.50
193.10
198.90
213.70
229.40
245.80
263.00
281.10
300.10
320.10
340.80
80-30-8
945 of 1035
TROUBLESHOOTING (CONT'D)
Temperature / Pressure Chart (Contd)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient
Temperature=90 degrees F.
90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system. Check with MCC for system specifications.
80-30-9
946 of 1035
TROUBLESHOOTING (CONT'D)
Figure 80-30-2
N-22411
80-30-10
947 of 1035
TROUBLESHOOTING (CONT'D)
HVAC Repair And Leaks
Figure 80-30-3
N-22134
80-30-11
948 of 1035
TROUBLESHOOTING (CONTD)
Figure 80-30-6
Electrical System
Check to see if the compressor clutch is engaging.
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN (Standard Panel)
OR press the RUN/ENTER Button (Deluxe Panel),
without starting the loader.
Figure 80-30-4
1
P-43640
N-22284
P-39465
N-22287
TROUBLESHOOTING (CONTD)
Figure 80-30-10
Figure 80-30-8
1
1
N-22256
N-22255
Figure 80-30-11
Figure 80-30-9
N-22257
N-22255
80-30-13
950 of 1035
TROUBLESHOOTING (CONTD)
Figure 80-30-14
1
1
P-68448
Figure 80-30-13
P-68118
80-30-14
951 of 1035
N-22257
TROUBLESHOOTING (CONTD)
Figure 80-30-16
Figure 80-30-15
1
1
P-68444
1
N-22261
80-30-15
952 of 1035
P-68118
TROUBLESHOOTING (CONTD)
Figure 80-30-20
Figure 80-30-18
H
B
M
L
N-22288
Figure 80-30-19
N-22265
80-30-16
953 of 1035
N-22262
TROUBLESHOOTING (CONTD)
Figure 80-30-21
N-22264
N-22262
Figure 80-30-22
Figure 80-30-24
N-22289
N-22263
TROUBLESHOOTING (CONTD)
Figure 80-30-27
N-22175
Figure 80-30-28
N-22290
Figure 80-30-26
N-22290
N-22201
80-30-18
955 of 1035
TROUBLESHOOTING (CONTD)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-29
Figure 80-30-31
3
1
N-22175
Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1, then turn the
temperature control (Item 3) [Figure 80-30-31] to the
High A/C position, with the loader ignition switch OFF.
Raise the operator cab. (See Raising on Page 10-30-1.)
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-601.)
Start the loader and run at high idle, for ten minutes.
Figure 80-30-32
B
N-22290
1
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-30] should be
around 39K Ohms.
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-30-30] should be
around 49K Ohms.
P-68119
N-22284
TROUBLESHOOTING (CONTD)
Figure 80-30-34
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 80-30-34], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate. Place a mark on
the loader shaft.
N-22284
Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1 and turn the
temperature control (Item 3) [Figure 80-30-33] to the
High A/C position, with the loader ignition switch OFF.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
80-30-20
957 of 1035
P-68117
Figure 80-40-2
Refrigerant Identification
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-40-1
N-23026
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
80-40-1
958 of 1035
Figure 80-40-4
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
N-22291
Figure 80-40-3
Use an approved recovery/charging unit [Figure 80-404] to evacuate the system.
Figure 80-40-5
2
1
N-22293
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
N-22380
80-40-2
959 of 1035
N-22292
N-22381
80-40-3
960 of 1035
Figure 80-40-9
Figure 80-40-10
N-22382
Check to see that the hand valves (Item 1) [Figure 8040-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be
recovered by an approved A/C reclamation procedure.
(See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
P-39475
80-40-4
961 of 1035
Figure 80-40-13
1
1
N-22385
Figure 80-40-12
Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
Stop the vacuum pump and close the Iso-valve on the
vacuum pump.
Close both hand valves on the manifold gauge set and
remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
N-22382
80-40-5
962 of 1035
P-39476
Figure 80-40-16
N-22284
Start loader engine, with the remote start switch, and run
at medium speed.
Figure 80-40-15
P-39478
80-40-6
963 of 1035
P-39477
COMPRESSOR
Belt Adjustment
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Figure 80-50-1
Raise the operator cab. (See Raising on Page 10-30-1.)
At the right side of the loader, remove the access cover
(Item 1) [Figure 80-50-1].
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-402.)
Figure 80-50-3
P-48199
80-50-1
964 of 1035
COMPRESSOR (CONT'D)
Oil
Figure 80-50-6
Figure 80-50-4
N-22243
P-39456
Figure 80-50-5
Whenever the refrigerant has leaked from the system.
Whenever the refrigerant is suddenly released from the
cooling cycle.
Whenever any oil-related problems occur in the cooling
cycle.
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
1
If the A/C compressor is changed, no oil should be added
to the system, because the compressor comes factory
filled with oil.
P-39542
80-50-2
965 of 1035
COMPRESSOR (CONT'D)
Figure 80-50-8
Oil Check
The compressor oil should be checked as follows when
oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,
charge the system. (See Reclamation And Charging With
Recovery / Charging Unit on Page 80-40-2.)
Figure 80-50-9
Figure 80-50-7
1
N-22246
N-22245
80-50-3
966 of 1035
P-16534A
COMPRESSOR (CONT'D)
Figure 80-50-11
Figure 80-50-10
N-22244
N-22245
Installation: Tighten the armature bolt to 8-10 ft.-lb. (1214 Nm) torque.
1
2
N-22277
80-50-4
967 of 1035
COMPRESSOR (CONTD)
Figure 80-50-15
1.32
1
1.32
1.32
N-22279
2
1
N-22275
N-22280
N-22278
80-50-5
968 of 1035
COMPRESSOR (CONTD)
Figure 80-50-19
N-22370
N-22283
N-22371
N-22369
80-50-6
969 of 1035
Figure 80-50-20
COMPRESSOR (CONTD)
Figure 80-50-23
N-22372
Remove the three coil mount bolts (Item 1) [Figure 8050-23] from the compressor.
N-22373
N-22374
N-22375
80-50-7
970 of 1035
CONDENSER
Figure 80-60-3
Lift the rear of the condenser, and pull toward the rear of
the loader [Figure 80-60-3].
Remove the condenser from the loader.
Figure 80-60-4
1
P-39459
P-39460
P-39459
RECEIVER / DRIER
Figure 80-70-2
Figure 80-70-1
N-22134
Note the flow direction on the drier (Item 1) [Figure 8070-2] for proper installation.
N-22134
N-22135
Figure 80-70-6
Figure 80-70-4
N-22256
N-22205
1
N-22206
This will cause the A/C system to shut down, saving the
compressor.
The Pressure Relief Valve is a secondary protection
device in the A/C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
80-70-2
975 of 1035
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
N-22166
80-70-3
976 of 1035
Figure 80-80-2
N-22119
P-66918
Disconnect the thermostat connector (Item 3) [Figure 8080-1] from the loader wiring harness.
80-80-1
978 of 1035
Figure 80-80-3
Figure 80-80-5
1
1
P-66921
80-80-2
979 of 1035
N-22126
THERMOSTAT
Figure 80-90-3
N-22072
A
B
P-39480
Figure 80-90-2
N-22072
Blue
White
Black
P-39481
80-90-1
980 of 1035
Figure 80-90-4
EXPANSION VALVE
Figure 80-100-2
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
N-22073A
Remove the two evaporator fittings (Item 1) [Figure 80100-2] from the expansion valve.
Figure 80-100-1
N-22150
80-100-1
982 of 1035
Installation: Tighten the two evaporator fittings to 22 ft.lb. (29,8 Nm) torque.
N-22074A
N-22085
80-100-2
983 of 1035
EVAPORATOR
Figure 80-110-3
Figure 80-110-1
Figure 80-110-4
1
N-22073
Figure 80-110-2
N-22076
Remove the two retaining clips (Item 1) [Figure 80-1104] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
80-110-1
984 of 1035
EVAPORATOR (CONT'D)
Removal And Installation (Cont'd)
Figure 80-110-5
N-22078
80-110-2
985 of 1035
HEATER COIL
Figure 80-120-2
1
N-22086
2
2
Figure 80-120-3
P-66921
N-22087
Remove the two retaining clips (Item 1) [Figure 80-1203] that connect the evaporator coil, to the heater coil.
80-120-1
986 of 1035
P-69829
N-22090
80-120-2
987 of 1035
Figure 80-120-7
Figure 80-120-6
2
2
P-69829
P-66921
Figure 80-120-8
N-22094
80-120-3
988 of 1035
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
BLOWER FAN
Figure 80-130-3
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
NOTE: The blower fan assembly can be removed
from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is remove here for photo clarity.
Figure 80-130-1
P-39553
Remove the two flange mount bolts (Item 1) [Figure 80130-3] from the evaporator/heater unit.
P-39550
1
Remove the cover (Item 1) [Figure 80-130-1] from the
evaporator/heater unit.
Figure 80-130-2
P-39554
P-68120
Remove the two flange mount bolts (Item 1) [Figure 80130-2] from the evaporator/heater unit.
80-130-1
990 of 1035
Figure 80-130-4
Figure 80-130-7
Figure 80-130-5
2
1
1
N-22102
P-68120A
1
Remove the blower motor mount.
Remove the blower motor assembly from the housing.
Figure 80-130-8
P-39556
1
2
N-22107
80-130-2
991 of 1035
Figure 80-130-11
N-22110
Figure 80-130-12
N-22112
N-22109
Inspect the end rings and blower wheel covers for wear
and replace as needed [Figure 80-130-10].
80-130-3
992 of 1035
N-22108
Connector Identification
Figure 80-130-15
Figure 80-130-13
P-68118
N-22111
Number on Connector
A
B
C
D
Wire Color
Orange
Red
Yellow
Black
N-22116
80-130-4
993 of 1035
HEATER VALVE
Figure 80-140-2
Figure 80-140-1
P-66922
1
3
P-66921
80-140-1
994 of 1035
Figure 80-140-5
Figure 80-140-3
1
1
P-66925
Remove the three mounting bolts (Item 1) [Figure 80140-5] from the heater valve mount plate.
P-66923
Figure 80-140-6
Figure 80-140-4
1
1
2
2
P-66926
P-66924
Remove the two mounting bolts (Item 1) [Figure 80-1406] from the heater valve.
80-140-2
995 of 1035
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD
TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD
ITEMS MAY VARY.
SPEC-01
996 of 1035
Dimensions are given for loader equipped with standard tires and 74 inch Construction & Industrial bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
97
156.6 in.
(3978 mm)
41.1
122.4 in.
(3109 mm)
21.6 in.
(549 mm)
25
8.5 in.
(216 mm)
30
48.3 in.
(1227 mm)
114.5 in.
(2908 mm)
142.9 in.
(3630 mm)
B-22281E
74 in.
(1880 mm)
84.2 in.
(2139 mm)
B-22281
60.3 in.
(1532 mm)
B-22282
72 in.
(1829 mm)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
SPEC-10-1
998 of 1035
95.4 in.
(2423 mm)
80.9 in.
(2055 mm)
Operating Weight
Push Force
Travel Speed
- Single Speed Loader
- Two-Speed Loader (Opt.) Low/High
Controls
Loader Hydraulics
- Lift and Tilt
Pressure relieved through quick couplers. Push couplers in, hold for 5 seconds.
Engine
Hand lever speed control; key-type starter switch and shutdown (or optional
keyless start).
Starting Aid
Service Brake
Secondary Brake
Engine
Make / Model
Fuel / Cooling
Diesel / Liquid
1225 - 1275
2525 - 2575
Number of Cylinders
Displacement
Bore / Stroke
Lubrication
Crankcase Ventilation
Air Cleaner
Open Breathing
Dry replaceable paper cartridge with safety element
Ignition
Diesel - Compression
Engine Coolant
Starting Aid
SPEC-10-2
999 of 1035
Vehicle Steering
Filter (Hydraulic)
Hydraulic Cylinders
Bore Diameter: Lift Cylinder (2)
Tilt Cylinder (2)
Rod Diameter: Lift Cylinder (2)
Tilt Cylinder (2)
Stroke: Lift Cylinder (2)
Tilt Cylinder (2)
Control Valve
Fluid Lines
Fluid Type
3.9 Seconds
2.5 Seconds
2.8 Seconds
2.1 Seconds
Electrical
Alternator
Battery
Starter
Instrumentation
SPEC-10-3
1000 of 1035
Axle Size
Wheel Bolts
Capacities
Fuel
23 Gal. (87,1 L)
12 qt. (11,4 L)
Hydraulic/Hydrostatic Reservoir
Hydraulic/Hydrostatic System
13 Gal. (49,2 L)
Chaincase Reservoir
Tires
Standard
Hippo
33 x 15.5 - 16.5
Bulky Hulk
33 x 15.5 - 16.5
Recommended Pressure
Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
SPEC-10-4
1001 of 1035
in.-lb.
(Nm)
x
x
x
x
x
x
x
x
x
x
x
x
ft.-lb.
(Nm)
THREAD SIZE
SAE GRADE 5
SAE GRADE 8
0.250
80 - 90
(9 - 10)
110 - 120
(13 - 14)
0.3125
180 - 200
(21 - 23)
215 - 240
(24 - 27)
0.375
25 - 28
(34 - 38)
35 - 40
(48 - 54)
0.4375
40 - 45
(54 - 61)
60 - 65
(82 - 88)
0.500
65 - 70
(88 - 95)
90 - 100
(125 - 135)
0.5625
90 - 100
(125 - 135)
125 - 140
(170 - 190)
0.625
125 - 140
(170 - 190)
175 - 190
(240 - 190)
0.750
220 - 245
(300 - 330)
300 - 330
(410 - 450)
0.875
330 - 360
(450 - 490)
475 - 525
(645 - 710)
1.000
475 - 525
(645 - 710)
725 - 800
(985 - 1085)
1.125
650 - 720
(880 - 975)
1050 - 1175
(1425 - 1600)
1.250
900 - 1000
(1200 - 1360)
1475 - 1625
(2000 - 2200)
1.375
1200 - 1350
(1630 - 1830)
2000 - 2200
(2720 - 2980)
1.500
1500 - 1650
(2040 - 2240)
2600 - 2850
(3530 - 3870)
1.625
2000 - 2800
(2720 - 2980)
3450 - 3800
(4680 - 5150)
1.750
2500 - 2750
(3390 - 3730)
4300 - 4800
(5830 - 6500)
1.875
3150 - 3500
(4270 - 4750)
5500 - 6100
(7450 - 8300)
2.000
3800 - 4200
(5150 - 5700)
6500 - 7200
(8800 - 9800)
SPEC-20-1
1002 of 1035
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Bobcat that have
zinc phosphate coating are specified by the letter H following the part number.
10.9
12.9
M4
M5
M6
M7
M8
18 - 19 ft.-lb.
(24 - 26 Nm)
M10
32 - 35 ft.-lb.
(43 - 47 Nm)
M12
55 - 60 ft.-lb.
(75 - 85 Nm)
78 - 85 ft.-lb.
(105 - 115 Nm)
91 - 110 ft.-lb.
(91 - 110 Nm)
M14
100 - 90 ft.-lb.
(125 - 140 Nm)
M16
M18
M20
M22
M24
M27
M30
M33
M36
SPEC-20-2
1003 of 1035
Thread Size
(Dia.)
Figure SPEC-30-2
O-ring Face Seal Tightening Torque
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
x
Tubeline
Outside
Diameter
x
x
x
Thread Size
*
TORQUE
ft.-lb.
(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)
1-7/16 - 12
118 (160)
1-1/4
1-11/16 - 12
154 (209)
1-1/2
2 - 12
163 (221)
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].
SPEC-30-1
1004 of 1035
Figure SPEC-30-3
Nut
Washer
Nut
Washer
O-ring
O-ring
A-1852
SPEC-30-2
1005 of 1035
TS-1619
x
x
Thread Size
TORQUE
ft.-lb.
(Nm)
1/4
7/16 - 20
13 (18)
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)
1-5/16 - 12
118 (160)
1-1/4
1-5/8 - 12
154 (209)
1-1/2
1-7/8 - 12
163 (221)
2-1/2 - 12
252 (342)
SPEC-30-3
1006 of 1035
Figure SPEC-30-7
Port Seal and O-ring Boss
Tightening Torque
Nut Seals
To Fitting
Nut Seals
To Port
x
x
Thread Size
TORQUE
ft.-lb.
(Nm)
7/16 - 20
13 18)
9/16 - 18
22 (30)
3/4 -1 6
40 (54)
7/8 - 14
60 (81)
1-1/16 - 12
84 (114)
1-3/16 - 12
98 (133)
1-5/16 - 12
118 (160)
1-7/16 - 12
154 (209)
1-5/8 - 12
163 (221)
P-13008
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
SPEC-30-4
1007 of 1035
WARNING
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
SPEC-40-1
1008 of 1035
CONVERSIONS
SPEC-50-1
1010 of 1035
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 1
7 February 2006
Bobcat Loader
S220
6904154 (11-05)
PUT IN
REVISION DECRIPTION
Cover
10-70
10-120
Cover
10-70
10-120
Revised Logo
Revised Text
Revised Text
20-01
20-40
20-01
Revised Text
Revised Text
20-41
20-50
20-60
20-41
20-50
20-61
20-70
20-61
20-70
Revised Text
Revised Text
20-71
20-71
Revised Text
30-10
30-30
30-10
30-30
Revised Text
Revised Text
40-30
40-30
Revised Text
50-01
50-31
50-01
50-31
Revised Text
Revised Text
ELECTRICAL SCHEMATICS
(Printed October 2005)
60-50
ELECTRICAL SCHEMATICS
(Printed February 2006)
60-50
Revised Text
60-160
60-160
Revised Text
20-40
20-60
Revised Text
Revised Text
Revised Text
Printed in U.S.A.
1012 of 1035
PUT IN
REVISION DECRIPTION
70-01
70-21
70-50
70-70
70-01
70-21
70-50
70-70
Revised Text
Revised Text
Revised Text
Revised Text
80-10
80-30
80-120
80-10
80-30
80-120
Revised Text
Revised Text
Revised Text
SPEC-01
SPEC-30
SPEC-40
SPEC-01
SPEC-30
SPEC-40
Revised Text
Revised Text
Revised Text
TAKE OUT
1013 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 2
6 April 2006
Bobcat Loader
S220
6904154 (11-05)
S220 Service Manual (P/N 6904154) Dated (3-06) contains updated service information which
replaces the previous S220 Service Manual (P/N 6904154) Dated (11-05)
.
.
Printed in U.S.A.
1014 of 1035
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
1015 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 3
14 September 2006
Bobcat Loader
S220
6904154 (9-06)
Printed in U.S.A.
1016 of 1035
1017 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 4
2 October 2006
Bobcat Loader
S220
6904154 (10-06)
Printed in U.S.A.
1018 of 1035
1019 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 5
17 July 2007
Bobcat Loader
S220
6904154 (7-07)
COVER
ALPHABETICAL INDEX
FOREWORD
10-01
10-20
10-30
10-40
10-60
10-61 ADDED
10-70
10-80
10-90
10-100
10-120
10-130
10-141
10-160
10-180
10-200
20-01
20-40
20-41
20-50
20-60
20-70
20-71
20-80
20-120
Printed in U.S.A.
1020 of 1035
60-150
60-180 ADDED
60-190 ADDED
60-200 ADDED
60-210 ADDED
70-01
70-10
70-50
80-50
80-70
SPEC-10
1021 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 6
8 August 2007
Bobcat Loader
S220
6904154 (8-07)
Printed in U.S.A.
1022 of 1035
1023 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 7
16 August 2007
Bobcat Loader
S220
6904154 (8-07)
Printed in U.S.A.
1024 of 1035
1025 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 8
17 September 2007
Bobcat Loader
S220
6904154 (9-07)
Printed in U.S.A.
1026 of 1035
1027 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 9
12 November 2007
Bobcat Loader
S220
6904154 (11-07)
Printed in U.S.A.
1028 of 1035
1029 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 10
10 December 2007
Bobcat Loader
S220
6904154 (12-07)
Printed in U.S.A.
1030 of 1035
1031 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 11
14 January 2008
Bobcat Loader
S220
6904154 (1-08)
Printed in U.S.A.
1032 of 1035
1033 of 1035
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
S220 - 12
3 March 2009
Bobcat Loader
S220
6904154 (3-09)
Printed in U.S.A.
1034 of 1035
1035 of 1035