pdf-bobcat-s175-s185-service-repair-manual-sn-525011001-525111001-525211001-525311001-and-above

Service Manual S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above INCLUDES HIGH FLOW

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6902732 (2-06)

Printed in U.S.A.

© Bobcat Company 2006

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

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

Never service the Bobcat SkidSteer Loader without instructions.

WRONG

B-15734

Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

CORRECT

CORRECT

B-15535

Use the correct procedure to lift or lower operator cab.

B-15524

Cleaning and maintenance are required daily.

WRONG

WRONG

B-15732

B-15525

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-15733

B-15523 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.

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.

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. MSW07-0805

ALPHABETICAL INDEX ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL .............. 60-01 AIR CLEANER .................................................... 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONING SERVICE.............................. 80-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR ........................................................ 60-01 BATTERY ............................................................... 60-01 BASIC TROUBLESHOOTING ................................80-01 BICS™ SYSTEM .................................................... 60-01 BOBCAT CONTROLLER ....................................60-01 BOB-TACH .............................................. 10-01, 50-01 BRAKE .................................................................... 40-01 BUCKET POSITION VALVE ............................... 20-01 CALIBRATION ........................................................ 60-01 CHAINCASE ........................................................... 40-01 CHARGE PRESSURE ............................................ 30-01 COMPONENTS ...................................................... 80-01 COMPRESSOR ...................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE ............................................... 50-01 CONTROL HANDLE (SJC)..................................... 50-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL ... 50-01 CONTROL PANEL.................................................. 50-01 CONTROL PANEL (SJC) ....................................... 50-01 CONTROL PEDALS ............................................... 50-01 CONTROL PEDALS (ACS) .................................... 50-01 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) ..................................................................... 50-01 CONVERSIONS ............................................SPEC-01 COOLING FAN ....................................................... 70-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (POWER BOB-TACH) ......................... 20-01 CYLINDER (TILT) ................................................ 20-01 DIAGNOSTICS SERVICE CODES ..................... 60-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ELECTRICAL/HYRAULIC CONTROLS REF.......... 60-01 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 ENGINE ................................................................. 70-01 ENGINE COMPONENTS AND TESTING .............. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM ......................... 10-01 ENGINE SPECIFICATIONS ..........................SPEC-01 ENGINE SPEED CONTROL .................................. 70-01 EVAPORATOR ....................................................... 80-01 EVAPORATOR/HEATER UNIT .............................. 80-01 EXPANSION VALVE .............................................. 80-01

FAN GEARBOX.......................................................10-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01 FLYWHEEL AND HOUSING ............................... 70-01 FLYWHEEL RPM SENSOR ....................................60-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01 FUEL SYSTEM........................................................10-01 FUEL TANK .............................................................50-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES .........................................................80-01 HEATER COIL.........................................................80-01 HEATER/AC FAN ....................................................80-01 HEATER VALVE .....................................................80-01 HIGH FLOW VALVE................................................20-01 HYDRAULIC CONNECTION SPECS. .............. SPEC-01 HYDRAULIC CONTROL VALVE.............................20-01 HYDRAULIC FILTER HOUSING.............................20-01 HYDRAULIC FLUID SPECIFICATIONS ........... SPEC-01 HYDRAULIC FLUID RESERVOIR ..........................20-01 HYDRAULIC/HYDROSTATIC SYSTEM .................10-01 HYDRAULIC PUMP ................................................20-01 HYDRAULIC PUMP (HIGH FLOW).........................20-01 HYDRAULIC PUMP (HIGH FLOW) (SJC)...............20-01 HYDARULIC PUMP (SJC) ......................................20-01 HYDRAULIC SYSTEM INFORMATION ..................20-01 HYDROSTATIC MOTOR .................................... 30-01 HYDROSTATIC MOTOR CARRIER .......................30-01 HYDROSTATIC MOTOR CARRIER (SJC) .............30-01 HYDROSTATIC PUMP ....................................... 30-01 HYDROSTATIC SYSTEM INFORMATION .........30-01 INSTRUMENT PANEL ............................................60-01 LIFT ARMS ..............................................................50-01 LIFT ARM BY-PASS CONTROL VALVE ............ 20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01 LIFTING AND BLOCKING THE LOADER...............10-01 LIGHTS ................................................................60-01 LOADER SPECIFICATIONS ............................. SPEC-01 LUBRICATING THE LOADER ................................10-01 MAIN RELIEF VALVE .............................................20-01 MUFFLER................................................................70-01 OIL COOLER...........................................................30-01 OPERATOR CAB .........................................10-01, 50-01 OPERATOR SEAT ..................................................50-01 OPERATOR SEAT (SUSPENSION) .......................50-01 POWER BOB-TACH ................................10-01, 50-01 POWER BOB-TACH BLOCK ..................................20-01 PRESSURE RELIEF VALVE...................................80-01 PRESSURE SWITCH..............................................80-01

ALPHABETICAL INDEX (CONT’D) RADIATOR ............................................................. 70-01 REAR AUXILIARY DIVERTER VALVE ...................20-01 REAR DOOR ...................................................... 50-01 REAR GRILL ...........................................................50-01 RECEIVER/DRIER ..................................................80-01 RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) ....................................... 70-01 REGULAR MAINTENANCE ................................... 80-01 REMOTE START ................................................ 10-01 RPM SENSOR ....................................................70-01 SAFETY...................................................................80-01 SEAT BAR ...............................................................50-01 SEAT BAR SENSOR...............................................60-01 SERVICE PC (LAPTOP COMPUTER)....................60-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER............................. 10-01 SPEED SENSOR ................................................... 60-01 STARTER ................................................................60-01 SYSTEM CHARGING AND RECLAMATION ......... 80-01 SYSTEM TROUBLESHOOTING CHART ...............80-01 TEMPERATURE/PRESSURE................................ 80-01 THERMOSTAT ....................................................... 80-01 TIRE MAINTENANCE .............................................10-01 TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01 TOWING THE LOADER ..........................................10-01 TRACTION LOCK....................................................60-01 TRANSPORTING THE BOBCAT LOADER ............10-01 TROUBLESHOOTING.............................................70-01 TURBOCHARGER ..................................................70-01

SAFETY & MAINTENANCE

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

HYDRAULIC SYSTEM

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM

DRIVE SYSTEM

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

ENGINE SERVICE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC

SPECIFICATIONS

SPECIFICATIONS

I

S175, S185 Bobcat Loader Service Manual

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: 1. Check lift arm support device, replace if damaged. (Stored Position)

9. The parking brake function correctly.

2. Check that ROPS mounting hardware is tightened and is Bobcat approved.

10. Enclosure door latches must open and close freely.

3. The seat belt must be correctly installed, functional and in good condition.

11. Bob-Tach wedges and linkages must function correctly and be in good condition.

4. The seat bar must be correctly adjusted, clean and lubricated.

12. Safety treads must be in good condition.

5. Check lift arm support device; replace if damaged.

13. Check for correct function of indicator lamps (Optional on some models).

6. Machine signs must be legible and in the correct location.

14. Check hydraulic fluid level, engine oil level and fuel supply.

7. Steering levers and foot pedals must return to neutral.

15. Inspect for fuel, hydraulic fluid leaks.

8. Check for correct function of the work lights

16. Lubricate the loader.

II

must

oil

or


17. Check the condition of the battery and cables.

22. Operate the loader and check all functions.

18. Inspect the air cleaner for damage or leaks. Check the condition of the element.

23. Check for any field modification not completed.

19. Check the electrical charging system.

24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.

20. Check tires for wear and pressure.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

21. Inspect for loose or broken parts or connections.

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.

III


IV


SAFETY INSTRUCTIONS

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

•

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

•

The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

•

Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

•

An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

•

The AEM Safety Manual delivered with the machine gives general safety information.

•

The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

•

The Skid-Steer Loader Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Skid-Steer Loader. The course is available in English and Spanish versions.

•

Service Safety Training Courses are available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com. They provide information for safe and correct service procedures.

•

The Skid-Steer Loader Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.

WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when 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

WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death. W-2044-1285

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. I-2019-0284

SI SSL-0206 SM

V


SAFETY INSTRUCTIONS (CONT’D) The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.

Call Before You Dig 1-888-258-0808 When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0206 SM VI


SAFETY INSTRUCTIONS (CONT’D)

•

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

•

Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Fire Prevention The machine and attachments have components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Figure 1

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential hazard. The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. •

Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

•

The operator cab, engine compartment, and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

•

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

•

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

•

Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.

•

Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

•

Stop the engine and let it cool before adding fuel. NO SMOKING!

•

Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].

SI SSL-0206 SM

VII


VIII


SERIAL NUMBER LOCATION

Engine Serial Number

Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Figure 3

Loader Serial Number Figure 2

P-48387

The engine serial number is in the location shown [Figure 3].

P-31846

The loader serial number plate is located on the outside of the loader frame [Figure 2]. Explanation of loader Serial Number: XXXX Model 1.-Model/ Engine Combination

XXXXX Model 2.-Production Sequence (Series)

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the loader is produced.

IX


DELIVERY REPORT Figure 4

B-16315

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 4].

X


BOBCAT LOADER IDENTIFICATION FRONT LIGHTS

OPERATOR SEAT WITH SEAT BELT

SEAT BAR REAR AUXILIARY QUICK COUPLERS

GRAB HANDLES STEERING LEVER TILT CYLINDER

STABILIZER ROD

† BUCKET

FRONT AUXILIARY QUICK COUPLERS

BUCKET STEPS

SAFETY TREAD

zOPERATOR CAB (ROPS & FOPS)

REAR WINDOW LIFT ARM LINK REAR GRILL

LIFT ARM LIFT CYLINDER

TAIL LIGHT

LIFT ARM SUPPORT DEVICE REAR LIGHT

REAR DOOR

* TIRES B-16604 B-16605

OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) * TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your Bobcat dealer for available tires. † BUCKET - Several different buckets and other attachments are available for the Bobcat loader. z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). XI


XII



SAFETY AND MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1


BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . Replacing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . .

10-90-1 10-90-2 10-90-1 10-90-2

10-110-1 10-110-1 10-110-1 10-110-2

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Removing Oil From The Chaincase. . . . . . . . . . . . . . . . . 10-130-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . .

10-100-1 10-100-1 10-100-2 10-100-1 10-100-2

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . .

10-120-1 10-120-3 10-120-1 10-120-1 10-120-1

DRIVE SYSTEM

ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE

SPECIFICATIONS

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1 Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . 10-20-2 LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . 10-160-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Continued On Next Page

10-01


SAFETY AND MAINTENANCE (CONT’D) OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . .

10-30-1 10-30-1 10-30-3 10-30-2 10-30-1

POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-151-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1 REMOTE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-170-1 10-170-1 10-170-1 10-170-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

10-02


LIFTING AND BLOCKING THE LOADER

Figure 10-10-2

Figure 10-10-1

N-18877 B-7023A

Put the floor jack under the front of the loader [Figure 1010-2]. Lift the front of the loader and put jackstands under the axle tubes [Figure 10-10-2].

WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals 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.

NOTE: Make sure the jackstands do not touch the tires. Make sure tires clear floor or any obstacles. Figure 10-10-3

W-2003-0199

Procedure Always park the loader on a level surface.

WARNING P-31849

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

Put the floor jack under the rear of the loader [Figure 1010-3]. Lift the rear of the loader and install jackstands [Figure 10-10-3].

10-10-1


10-10-2


Figure 10-20-2

LIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device

1

WARNING

P-34556

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-31857

WARNING

The operator must be in the operator's seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is installed.

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death. W-2271-1197

Figure 10-20-1

Start the engine, and raise the lift arms all the way up. Have a second person install the lift arm support device (Item 1) [Figure 10-20-2] over the rod of one of the lift cylinders. The lift arm support device must be tight against the cylinder rod. The tabs of the lift arm support device must be under the cylinder as shown (Inset) [Figure 10-20-2].

1

P-31849

P-31842

Put jackstands under the rear corners of the loader frame (Inset) [Figure 10-20-1]. Remove the lift arm support device (Item 1) [Figure 1020-1] from storage position.

10-20-1


LIFT ARM SUPPORT DEVICE (CONT’D) Installing Lift Arm Support Device (Cont’d) Figure 10-20-3

1

P-31856

Lower the lift arms slowly until the lift arm support device is held between the lift arms and lift cylinder [Figure 1020-3]. Removing Lift Arm Support Device The operator must be in the operator's seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is removed and the lift arms are lowered all the way. Start the engine, raise the lift arms all the way up. Have a second person remove the lift arm support device. Lower the lift arms all the way and stop the engine. Return the lift arm support device to storage position and secure with clamping knobs. Remove the jackstands.

10-20-2


OPERATOR CAB

Raising The Operator Cab

Description

Figure 10-30-1

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 roll over protection. ROPS/FOPS - Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. Level I - Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services. Level II - Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

P-31849

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 Installing Lift Arm Support Device on Page 10-20-1.) Install jackstands under the rear of the loader frame [Figure 10-30-1]. Figure 10-30-2

P10564

P10563

Remove the nut and plate (both sides) at the front corners of the operator cab [Figure 10-30-2].

10-30-1


OPERATOR CAB (CONT'D)

Lowering The Operator Cab

Raising The Operator Cab (Cont’d)

Figure 10-30-4

WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

N-20120

W-2069-1299

Figure 10-30-3 P-31859

Always stop the engine before raising or lowering the cab. NOTE: Make sure seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab. Pull down on the bottom of the operator cab until it stops at the latching mechanism [Figure 10-30-4]. P-31858

Release the latching mechanism (Inset) [Figure 10-30-4] and pull the cab all the way down.

Lift on the grab handle and bottom of the operator cab slowly until the cab is all the way up and the latching mechanism engages [Figure 10-30-3].

Figure 10-30-5

Advanced Hand Controls (AHC) and Advanced Control System (ACS)

P10563

P10564

P10563

Install the plates and nuts [Figure 10-30-5] (both sides). Tighten the nuts to 40-50 ft.-lb. (54-68 N•m) torque.

10-30-2


Figure 10-30-8

OPERATOR CAB (CONT’D) Emergency Exit Figure 10-30-6

N-20171

Front Door (If Equipped) P0660

The front opening on the operator cab and rear window provide exits. Rear Window (If Equipped) Pull on the tag on the top of the rear window to remove the rubber cord [Figure 10-30-6]. Figure 10-30-7

NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [Figure 10-30-8]. NOTE: If the loader has a Special Application Door Kit installed, the window of the front door is NOT an emergency exit. Pull the plastic loop at the top of the window in the front door to remove the rubber cord [Figure 10-30-8]. Figure 10-30-9

x N-18495 P-24472

Push the rear window out of the rear of the operator cab. Exit through the rear of the operator cab [Figure 10-307].

Push the window out with your foot [Figure 10-30-9] at any corner of the window. Exit through the front door.

10-30-3


10-30-4


Figure 10-40-2

TRANSPORTING THE BOBCAT LOADER Procedure

WARNING P-24480

P-24785

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury. W-2058-0494

Figure 10-40-1

P-31829

1 P-31912

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure 1040-1].

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [Figure 10-40-2]. •

Lower the bucket or attachment to the floor.

•

Stop the engine.

•

Engage the parking brake.

•

Install chains at the front and rear loader tie down positions (Inset) [Figure 10-40-2].

•

Fasten each end of the chain to the transport vehicle.

10-40-1


Be sure the transport and towing vehicles are of adequate size and capacity (See LOADER SPECIFICATIONS on Page SPEC-10-1.), for weight of loader.) The rear of the trailer must be blocked or supported (Item 1)[Figure 10-40-1] when loading or unloading the loader to prevent the front end of the trailer from raising up.

10-40-2


TOWING THE LOADER Procedure Because of the design of the loader, there is not a recommended towing procedure. •

The loader can be lifted onto a transport vehicle.

•

The loader can be skidded a short distance to move for service (EXAMPLE: Move onto a transport vehicle.) without damage to the hydrostatic system. (The tires/tracks will not turn.) There might be slight wear to the tires/tracks when the loader is skidded. The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the loader. (See LOADER SPECIFICATIONS on Page SPEC-10-1.)

10-50-1


10-50-2


Figure 10-60-2

REMOTE START Procedure

WARNING AVOID INJURY OR DEATH With the 7-pin connector plugged into the loader and Remote Start Key Switch in the OFF position, the loader can still be started from the operator panel inside the cab. Placing the key switch of the remote start tool in the run position disconnects the operator panel key switch from the start circuit. If the service technician will be working the engine area it is important to remove the operator panel keys. W-2357-0899

1

P-24651

Figure 10-60-3

Figure 10-60-1

1

1

P-24653 P16115

Lift and block the loader. (See Procedure on Page 10-101.)

The tool listed will be need to do the following procedure: Raise the lift arms (if required by the procedure) and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

MEL1563 - Remote Start Tool Kit The remote start (Item 1) [Figure 10-60-1] is required when the operator cab is in the raised position for service and the service technician needs to turn the key switch on or start the engine. Example: Control Handle: linkage neutral adjustment.

Raise the operator cab (if required by the procedure). (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Remove the plug (Item 1) [Figure 10-60-2] or disconnect the attachment control harness (Item 1) [Figure 10-60-3] if connected.

10-60-1


REMOTE START (CONT'D) Procedure (Cont'd) Figure 10-60-4

1

Figure 10-60-6

P-24652

Connect the remote start tool to the engine harness connector (Item 1) [Figure 10-60-4]. NOTE: The key switch on the right-hand side operator panel must be in the off position or the Remote Start Kit will not operate.

3

Figure 10-60-5

2

1

P16118

The traction lock switch (Item 1) [Figure 10-60-6] is used to turn traction lock on or off. Push the switch to the override position. The switch will illuminate to indicate traction lock OVERRIDE, in this position the wheels are able to turn.

1

The maximum flow/variable flow switch (Item 2) [Figure 10-60-6] is used to activate the auxiliary hydraulics. Pressing the switch once will activate variable flow. Pressing the switch again will activate maximum flow. The switch will illuminate to indicate which flow rate is active. Pressing the switch a third time will turn the flow OFF. The switch is used when checking pressures and flow rate.

P16116

The remote start tool (Item 1) [Figure 10-60-5] has three rocker switches.

The auxiliary pressure release (Item 3) [Figure 10-60-6] is used to release hydraulic pressure to the right hand auxiliary and/or rear auxiliary couplers ONLY. NOTE: With the engine running; pushing and holding the pressure release switch will cause the engine to stop in three seconds. To relieve the pressure; continue to press the switch after the engine has stopped.

10-60-2


REMOTE START (CONT'D) Procedure (Cont'd) Figure 10-60-7

P-34661

Push the couplers on the front auxiliary block toward the block and hold for five seconds to release the front auxiliary pressure [Figure 10-60-7].

10-60-3


10-60-4


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

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when 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 W-2003-0903 death. SERVICE SCHEDULE

HOURS

ITEM

SERVICE REQUIRED

Engine Oil Engine Air Filter and Air System

Check the oil level and add oil as needed. Check display panel. Service only when required. Check for leaks and damaged components. Clean debris from oil cooler, radiator & grill. Check coolant level COLDand add premixed coolant as needed. Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on sidewall of tire. Check the condition of seat belt. Check the seat bar and control interlocks for correct operation. Clean dirt and debris from moving parts. Clean or replace seat belt retractors as needed. Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn. Check for correct operation of all indicators and lights. Check the fastening bolts, washers and nuts. Check the condition of the cab. Lubricate with multi-purpose lithium based grease.

Engine Cooling System Tires Seat Belt, Seat Bar, Control Interlocks and Seat Belt Retractors Safety Signs and Safety Treads Indicators & Lights Operator Cab Lift Arms, Cylinders, Bob-Tach Pivot Pins and Wedges Fuel Filter Heater Filters Bobcat Interlock Control System (BICS™) Hydraulic Fluid, Hoses and Tubelines Final Drive Trans. (Chaincase), Foot Pedals or Hand Controls and Steering Levers Wheel Nuts

8-10

50

100

■

250

■

■

500 1000

Remove the trapped water. Clean or replace filters as needed during heating/cooling season. Check the four (4) BICS™ indicator lights and functions are activated. See details in this Manual. Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed. Check oil level. Check for correct operation. Repair or adjust as needed. Check for correct operation. Repair or adjust as needed. Check for loose wheel nuts and tighten to correct torque. (See

TIRE

❏

MAINTENANCE on Page 10-170-1.) Parking Brake Spark Arrestor Muffler Battery Steering Lever Pivots Engine/Hydrostatic Drive Belt Fan Drive Gearbox Alternator Belt Engine Oil and Filter Fuel Filter Bobcat Interlock Control System (BICS™)

Check operation. Clean the spark chamber. Check cables, connections and electrolyte level. Add distilled water as needed. Grease two fittings. Check for wear or damage. Adjust as needed. Check gear lube level. Add as needed. Check belt tension and adjust as needed. Replace oil and filter. Use CD or better grade oil and Bobcat filter. Replace the filter element. Check the function of the lift arm by-pass control

Hydraulic Reservoir Breather Cap

Replace the reservoir breather cap. Replace the filter element. Replace the fluid Replace the fluid Replace the filters

Hyd./Hydro. Filter Hydraulic Reservoir Final Drive Trans. (Chaincase) Case Drain Filters ❏ * ● ^ ■

*

^

●

Check wheel nut torque every 8 hours for the first 24 hours. Inspect the new belt after first 50 hours. Replace filter element after the first 50 hours and when the transmission warning light comes ON. First oil and filter change must occur at 50 hours; 250 hours thereafter. Or every 12 months.

10-70-1


10-70-2


AIR CLEANER SERVICE

Replacing Filter Element(s)

Checking

OUTER FILTER

Figure 10-80-1

Figure 10-80-3

1

1

P-21769

P-31836

It is important to change the air filter element only when the Air Cleaner icon in the right panel is ON (Item 1) [Figure 10-80-1] and you hear three beeps from the alarm.

Remove the wing nut (Item 1) [Figure 10-80-3] and remove the dust cover. Figure 10-80-4

Replace the inner filter every third time the outer filter is replaced or as indicated on Contents Page 70-01. Figure 10-80-2

1

1

2

P-31837

Remove the wing nut (Item 1) [Figure 10-80-4] from the outer filter element and the outer filter element. N-18409

Press and hold the LIGHT Button (Item 1) [Figure 10-802] for two seconds. 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].

10-80-1


AIR CLEANER SERVICE (CONT’D)

INNER FILTER

Replacing Filter Element(s) (Cont’d)

Figure 10-80-6

Figure 10-80-5

1

P-31838 P-31837

Only replace the inner filter element under the following conditions:

NOTE: Be sure all sealing surfaces are clean. Install the new filter element and washer. Tighten the wing nut. NOTE: Be sure sealing washer is in place on each wing nut [Figure 10-80-4].

•

Replace the inner filter element every third time the outer filter is replaced.

•

After the outer element has been replaced, start the engine and run at full RPM. If the HOURMETER / CODE DISPLAY shows [01-17] (Air Filter Plugged), replace the inner filter element.

Install the dust cover and tighten the wing nut. Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight.

Remove the inner filter wing nut [Figure 10-80-6]. Remove the inner filter (Item 1) [Figure 10-80-6]. Install a new filter and tighten the wing nut.

10-80-2


ENGINE COOLING SYSTEM

IMPORTANT

Cleaning The Cooling System

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

WARNING Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used. W-2019-1285

To much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

Figure 10-90-1

I-2124-0497

Figure 10-90-2

P-45101

Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the rear door and remove the rear grill. (See Removal And Installation on Page 50-60-1.) Use air pressure or water pressure to clean the top of the oil cooler [Figure 10-90-1].

P-45103

Raise the air conditioning condenser (If equipped) and the oil cooler and clean the top of the radiator [Figure 1090-2]. Lower the oil cooler on the loader frame.

WARNING

Check cooling system for leaks. Lower the rear grill and close the rear door.

Do not use your bare hands to remove debris from the oil cooler. Cooling fins are sharp and may cause injury. W-2460-0303

10-90-1


Replacing the Coolant

ENGINE COOLING SYSTEM (CONT'D) Checking The Coolant Level

WARNING

Figure 10-90-3

Do not remove radiator cap when the engine is hot. You can be seriously burned.

MAX

W-2070-1285

MIN

Figure 10-90-4

P-45106

1

P-45102

Open the rear door and raise the rear grill. Check the coolant level [Figure 10-90-3]. The level markers are on the outside of the tank. Coolant must be between the bottom marker and the top marker when the engine is cold. Close the rear door before operating the loader.

P-45102

Open the rear door and remove the rear grill. Remove the radiator cap (Item 1) [Figure 10-90-4].

IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. To much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. I-2124-0497

10-90-2


ENGINE COOLING SYSTEM (CONT'D) Replacing the Coolant (Cont’d) Figure 10-90-5

1

P-48075

Turn the valve (Item 1) [Figure 10-90-5] 90 degrees and drain the coolant into a container. Recycle or dispose of used coolant in an environmentally safe manner. Close the drain valve and remove the hose. NOTE: The loader is factory filled with propylene glycol coolant (purple color). DO NOT mix propylene glycol with ethylene glycol. Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low. 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 -34°F (-37°C) freeze protection. Use a refractometer to check the condition of propylene glycol in your cooling system. Fill the radiator with the premixed coolant. Install the radiator cap. Remove the cover from the coolant recovery tank. Fill the tank until it is at the lower marker (inside the tank). Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant as needed. Lower the rear grill and close the rear door.

10-90-3


10-90-4


FUEL SYSTEM

Figure 10-100-1

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures: TEMP. F° (C°)

NO. 2

NO. 1

+15° (9°)

100%

0%

Down to -20° (-29°)

50%

50%

Below -20° (29°)

0%

100%

1

P-48074

Contact your fuel supplier for local recommendations.

Open the rear door.

Filling The Fuel Tank

Remove the fuel fill cap (Item 1) [Figure 10-100-1] Figure 10-100-2

WARNING

WRONG

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W-2063-0887

WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285

B-15650

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [Figure 10-100-2]. Install and tighten the fuel fill cap (Item 1) [Figure 10100-1].

10-100-1


FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System

Fuel Filter

After replacing the filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

Figure 10-100-3

WARNING 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.

2 1

W-2072-0496

Figure 10-100-4

P-48077

(See SERVICE SCHEDULE on Page 10-70-1), for the service interval for removing water from, or replacing the fuel filter.

3

Removing Water Loosen the drain (Item 1) [Figure 10-100-3] at the bottom of the filter element to remove water from the filter.

1 2

Replacing Element Remove the filter element (Item 2) [Figure 10-100-3].

P-48076

Clean the area around the filter housing. Put clean oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove the air from the fuel system. (See Removing Air From The Fuel System on Page 10-100-2)

Open the vent (Item 1) [Figure 10-100-1] on the fuel filter housing. Squeeze the hand pump (priming bulb) (Item 2) [Figure 10-100-1] until fuel flows from the vent with no air bubbles. Close the vent (Item 1) [Figure 10-100-1] on the fuel filter housing. Open the vent (Item 3) [Figure 10-100-1] on the fuel injection pump. Squeeze the hand pump (priming bulb) (Item 2) [Figure 10-100-1] until the pump feels solid. Tighten the vent plug (Item 3) [Figure 10-100-1]. Start the engine. It may be necessary to open the vent plug (Item 3) [Figure 10-100-1] briefly while the engine is running. Close the vent when the engine runs smoothly.

10-100-2


Oil Chart

ENGINE LUBRICATION SYSTEM Checking Engine Oil Check the engine oil level every day before starting the engine for the work shift. Figure 10-110-1

1

P-48079

Park the loader on level ground. Open the rear door and remove the dipstick (Item 1) [Figure 10-110-1]. Keep the oil level between the marks on the dipstick. DO NOT OVERFILL. Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart.) Install the dipstick and close the rear door.

10-110-1


ENGINE LUBRICATION SYSTEM (CONT’D)

WARNING

Replacing Oil And Filter (See SERVICE SCHEDULE on Page 10-70-1), for the service interval for replacing the engine oil and filter. Run the engine until it is at operating temperature. Park the loader on level ground and stop the engine.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285

Open the rear door. Figure 10-110-3

Figure 10-110-2

1

3

2

1

P-1575 P-48078

Remove the drain plug (Item 1) [Figure 10-110-2].

Put oil in the engine. (See Capacities on Page SPEC-104.)[Figure 10-110-3] (See Oil Chart on Page 10-110-1.)

Drain the oil into a container and dispose of used oil in an environmentally safe manner.

Start the engine and let it run for several minutes.

Remove the oil filter (Item 2) [Figure 10-110-2]. Clean the filter housing surface.

Stop the engine and check for leaks at the oil filter. Remove the dipstick and check the oil level.

Put clean oil on the new oil filter gasket.

Add oil until it reaches the top mark (Item 1) [Figure 10110-3] on the dipstick. DO NOT OVERFILL.

Install the filter and hand tighten.

Install the dipstick and the fill plug.

Install and tighten the drain plug.

Close the rear door.

Remove the fill cap (Item 3) [Figure 10-110-2].

10-110-2


HYDRAULIC/HYDROSTATIC SYSTEM

Replacing Hydraulic/Hydrostatic Filter

Checking And Adding Fluid

(See SERVICE SCHEDULE on Page 10-70-1) for the correct service intervals.

Figure 10-120-1

Open the rear door. Remove the filter element (Item 2) [Figure 10-120-2]. Clean the surface of the filter housing where the seal contacts the housing. Put clean oil on the seal of the new filter element. Install and hand tighten the filter element. Close the rear door before operating the loader. Replacing Hydraulic Fluid N-18445

Use only recommended fluid in the hydraulic system. (See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.) Stop the loader on a level surface. Lower the lift arms and tilt the Bob-Tach fully back.

(See SERVICE SCHEDULE on Page 10-70-1), for the service interval. The fluid must be replaced if it becomes contaminated or after major repairs. If the fluid is replaced, the hydrostatic filter and both case drain filters must be replaced.

Stop the engine.

Use only recommended fluid in the hydraulic system. (See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.)

Check fluid level in the sight gauge [Figure 10-120-1].

Stop the loader on a level surface.

Open the rear door and remove the rear grill.

Lower the lift arms and tilt the Bob-Tach fully back.

Figure 10-120-2

Stop the engine. Check fluid level in the sight gauge [Figure 10-120-1]. Open the rear door and remove the rear grill. Figure 10-120-3

2 1

P-45243 P-45243

P-48866

1 Remove the fill cap (Item 1) [Figure 10-120-2]. Add the fluid as needed to bring the level to the center of the sight gauge [Figure 10-120-1]. Install the fill cap. Replace the rear grill and close the rear door.

P-45245

Remove the reservoir fill cap (Item 1) [Figure 10-120-3].

10-120-1


Figure 10-120-5

HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Replacing Hydraulic Fluid (Cont’d)

WARNING 1

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately.

2

W-2145-0290 P-45493


Figure 10-120-4

Disconnect the hose (Item 1) [Figure 10-120-5] from the case drain filter located on the right drive motor. Use a plug and cap on the filter and case drain hose to prevent leakage. Remove the case drain filters (Item 2) [Figure 10-120-4] & [Figure 10-120-5] and drain the fluid into a container. Replace the hydraulic/hydrostatic filter element. (See Replacing Hydraulic/Hydrostatic Filter on Page 10-1201.) Replace both hydrostatic motor case drain filters (Item 2) [Figure 10-120-4] & [Figure 10-120-5]. Connect the hoses to the case drain filters.

2

1

P-45499

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the hydraulic fluid reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Disconnect the hoses (Item 1) [Figure 10-120-4] from the case drain filter located on the reservoir. Use a plug and cap on the filter hose and case drain hose to prevent leakage.

10-120-2


HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Breather Cap

Replacing Hydraulic Fluid (Cont’d)

Figure 10-120-7

Figure 10-120-6

1 1

P-34227 P-64317

On SJC equipped loaders, the hydrostatic charge pressure filter (Item 1) [Figure 10-120-6] is located on a bracket mounted to the transmission.

(See SERVICE SCHEDULE on Page 10-70-1), for the correct replacement interval. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

Remove and replace the hydrostatic charge pressure filter.

Remove the breather cap (Item 1) [Figure 10-120-7] and discard.

Add the correct fluid to the reservoir until the fluid level is at the center of the sight gauge (Do not overfill).

Install new cap.

Lower the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

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

10-120-3


10-120-4


FINAL DRIVE TRANSMISSION (CHAINCASE)

Removing Oil From The Chaincase

Checking And Adding Oil

Figure 10-130-2

Figure 10-130-1

1 1

P-64141 P-45496

The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/ hydrostatic system. (See LOADER SPECIFICATIONS on Page SPEC-10-1.)

Remove the chaincase cover (Item 1) [Figure 10-1302](See CHAINCASE on Page 40-30-1.) Use a vacuum pump to extract the fluid from the chain case.

To check the chaincase oil level, use the following procedure: Stop the loader on a level surface. Stop the engine. Remove the plug (Item 1) [Figure 10-130-1] from the front of the chaincase housing. If oil can be reached with the tip of your finger through the hole, the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

10-130-1


10-130-2


FAN GEARBOX Checking And Maintaining Figure 10-140-1

1

N-18460

(See SERVICE SCHEDULE on Page 10-70-1), for the correct service interval. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the plug (Item 1) [Figure 10-140-1] to check the lubricant level. If the level is low, add SAE 90W gear lubricant through the check plug hole until lubricant flows from the hole. Install and tighten the plug. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

10-140-1


10-140-2


Figure 10-150-3

BOB-TACH Inspection And Maintenance

Bob-Tach Wedge

WARNING Bob-Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. W-2102-0588

Wedge Must Contact Lower Edge Of Hole In The Attachment

Figure 10-150-1

B-15177

The spring-loaded wedge (Item 1) [Figure 10-150-1] must contact the lower edge of the hole in the attachment (Item 1) [Figure 10-150-2] and [Figure 10-150-3].

1

If the wedge does not contact the lower edge of the hole [Figure 10-150-2] and [Figure 10-150-3], the attachment will be loose and can come off the Bob-Tach. Figure 10-150-4

N-17027

Move the Bob-Tach levers to engage the wedges [Figure 10-150-1]. The levers and wedges must move freely. Figure 10-150-2

TS-1062

Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-150-4]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

1

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. N-16044A

The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-150-2].

Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1) and (See LUBRICATION OF THE BOBCAT LOADER on Page 10-160-1.)

10-150-1


10-150-2


Figure 10-151-3

POWER BOB-TACH (OPTION) Inspection And Maintenance Figure 10-151-1 FRONT ACCESSORY PANEL

1 B-15177

Wedge Must Contact Lower Edge Of Hole In The Attachment

P-24487

If the wedge does not contact the lower edge of the hole [Figure 10-151-3], the attachment will be loose and can come off the Bob-Tach.

B-15891

Push and hold the BOB-TACH "WEDGES UP" switch [Figure 10-151-1] until wedges are fully raised. Push and hold the BOB-TACH "WEDGES DOWN" switch [Figure 10-151-1] until the wedges are fully down. The wedges must move freely.

Figure 10-151-4

Figure 10-151-2

B-17460

1

P-24487

The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-151-2] and must contact the lower edge of the hole in the attachment [Figure 10-151-2] and (Item 1) [Figure 10151-3].

Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-151-4]. Replace any parts including decals and lever that are damaged, bent, or missing. Keep all fasteners tight. Inspect the hoses and fittings for leaks. Look for cracked welds. Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1) and (See LUBRICATION OF THE BOBCAT LOADER on Page 10-160-1.)

10-151-1


10-151-2


Figure 10-160-2

LUBRICATION OF THE BOBCAT LOADER

3

Procedure Figure 10-160-1

2 1 N-18506

4 P-18506 N-18505

Access Hole

Lubricate the loader as specified in the SERVICE SCHEDULE, Contents Page 10-01, for the best performance of the loader. Record the operating hours each time you lubricate the Bobcat loader.

P-31841

Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply lubricant until extra grease shows.

2. Stabilizer Rod - Rear (Both Sides) [Figure 10-160-2]

Lubricate the following locations on the loader:

4. Lift Cylinder Base End (Both Sides) [Figure 10-1602].

1. Stabilizer Rod - Front (Both Sides) [Figure 10-160-1].

3. Lift Cylinder Rod End (Both Sides) [Figure 10-160-2].

Figure 10-160-3

5

N-18510

5. Tilt Cylinder Base End (Both Sides) [Figure 10-1603]

10-160-1


Figure 10-160-6

LUBRICATION OF THE BOBCAT LOADER (CONT’D) Procedure (Cont’d) Figure 10-160-4

10

7

6

N-18508

10. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-6]. P-48104

Figure 10-160-7

6. Tilt Cylinder Rod End. [Figure 10-160-4]. 7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-4]. Figure 10-160-5 11

8

N-18511 P-31839

11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-1607].

9 P16045

8. Bob-Tach Wedge (Both Sides) [Figure 10-160-5]. 9. Power Bob-Tach Cylinder (Both Sides) [Figure 10160-5].

10-160-2


LUBRICATION OF THE BOBCAT LOADER (CONT’D) Procedure (Cont’d) Figure 10-160-8

12 P1533

12. 250 Hours: Steering Lever Shaft (2) [Figure 10-1608].

10-160-3


10-160-4


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.

TIRE MAINTENANCE Wheel Nuts Figure 10-170-1

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. Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage. The rim flange must be cleaned and free of rust. N-18514

(See SERVICE SCHEDULE on Page 10-70-1), for the service interval to check the wheel nuts [Figure 10-1701]. When installing wheel nuts, tighten to 160 ft.-lb. (217 N•m) torque.

The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire. Avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

When checking wheel nut torque, set the torque wrench to 140 ft.-lb. (190 N•m) torque to prevent over-tightening.

IMPORTANT

Rotating Figure 10-170-2

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader. I-2057-0794

WARNING Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death. W-2078-1285 B-9976

Check the tires regularly for wear, damage and pressure. (See Tires on Page SPEC-10-4), for the correct tire pressure. Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure 10-170-2]. 10-170-1


10-170-2


SPARK ARRESTOR MUFFLER

WARNING

Cleaning Procedure Figure 10-180-1

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W-2006-0284

Start the engine and run for about ten seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. 1

This will force contaminants out through the cleanout hole. Stop the engine. P-45498

Install and tighten the plug. (See SERVICE SCHEDULE on Page 10-70-1), for service interval for cleaning the spark arrestor muffler.

Lower the rear grill and close the rear door.

Do not operate the loader with a defective exhaust system.

IMPORTANT This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation. If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

WARNING When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning. W-2050-1285

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

Make reference to local laws and regulations for spark arrestor requirements.

WARNING

I-2022-0595

Stop the engine. Open the rear door and rear grill. Remove the plug (Item 1) [Figure 10-180-1] from the bottom of the muffler.

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.

10-180-1

W-2068-1285


10-180-2


HYDRAULIC SYSTEM BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-90-1 20-90-5 20-90-3 20-90-1 20-90-2

CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-20-1 20-20-7 20-20-1 20-20-6 20-20-5 20-20-2

CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-22-1 20-22-5 20-22-1 20-22-4 20-22-3 20-22-2

CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Rod End Pivot Pin Bushing And Seal Replacement . . . . .

20-21-1 20-21-7 20-21-3 20-21-1 20-21-6 20-21-5 20-21-2 20-21-4

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . 20-130-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The High Flow Relief Valve . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . High Flow Relief Valve Adjustment Procedure . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SAFETY SYSTEM &

DRIVE SYSTEM


SPECIFICATIONS

20-100-1 20-100-1 20-100-6 20-100-3 20-100-4 20-100-8

Continued On Next Page

20-01


HYDRAULIC SYSTEM (CONT’D) HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . 20-43-6 Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12 Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-43-24 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-43-23 BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-43-28 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-43-29 BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . 20-43-10 BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-43-26 BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-43-25 End Cap Block Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 20-43-16 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Lift Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17 Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . 20-43-11 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-29 Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10 Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-15 Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-43-13 Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-43-13 Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-43-14 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-21 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) 20-42-1 Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-9 Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-42-28 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-42-26 BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-42-32 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-42-33 BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . 20-42-7 BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-42-30 BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-42-29 End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . 20-42-14 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1 Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . . 20-42-15 Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . 20-42-8 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-33 Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7 Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-42-10 Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-42-11 Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-42-10 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11 Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1 Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-13 Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24 Continued On Next Page

20-02


HYDRAULIC SYSTEM (CONT’D) HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Actuator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12 Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18 Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17 Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-21 BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . 20-41-8 BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . 20-41-7 BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-41-9 BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5 BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 20-41-10 BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11 Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13 Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-41-20 Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14 Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15 Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) 20-40-1 Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-28 BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . 20-40-7 BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . 20-40-6 BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-40-8 BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-9 BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10 Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11 Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . . . 20-40-17 Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13 Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26 Continued On Next Page

20-03


HYDRAULIC SYSTEM (CONT’D) HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . . 20-70-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8 Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . 20-60-3 Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . 20-60-1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5 HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . 20-61-3 Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . 20-61-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5 HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-7 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-4 Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-62-1 Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-62-2 HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-9 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-6 Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-63-1 Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-63-2 Test The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . . . 20-63-4 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5 LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Continued On Next Page

20-04


HYDRAULIC SYSTEM (CONT’D) MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-30-1 20-30-2 20-30-1 20-30-3

POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-120-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 REAR AUXILIARY DIVERTER VALVE. . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-110-1 20-110-4 20-110-9 20-110-1 20-110-9

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE SPECIFIED.

20-05


20-06


HYDRAULIC/HYDROSTATIC SCHEMATIC S175 (S/N 525211001 - 525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED APRIL 2005) Printable Version Click Here V-0444legend

LEGEND 1

RESERVOIR: Capacity . . . . . . . 19.2 Qts. (18,2 L)

14 LOAD CHECK VALVE

27

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY

2

SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 Bar)

28

RESTRICTOR - 0.140 inch (3,6 mm)

3

DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 Bar) Normally Closed

15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP

4 5 6

DRIVE MOTOR SHUTTLE VALVE RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar) RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid

16

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL

17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 19

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

41

30

RELIEF VALVE:

3300 PSI (228 Bar)

43 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END) 3500 PSI (241,3 Bar)

32 FILTER - CASE DRAIN (SINTERED BRONZE)

44

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH

45

RESTRICTION - 0.089 inch (2,26 mm)

46


47

RELIEF VALVE - 2000 PSI (137 Bar)

33 FILTER - BICS CONTROL VALVE (SCREEN)

20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL

34 CHECK VALVE - BUCKET POSITION VALVE 35

RESTRICTION

36

VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP

8

HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle

21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL

RELIEF VALVE - MAIN: 3250 - 3350 PSI (224-231 Bar) at Front Quick Couplers

22

FLOW DIVIDER ADJUSTMENT VALVE

23

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE

24

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD

38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

25

LOAD SHUTTLE VALVE - BLEED OFF

26

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL

39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring

RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)

37

11 ANTICAVITATION VALVE 12 13

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)

42 RELIEF VALVE - PORT: 3500 PSI (241,3 Bar)

31 FILTER - HYDRAULIC (CANISTER)

FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE

10

CHECK VALVE - BICS CONTROL VALVE

29 RESTRICTOR - 0.031 inch (0,8 mm)

7

9

40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)

48 RELIEF VALVE - 1200 PSI (83 Bar)

SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 Bar)

49

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

50

CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice

NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A.

V-0444legend (4-11-05)

(PRINTED APRIL 2005) V-0444

(REAR QUICK COUPLERS)

FEMALE

HYDRAULIC/HYDROSTATIC SCHEMATIC S175 (S/N 525211001 - 525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999)

BASE

Printable Version Click Here

MALE

ROD

REAR AUX VALVE (OPTIONAL)

INTEGRATED QUICK COUPLER BLOCK

24

23

MALE

25

26

28

7

(FRONT AUXILIARY LEFT SIDE LIFT ARM)

MALE 7

DRIVE MOTOR 29

30

1

FEMALE 27

4

37 P-OUT

P-IN

T

32

BUCKET POSITION VALVE (OPTIONAL)

38

D 34

HYDRAULIC FILTER 31 OIL COOLER

2 B

HYDROSTATIC PUMPS 36

5

22

A 5

A

6

40

3

C 21

HYDRAULIC CONTROL VAVLE

20 12

12

13

CHARGE INLET

B B

BOB-TACH CYLINDER (OPTIONAL)

A

AUXILIARY SPOOL HYDRAULIC POWERED BOB-TACH (OPTIONAL)

36

5

14 TILT CYLINDERS

43

BICS CONTROL VALVE

5 D

C

39 DR

8 INLET

OUTLET 50 48

46 49

B

47

TILT CYLINDER SPOOL

45 PP

DRIVE MOTOR

11 14

P2

P1 44

38

17

A

42

LIFT CYLINDERS

10 18 B

A LIFT CYLINDER SPOOL

35

15 14 4

37 9

WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS

16 33

41

33

LIFT ARM BY PASS VALVE 32 19

Printed in U.S.A.

V-0444 (4-11-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2005) Printable Version Click Here V-0445legend

LEGEND 1


14 LOAD CHECK VALVE

27


2


28


3



4 5 6

7 8

9

10

DRIVE MOTOR SHUTTLE VALVE RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar) RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 Bar) at Front Quick Couplers RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)

16


SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY

13

RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)


41


29 RESTRICTOR - 0.031 inch (0,8 mm) 30

RELIEF VALVE:

3300 PSI (228 Bar)

42 RELIEF VALVE - PORT: 3500 PSI (241,3 Bar)


43 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END) 3500 PSI (241,3 Bar)


44


45


46


47




34 CHECK VALVE - BUCKET POSITION VALVE


35

RESTRICTION

36



22


23


24



25



26


37

11 ANTICAVITATION VALVE 12




49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) 50


51

DUMP VALVE - (ON/OFF)

52

CHECK VALVE

53

AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice

54


V-0445legend (4-11-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 - 525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999)

BASE

MALE

ROD



24

23


(PRINTED APRIL 2005) V-0445


FEMALE

MALE

25

26

28

7


MALE 7

DRIVE MOTOR 29

30

1

FEMALE 27

4

37 P-OUT

P-IN

T

32


38

D 34


2 B


5

22

A 5

A

6

40

3

C 21

HYDRAULIC CONTROL VAVLE

20 12

12

13

CHARGE INLET

B B

A

AUXILIARY SPOOL 14

36

TILT CYLINDERS

43 5 D

BICS CONTROL VALVE

HIGH FLOW VALVE

5 C

51

8 50

52

OUTLET

INLET

B

17

A TILT CYLINDER SPOOL

42

53 BOB-TACH CYLINDER (OPTIONAL) DRIVE MOTOR 38

11

HYDRAULIC POWERED BOB-TACH (OPTIONAL)

14 LIFT CYLINDERS

10 18

39 B

DR


54 46

48

4

49

37

35

15

47 14

45 PP 9 P2

P1


16 33

41

33

44

LIFT ARM BY PASS VALVE 32 19

Printed in U.S.A.

V-0445 (4-11-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) Printable Version Click Here V-0565legend

LEGEND 1


14 LOAD CHECK VALVE

27


2


28


3



4 5 6


16





RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL) 3500 PSI (241,3 Bar)

43


44


45


46


47




23


24



25


26



11 ANTICAVITATION VALVE

13


37

22




RELIEF VALVE - MAIN: 3250 - 3350 PSI (224-231 Bar) at Front Quick Couplers


42 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)


36


12

3300 PSI (228 Bar)

RESTRICTION


RELIEF/ANTICAVITATION VALVE PORT 3500 PSI (241,3 Bar)

RELIEF VALVE:

35

8

10

30



9

41 29 RESTRICTOR - 0.031 inch (0,8 mm)


7


49 FILTER - BOB-TACH VALVE (S/N 525217391 & Above) (S/N 525315822 & Above) (S/N 525019833 & Above) (S/N 525115274 & Above)


V-0565legend (7-12-05)


FEMALE

HYDRAULIC/HYDROSTATIC SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE)

BASE

(PRINTED JULY 2005) Printable Version Click Here V-0565

MALE

ROD



24

23

MALE

25

26

28

7


MALE 7

DRIVE MOTOR 29

30

1

FEMALE

27 4

37 P-OUT

P-IN

T

32


38

D 34


2 B


5

22

A 5

A

6

40

3

C 21

HYDRAULIC CONTROL VAVLE 13

20 12

12

13

CHARGE INLET

B B

BOB-TACH CYLINDER (OPTIONAL)

A

AUXILIARY SPOOL HYDRAULIC POWERED BOB-TACH (OPTIONAL)

36

5

D

C

14 TILT CYLINDERS

10

BICS CONTROL VALVE

5 39 DR 10

INLET

OUTLET 43 48

46

B

47

17


13

8

42

45 PP

DRIVE MOTOR

11

49

38

14 LIFT CYLINDERS

10

P2

P1

18

44 B

A LIFT CYLINDER SPOOL 15

13

4

35

37 14 9 33

41

16 33

WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS LIFT ARM BY PASS VALVE

32 19

Printed in U.S.A.

V-0565 (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) Printable Version Click Here V-0566legend

LEGEND 1


14 LOAD CHECK VALVE

27


2


28


3



4 5 6


16




22


23


24



13

RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL) 3500 PSI (241,3 Bar)


37




RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 Bar) at Front Quick Couplers

25


26


42

AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle

43


44


45


46


47



36



3300 PSI (228 Bar)

RESTRICTION


10 RELIEF/ANTICAVITATION VALVE PORT 3500 PSI (241,3 Bar)

RELIEF VALVE:

35

8

9

30



41 29 RESTRICTOR - 0.031 inch (0,8 mm)


7




38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring

49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) 50


51


52

CHECK VALVE

53

FILTER - BOB-TACH VALVE (S/N 525217391 & Above) (S/N 525315822 & Above) (S/N 525019833 & Above) (S/N 525115274 & Above)


V-0566legend (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0566


FEMALE

BASE

MALE

ROD




24

23

MALE

25

26

28

7


MALE 7

DRIVE MOTOR 29

30

1

FEMALE

27 4

37 P-OUT

P-IN

T

32


38

D 34


2 B


5

22

A 5

A

6

40

3

C 21

HYDRAULIC CONTROL VAVLE 13

20 12

12

13

CHARGE INLET

B B

A

AUXILIARY SPOOL 14

36 10

TILT CYLINDERS BICS CONTROL VALVE

5

HIGH FLOW VALVE

5 D

C 51

8 50

52

OUTLET

INLET

B 42 BOB-TACH CYLINDER (OPTIONAL) DRIVE MOTOR 38

17


10

13

11

HYDRAULIC POWERED BOB-TACH (OPTIONAL)

14 LIFT CYLINDERS

10 18

39 B

DR


13 43 46

48

4

49

37

35

15

47

45 PP 9

53

14 33

41

16 33

P2

P1


44 LIFT ARM BY PASS VALVE 32 19

Printed in U.S.A.

V-0566 (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC With SJC Option S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0715legend


LEGEND 1

RESERVOIR: Capacity . . . . . . . 19.2 qt. (18,2 L)

2

SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 bar)

3

DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 bar) Normally Closed

4

DRIVE MOTOR SHUTTLE VALVE

5

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5250 PSI (362 bar)

15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP 16


6

7 8

9

10

RELIEF VALVE - CHARGE INLET: 360 PSI (24,8 bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 bar) at Front Quick Couplers PORT RELIEF/ANTICAVITATION VALVE 3500 PSI (241,3 bar)

11 ANTICAVITATION VALVE



20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL 21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL


RELIEF VALVE:


13

PORT RELIEF/ANTICAVITATION VALVE: . . . . . (Optional) 3500 PSI (241,3 bar)

27


28


35

RESTRICTION

49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

36


50

CHECK VALVE - With 300 PSI (20,7 bar) Spring with 0.016 inch (0,40 mm) orifice

37

SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 bar)

51

CHARGE PRESSURE SENSOR

52

POSITION SENSOR - Swash Plate

53

SERVO PISTON - Swash Plate

54

SOLENOID ACTIVATED CONTROL VALVE - FORWARD/REVERSE

55

CHARGE PUMP . . . . . . . Gear Type 12.8 GPM (48,5 L/min.) at High Engine Idle

39 CHECK VALVE - With 80 PSI (5,5 bar) Spring


46

48 RELIEF VALVE - 1200 PSI (83 bar)


26





45

47 RELIEF VALVE - 2000 PSI (137 bar)


12



23


44 31 FILTER - HYDRAULIC (CANISTER)


25

FILTER - Bob-Tach Valve

3300 PSI (228 bar)

22

24

43

40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 41


42



14 LOAD CHECK VALVE NOTE: Unless otherwise specified, springs have NO significant pressure value. Printed in U.S.A.

V-0715legend (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) (V-0715)


FEMALE

BASE

MALE

ROD



24

23


MALE

25

26

28

7


MALE 7

DRIVE MOTOR

29

30

1

FEMALE

27 4

37 P-OUT

P-IN

T

32

BUCKET POSITION VALVE (OPTIONAL) D

38

34

HYDRAULIC FILTER 31

B

HYDROSTATIC PUMPS

A 2

54

OIL COOLER

22

53

A

HYDRAULIC CONTROL VALVE 5

52

40

3

5

C 21

6

13

36

20 12 12

CHARGE INLET

B

AUXILIARY SPOOL A

B

42 51

2

52

31

14

36

TILT CYLINDERS

10

53

5

BICS CONTROL VALVE

5

54 3 B

TILT SPOOL

A

17

C

D 8

11

10

14

INLET

LIFT CYLINDERS 55

10 HYDRAULIC POWERED BOB-TACH (OPTIONAL)

OUTLET

38 39

18 B

A

LIFT SPOOL 35

47 15

DR 14 50 48

33

46 49 4

9

41

33

16

45 PP

37

43 LIFT ARM BY PASS VALVE

P2

P1 32

44

19

Printed in U.S.A. DRIVE MOTOR V-0715 (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC AND HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0716legend


LEGEND 1

RESERVOIR: Capacity . . . . . . . 19.2 qt. (18,2 L)

2

SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 bar)

3

16



17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL


DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 bar) Normally Closed

18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL

34

4

DRIVE MOTOR SHUTTLE VALVE

19

5

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5250 PSI (362 bar)

6

7

RELIEF VALVE - CHARGE INLET: 360 PSI (24,8 bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE LIFT ARM BY-PASS

20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL 21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL

47 RELIEF VALVE - 2000 PSI (137 bar) 48 RELIEF VALVE - 1200 PSI (83 bar) 49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

CHECK VALVE - BUCKET POSITION VALVE

50

RELIEF VALVE - 3300 PSI (228 bar)

35

RESTRICTION

51


36

VARIABLE CAPACITY DISPLACEMENT BI-DIRECTIONAL HYDROSTATIC PUMP

52

CHECK VALVE

53

37

SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 bar)

38 FIXED CAPACITY DISPLACEMENT BI-DIRECTIONAL HYDROSTATIC MOTOR

55 56

AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle CHECK VALVE - With 300 PSI (20,7 bar) Spring with 0.016 inch (0,40 mm) orifice SOLENOID ACTIVATED CONTROL VALVE - FORWARD/REVERSE SERVO PISTON -Swash Plate

54


22


8


23


39 CHECK VALVE - With 80 PSI (5,5 bar) Spring

57

POSITION SENSOR -Swash Plate

9

24



58

CHARGE PRESSURE SENSOR

RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 bar) at Front Quick Couplers

59

25


CHARGE PUMP 12.8 GPM (48,5 L/min) at High Engine Idle

41


26


42


27


43

FILTER - Bob-Tach Valve

44


45


46


10

PORT RELIEF/ANTICAVITATION VALVE 3500 PSI (241,3 bar)



28


13

PORT RELIEF/ANTICAVITATION VALVE: . . . . . (Optional) 3500 PSI (241,3 bar) 14 LOAD CHECK VALVE 15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP Printed in U.S.A.


RELIEF VALVE:

3300 PSI (228 bar)


NOTE: Unless otherwise specified, springs have NO significant pressure value. V-0716legend (7-12-05)

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC AND HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) (V-0716)


FEMALE

BASE

MALE

ROD



24

23


MALE

25

26

28

7


MALE 7

DRIVE MOTOR

29

30

1

FEMALE

27 4

37 P-OUT

P-IN

T

32

BUCKET POSITION VALVE (OPTIONAL) D

38

34

HYDRAULIC FILTER 31

B

HYDROSTATIC PUMPS

A

OIL COOLER

2

55

22

56

A

HYDRAULIC CONTROL VALVE 5

57

40

3

5

C 21

6

13

36

20 12 12

CHARGE INLET

B

AUXILIARY SPOOL A

B

42 58

2

57

31

14

36

TILT CYLINDERS

10

BICS CONTROL VALVE

HIGH FLOW VALVE 56

5

5 51

55 50

52

3

B

TILT SPOOL

A

17

C

D 8

10

11 14

INLET

LIFT CYLINDERS 59

10 HYDRAULIC POWERED BOB-TACH (OPTIONAL)

OUTLET

53 38

39

18 B

A

LIFT SPOOL 35

47 15

DR 14 54 48 46 49 4

9

33

41

33

16

45 PP

37

43 LIFT ARM BY PASS VALVE

P2

P1 32

44

19

Printed in U.S.A. DRIVE MOTOR V-0716 (7-12-05)

HYDRAULIC SYSTEM INFORMATION

20-10-1


HYDRAULIC SYSTEM INFORMATION (CONT’D)

20-10-2


HYDRAULIC SYSTEM INFORMATION (CONT’D)

20-10-3


20-10-4


HYDRAULIC SYSTEM INFORMATION (CONT'D)

WARNING

Troubleshooting Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285

PROBLEM

CAUSE

The hydraulic system will not operate. The transmission warning light come ON when hydraulics are operating. Slow hydraulic system action. Hydraulic action is not smooth. Lift arms go up slowly at full engine RPM The lift arms or Bob-Tach will move when the pedal is in neutral position The lift arms come down with the pedal is in neutral position By-pass valve stuck By-pass valve stem bent or broke

1, 2, 3, 5, 8 1, 3 1, 3, 4, 6, 8 1, 4, 5, 6, 7 1, 3, 4, 5, 6, 7, 8, 9 4 4, 9, 10, 11 12 13

KEY TO CORRECT CAUSE 1. The fluid level is not correct. 2. The pedal linkage is disconnected. 3. The hydraulic pump has damage. 4. The pedal linkage is not adjusted correctly. 5. Relief valve is not at the correct pressure. 6. Suction leak on the inlet side of the hydraulic pump. 7. Fluid is cold. Wrong viscosity fluid. (See LOADER SPECIFICATIONS on Page SPEC-10-1.) 8. Using the loader for more than its rated capacity. 9. Internal leak in the lift cylinder(s). 10. External leak from the cylinder(s). 11. Damaged lift spool. 12. Rotate shaft. 13. Replace manual spool cartridge.

20-10-5


20-10-6


Figure 20-20-2

CYLINDER (LIFT) Checking

WARNING 2 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

N-18786

W-2072-0496

Figure 20-20-1

Install a plug in the hose (Item 1) [Figure 20-20-2] and tighten. Connect the negative ground cable to the battery. Engage the parking brake. Lower the seat bar. Start the engine. Press the PRESS TO OPERATE BUTTON. Push the top (toe) of the lift pedal.

1

If there is any leakage from the base end cylinder port (Item 2) [Figure 20-20-2], remove the lift cylinder for repair. Repeat the procedure to check the other lift cylinder. N-18785

Lower the lift arms. Stop the engine. Pull up on the lift arm by-pass control and move the lift pedal to release the hydraulic pressure. Raise the seat bar. Check only one cylinder at a time. Open the rear door.


Disconnect the negative ground cable to the battery. Disconnect the hose (Item 1) [Figure 20-20-1] from the lift cylinder base end port.

20-20-1


Figure 20-20-4

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

1

Figure 20-20-3 2

1

N-18806

Remove the retainer bolt (Item 1) [Figure 20-20-4] and nut from the lift arm pin (both sides).

N-18785

Stop the engine. Pull up on the lift arm by-pass control to release the hydraulic pressure. Open the rear door.

Installation: Tighten the bolt and nut to standard torque. Use a drift pin and hammer, remove the lift arm pivot pin (Item 2) [Figure 20-20-4] (both sides). Roll the lift arm link back.

Disconnect the negative ground cable to the battery. Disconnect the hose (Item 1) [Figure 20-20-3] from the lift cylinder base end port.

Figure 20-20-5

Install a plug in the hose and tighten. 1

P-34048

Remove the retainer bolt (Item 1) [Figure 20-20-5] and nut from the lift cylinder rod end pivot pin (both sides). Installation: Tighten the bolt and nut to standard torque.

20-20-2


Figure 20-20-8

CYLINDER (LIFT) (CONT’D) Removal And Installation (Cont’d) Figure 20-20-6

1

1

2

N-18782

Remove the retainer bolt (Item 1) [Figure 20-20-8] and nut from the lift cylinder pivot pin.

P-34049

Use a slide hammer, remove the lift cylinder rod end pivot pin (Item 1) [Figure 20-20-6]. Figure 20-20-7

Installation: Tighten the bolt and nut to standard torque. Use a drift pin and hammer, remove the lift arm pivot pin (Item 2) [Figure 20-20-8].

1

P-34047

Install a smaller pin (Item 1) [Figure 20-20-7] to hold the cylinder in place. Disconnect the hose (item 2) [Figure 20-20-7] from the lift cylinder rod end port. Install a plug in the hose and tighten.

20-20-3


CYLINDER (LIFT) (CONT’D) Removal And Installation (Cont’d) Figure 20-20-9

1

P-34050

Remove the smaller pin (Item 1) [Figure 20-20-7] and lift the lift cylinder (Item 1) [Figure 20-20-9] out from the loader.

20-20-4


CYLINDER (LIFT) (CONT’D) Identification

1. Plug 2. O-ring 3. Cylinder 4. O-ring 5. Nut 6. Piston 7. Seal 8. O-ring

9. Spacer 10. Seal 11. O-ring 12. Head 13. Rod Seal 14. Wiper Seal 15. Rod

9

7

8

6

1

15

2

5 4

14 1 2

13

12

3 11

10

B-13593

20-20-5


Figure 20-20-12

CYLINDER (LIFT) (CONT’D) Disassembly

2

Use the following tools to disassemble the cylinder: MEL1074 - O-ring Seal Hook Spanner Wrench

1

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

3

Figure 20-20-10

P-48038

Remove the seal (Item 1) and O-ring (Item 2) [Figure 2020-12] from the piston.

1

NOTE: If the fiber surface (Item 3) [Figure 20-20-12] on the piston head, becomes damaged, the complete piston head must be replaced. Figure 20-20-13 1 P-48033

Use a spanner wrench to loosen the head (Item 1) [Figure 20-20-10] from the cylinder case.

2

Figure 20-20-11 4 3

P-48039

2 1

Remove the two O-rings (Item 1) and the back-up washer (Item 2) [Figure 20-20-13] from the cylinder head.

P-48036

Remove the nut (Item 1), piston (Item 2), spacer (Item 3) and head (Item 4) [Figure 20-20-11].

20-20-6


CYLINDER (LIFT) (CONT'D)

Assembly

Disassembly (Cont'd)

Use the following tools to assemble the cylinder:

Figure 20-20-14

MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Figure 20-20-16

1

P-48040

Remove the wiper seal (Item 1) [Figure 20-20-14] from the cylinder head. P7424

Figure 20-20-15

Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. 1

Lubricate all O-rings and seals with hydraulic oil during installation. Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-20-16]. Allow the seal to stretch for 30 seconds before installing it on the piston.

P-48042

Remove the rod seal (Item 1) [Figure 20-20-15] from the cylinder head.

20-20-7


Figure 20-20-19

CYLINDER (LIFT) (CONT'D) Assembly (Cont'd) Figure 20-20-17

1 2

P7425

Install the rod seal in the head [Figure 20-20-19]. P-48038

Figure 20-20-20

Install the O-ring (Item 1) and seal (Item 2) [Figure 2020-17] on the cylinder piston. 2

Figure 20-20-18 1 1

P-48041A

P-48043A

P-48042

Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2020].

P7427

Install the rod seal on the rod seal tool [Figure 20-20-18]. NOTE: During installation the spring side of the seal (Item 1) [Figure 20-20-18] must be installed toward the inside of the cylinder. Rotate the handles to collapse the rod seal [Figure 2020-18].

20-20-8


CYLINDER (LIFT) (CONT'D) Assembly (Cont'd) Figure 20-20-21

1

2

3 4

P-48036

NOTE: Clean and dry the threads before installing the nut. Install the new nut from the kit. Install the head (Item 1), spacer (Item 2) piston (Item 3), and nut (Item 4) [Figure 20-20-21]. Tighten the nut (Item 4) [Figure 20-20-21] to 600 ft.-lb. (814 N•m) torque. Figure 20-20-22

1

P-48035

Put the base end of the hydraulic cylinder in a vise. Tighten the head (Item 1) [Figure 20-20-22] using a spanner wrench.

20-20-9


20-20-10


CYLINDER (TILT)

Figure 20-21-2

Checking

WARNING

1

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290 N-18802

Figure 20-21-1 Remove the attachment. Roll the Bob-Tach fully back. Stop the engine. Raise the seat bar. Disconnect the hose (Item 1) [Figure 20-21-1] which goes to the base end of the tilt cylinder. Install a cap (Item 1) [Figure 20-21-2] on the fitting and tighten. Engage the parking brake. Lower the seat bar. 1

Start the engine and push the Press to Operate button. Push the bottom (heel) of the tilt pedal. N-18801

If there is leakage from the open port, remove the tilt cylinder for repair.

20-21-1


Figure 20-21-4

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

WARNING

1

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285

Figure 20-21-3

N-18545

Use a drift pin and hammer, remove the rod end pivot pin (Item 1) [Figure 20-21-4]. Figure 20-21-5 1

1

N-18544

3

2

Remove the attachment. Roll the Bob-Tach forward. Stop the engine. Raise the seat bar. Remove the retainer bolt (Item 1) [Figure 20-21-3] and nut from the rod end pin. Installation: Tighten the bolt and nut to standard torque.

P-34137

Remove the retainer bolt (Item 1) [Figure 20-21-5] from the tilt cylinder rod end pivot pin. Installation: Tighten the bolt and nut to 125-140 ft.-lb. (170-190 N•m) torque. Remove the step (Item 2) [Figure 20-21-5]. Disconnect the hose (Item 3) [Figure 20-21-5] from the cylinders.

20-21-2


CYLINDER (TILT) (CONT'D)

Base End Pivot Pin Replacement

Removal And Installation (Cont’d)

Figure 20-21-7

Figure 20-21-6

1 1

2 P-24709 P-34228

Disconnect the hose (Item 1) [Figure 20-21-6] from the cylinder. Remove the cylinder (Item 2) [Figure 20-21-6] from the rod end pivot pin. Remove the cylinder from the loader.

Remove the tilt cylinder from the Bob-Tach. (See Removal And Installation, Page 20-21-2.) Loosen the retainer bolt (Item 1) [Figure 20-21-7] from the tilt cylinder rod base end pin. Installation: Tighten the retainer bolt to 175-190 ft.-lb. (240-260 N•m) torque. Strike the head of the bolt (Item 1) [Figure 20-21-7] to push the pivot pin out. Reverse the removal procedure to install the pivot pin.

20-21-3


Figure 20-21-10

CYLINDER (TILT) (CONT'D) Rod End Pivot Pin Bushing And Seal Replacement Figure 20-21-8

1

1 N-18554

Reverse the removal procedure to install the pivot pin bushing and seal.

N-18556

Remove the rod end of the tilt cylinder from the BobTach. (See Rod End Pivot Pin Bushing And Seal Replacement, Page 20-21-4.) Use a seal pick to remove the seals (Item 1) [Figure 2021-8] on both sides of the pivot bushing. Figure 20-21-9

N-18555

Remove and replace bushing with a driver tool and hammer [Figure 20-21-9].

20-21-4


CYLINDER (TILT) (CONT'D) Parts Identification

1. Case 2. Plug 3. O-ring 4. Nut 5. Piston 6. Seal 7. O-ring 8. O-ring

9. Washer 10. O-ring 11. Head 12. Seal 13. Seal 14. Rod 15. Seal 16. Bushing

MC-1688B

3 MC-01688A

2 1 8

9

4

10 7

12 6

13

11

5

MC-01688D

MC-01688C

14 15

16 15

PE-1056A

20-21-5


Figure 20-21-13

CYLINDER (TILT) (CONT'D) Disassembly

2

Use the following tools to disassemble the cylinder: MEL1074 - O-ring Seal Hook Spanner Wrench

1

Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Put the base end of the cylinder in a vise. Figure 20-21-11

P-48073

Remove the seal (Item 1), and O-ring (Item 2) [Figure 20-21-13] from the piston.

1

Figure 20-21-14 1

2 P-48034

Use a spanner wrench to loosen the head (Item 1) [Figure 20-21-11] from the cylinder case. Figure 20-21-12

P-48039

3

Remove the two O-rings (Item 1) and the back-up washer (Item 2) [Figure 20-21-14] from the cylinder head.

2 1

P-48071

Remove the nut (Item 1), piston (Item 2) and head (Item 3) [Figure 20-21-12].

20-21-6


CYLINDER (TILT) (CONT'D)

Assembly

Disassembly (Cont'd)

Use the following tools to assemble the cylinder:

Figure 20-21-15

MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Figure 20-21-17

1

P-48040

Remove the wiper seal (Item 1) [Figure 20-21-15] from the cylinder head. P7424

Figure 20-21-16

Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. 1

Lubricate all O-rings and seals with hydraulic oil during installation. Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-21-17]. Allow the seal to stretch for 30 seconds before installing it on the piston.

P-48042

Remove the rod seal (Item 1) [Figure 20-21-16] from the cylinder head.

20-21-7


Figure 20-21-20

CYLINDER (TILT) (CONT'D) Assembly (Cont'd) Figure 20-21-18

1 2

P7425

Install the rod seal in the head [Figure 20-21-20]. P-48073

Figure 20-21-21

Install the O-ring (Item 1) and seal (Item 2) [Figure 2021-18] on the cylinder piston. 2

Figure 20-21-19 1 1

P-48041

P-48043

P-48042

Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2121].

P7427

Install the rod seal on the rod seal tool [Figure 20-21-19]. NOTE: During installation the spring side of the seal (Item 1) [Figure 20-21-19] must be installed toward the inside of the cylinder. Rotate the handles to collapse the rod seal [Figure 2021-19].

20-21-8


Figure 20-21-24

CYLINDER (TILT) (CONT'D) Assembly (Cont'd) Figure 20-21-22

1 1 2 3

P-48070

Put the base end of the hydraulic cylinder in a vise. P-48071

NOTE: Clean and dry the threads before installing the nut. Install the new nut from the kit.

Tighten the head (Item 1) [Figure 20-21-24] using a spanner wrench.

Install the head (Item 1), piston (Item 2) and nut (Item 3) [Figure 20-21-22]. Tighten the nut (Item 3) [Figure 20-21-22] to 100 ft.-lb. (136 N•m) torque. Figure 20-21-23

P-48088

P-48089

Mark the end of the shaft and nut. Tighten the nut an additional 135 degrees or 2-1/4 flats [Figure 20-21-23].

20-21-9


20-21-10


Figure 20-22-2

CYLINDER (POWER BOB-TACH) Checking


1 P16330

WARNING 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.

Disconnect the hose (Item 1) [Figure 20-22-2] from the power Bob-Tach cylinder base end port. Figure 20-22-3

W-2072-0496

2

Figure 20-22-1

1

P16332

Install a plug in the hose (Item 1) [Figure 20-22-3] and tighten. Engage the parking brake. Lower the seat bar. Start the engine. N-21401

Tilt the Bob-Tach forward, so it is parallel to the floor [Figure 20-22-1].

Push and hold the BOB-TACH "WEDGES UP" Switch (Front Accessory Panel). If there is any leakage from the base end cylinder port (Item 2) [Figure 20-22-3], remove the Power Bob-Tach cylinder for repair.

20-22-1


CYLINDER (POWER BOB-TACH) (CONT’D) Removal And Installation Figure 20-22-4

1

1

N-21401

Disconnect the hoses from the cylinder fittings (Item 1 & 2) [Figure 20-22-4]. Install plugs and cap on fittings. NOTE: Connect the hose with the 45° end (Item 1) [Figure 20-22-4] to the base end fitting on the cylinder. Figure 20-22-5

N-21400

Remove the bolts (Item 1) [Figure 20-22-5]. Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the washers and cylinder from the lever pivots.

20-22-2


CYLINDER (POWER BOB-TACH) (CONT’D) Identification 1. Cylinder 8. Ring 2. Nut 9. O-ring 3. Piston 10. Head 4. O-ring 11. Seal 5. Ring 12. Seal 6. Spacer 13. Rod 7. O-ring

1

2

7

8

3

4

5

6

9 10 11 12

13

B-16276

20-22-3


Figure 20-22-8

CYLINDER (POWER BOB-TACH) (CONT’D) Disassembly

3

Use the following tools to disassemble the cylinder:

2 1

MEL1074 - O-ring Seal Hook Spanner Wrench Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Figure 20-22-6 P16295

Piston: Remove the O-ring (Item 1) [Figure 20-22-8], and seal (Item 2) [Figure 20-22-8] from the piston (Item 3) [Figure 20-22-8]. Figure 20-22-9

3

5

4 P16293

Put the base end of the cylinder in a vise.

1

2

Use a spanner wrench to loosen the head [Figure 20-226]. Figure 20-22-7 N-20611

3

2 Remove the wiper seal (Item 1) [Figure 20-22-9], and rod seal (Item 2) [Figure 20-22-9], the back up washer (Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure 20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9] from the head.

1

P16294

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


Figure 20-22-11

CYLINDER (POWER BOB-TACH) (CONT’D) Assembly

3

2

Use the following tools to assembly the cylinder: MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench

1

4

Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. P16295

Always install new O-rings and seals during assembly. Lubricate all O-rings and seals with hydraulic oil during installation.

Piston: Install the O-ring (Item 1) [Figure 20-22-11] and seal (Item 2) [Figure 20-22-11] on the piston (Item 3) [Figure 20-22-11].

Figure 20-22-10 NOTE: The piston center hole (Item 4) [Figure 20-2211] has a bevel on one end. The bevel goes toward the rod. Figure 20-22-12

P7424

Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-22-10]. N-20612

Allow the seal to stretch for 30 seconds before installing it on the piston.

Install the rod seal on the rod seal tool [Figure 20-22-12]. NOTE: During installation the O-ring side of the seal must be toward the inside of the cylinder.

20-22-5


Figure 20-22-15

CYLINDER (POWER BOB-TACH) (CONT’D) Assembly (Cont’d) Figure 20-22-13

1 2 3

P7422

Install the thin O-ring (Item 1) [Figure 20-22-15]. N-20613

Rotate the handles to collapse the rod seal [Figure 2022-13].

Install the back-up washer (Item 2) [Figure 20-22-15] and thick O-ring (Item 3) [Figure 20-22-15] into the groove on the head. NOTE: Clean and dry the threads before installing the nut. Install the new nut from the seal kit.

Figure 20-22-14

Figure 20-22-16

1

2

3

4

P7425

P16294

Install the rod seal in the head [Figure 20-22-14]. Install the wiper seal with the wiper toward the outside of the head.

Install the head (Item 1) [Figure 20-22-16], and spacer (Item 2) [Figure 20-22-16]. Install the piston (Item 3) [Figure 20-22-16]. Grease the piston where the nut contacts the piston. do not get grease on the threads. Install the new nut (Item 4) [Figure 20-22-16]. Tighten the nut to 90 ft.-lb. (122 N•m) torque.

20-22-6


CYLINDER (POWER BOB-TACH) (CONT’D) Assembly (Cont’d) Figure 20-22-17

P16293

Put the base end of the hydraulic cylinder in a vise. Tighten the head using a spanner wrench [Figure 20-2217].

20-22-7


20-22-8


Figure 20-30-1

MAIN RELIEF VALVE Checking

IMPORTANT

2

The hydraulic tester must be in the fully open position before you start the engine.

1

I-2024-0284

WARNING

P-34480

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.

Connect the IN port (Item 1) [Figure 20-30-1] of the hydraulic tester to the bottom (female) quick coupler on the loader.

W-2006-0284

Connect the OUT port (Item 2) [Figure 20-30-1] of the hydraulic tester to the top (male) quick coupler on the loader.

WARNING

Figure 20-30-2


The tools listed will be needed to do the following procedure:

1

MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Turn the key switch to the OFF position. To release the hydraulic pressure at the front auxiliary quick couplers push the couplers into the coupler block and hold for three seconds.

N-18409

•

Press the AUXILIARY HYDRAULICS Button (Item 1) [Figure 20-30-2] Maximum Flow.


20-30-1


MAIN RELIEF VALVE (CONT’D)

Adjustment

Checking (Cont’d)

Figure 20-30-4

Figure 20-30-3 Right Steering Lever Control

O-ring

1 Back-up

B-6764

1

• •

P-31833

Push the front switch (Item 1) [Figure 20-30-3] to give the front quick couplers a constant flow of fluid. To release from continuous operation, press the front switch (Item 1) [Figure 20-30-3] a second time.

Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full RPM.

If the pressure is not correct, adjust the main relief valve. Remove the end cap (Item 1) [Figure 20-30-4]. Turn the adjusting screw in or out until the pressure is correct. NOTE: If the correct pressure can not be reached, replace the main relief valve. Check the pressure setting of the new relief valve.

Refer to Specifications, (Contents Page SPEC-01) for both flow and pressure specifications of the hydraulic system. Check the free flow specification. Turn the restrictor control, on the tester, until the main relief valve opens. Check the relief pressure. If the relief pressure is not correct, stop the engine and adjust the main relief valve.

20-30-2


Figure 20-30-6

MAIN RELIEF VALVE (CONT’D) Removal and Installation Figure 20-30-5

1 1

P-48874

1

Clean the area around the control valve. Loosen and remove the main relief valve (Item 1) [Figure 20-30-6].

P-48872

Remove the four motor cover mounting bolts (Item 1) [Figure 20-30-5]. Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Remove the O-rings and back-up washers [Figure 2030-4]. Clean the main relief valve in clean solvent. Use air pressure to dry the valve. Install new O-rings and back-up washers. Install the main relief valve (Item 1) [Figure 20-30-6] and tighten. Check the pressure again. (See Checking on Page 20-30-1.) Installation: Tighten the main relief valve to 35-40 ft.-lb. (47-54 N•m) 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

20-30-3


20-30-4


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)

IMPORTANT

Identification Figure 20-40-1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888

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 Lift Arm Support Device on Page 10-20-1.)

1

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

N-18695

The hydraulic control valve (2 piece casting) (foot control) has a removable BICS™ section (Item 1) [Figure 20-401]. The BICS™ section and main control valve are in two seperate castings. For identification of the hydraulic control valve (1 piece casting) (foot control), (See Identification Chart on Page 20-42-6.). Removal And Installation

Clean the area around the control valve. Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.) Remove the control pedal crossbar linkage and tilt linkage. (See Crossbar Linkage Removal and Installation on Page 50-90-2.) Figure 20-40-2

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-34004

Remove the right rear tire. Locate and remove the access covers (Item 1) [Figure 20-40-2] on the right side of the machine.

20-40-1


Figure 20-40-5

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal and Installation (Cont’d) Figure 20-40-3

3 1 1

2 P-34387

Disconnect the tubeline (Item 1) [Figure 20-40-5] from the lift arm by pass valve. P-31998

Remove the drain tubeline (Item 2) [Figure 20-40-5] from the lift arm by-pass valve and the control valve.

Mark all tubelines and hoses for correct installation. The fixed end main valve hose assembly (Item 1) [Figure 20-40-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.

Remove the bolts (Item 3) [Figure 20-40-5] from the lift arm by-pass control valve. Installation: Tighten the bolts to 180-200 in.-lb. (21-23 N•m) torque. Figure 20-40-6

NOTE: Remember the hose routing for ease of control valve installation.

1

Figure 20-40-4

2 1

1

P-34388

Label and disconnect the four electrical connectors (Item 1) [Figure 20-40-6]. Disconnect the outlet tubeline (Item 2) [Figure 20-40-6] from the control valve.

P-31999

Remove the tie - strap (Item 1) [Figure 20-40-4] from the fixed end main valve hose.

20-40-2


Figure 20-40-9


5

1

1

3

4

P-31997

2

Disconnect the BICS valve electrical connector (Item 1) [Figure 20-40-9]. P-34389

Figure 20-40-10 Disconnect the drive motor case drain hose (Item 1) [Figure 20-40-7]. Disconnect the Power Bob-Tach drain hose (Item 2) [Figure 20-40-7] if so equipped. 1

Disconnect the drain to reservoir hose (Item 3) [Figure 20-40-7]. Disconnect the auxiliary tubeline (Item 4) and (Item 5) [Figure 20-40-7]. Figure 20-40-8

P-34005

Disconnect the inlet hose (Item 1) [Figure 20-40-10] from the bottom of the control valve.

1 2

3 4 P-34390

Disconnect the tilt tubeline (Item 1) [Figure 20-40-8]. Disconnect the tilt tubeline (Item 2) [Figure 20-40-8]. Disconnect the drain hose (Item 3) [Figure 20-40-8]. Disconnect the lift tubeline (Item 4) [Figure 20-40-8].

20-40-3


Figure 20-40-13


1

P-34391

Remove the control [Figure 20-40-13].

valve

from

the

loader

P-34391

Connect a hoist (Item 1) [Figure 20-40-11] to the control valve.

Figure 20-40-12

1

P-34006

Locate and remove the two control valve mounting bolts (Item 1) [Figure 20-40-12] through the right side access panels. Installation: Tighten the bolts to 25-28 ft.-lb. 38 N•m) torque.

(34-

20-40-4


Figure 20-40-16

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve Removal And Installation Figure 20-40-14

1

1

1

1 2

1

1 N-18697

1 1

Remove the four large O-rings (Item 1) and the small Oring (Item 2) [Figure 20-40-16] from the top of the control valve.

N-18679

Remove the control valve. (See Removal And Installation on Page 20-40-1.) To remove the BICS™ from the control valve loosen and remove the six mounting bolts (Item 1) [Figure 20-40-14].

Installation: Install the four large O-rings (Item 1) and the small O-ring (Item 2) [Figure 20-40-16] on the top of the control valve. Figure 20-40-17

Figure 20-40-15

6

3 1

2

5

4 N-18679

Install the six mounting bolts [Figure 20-40-17]. N-18695

Remove the BICS™ valve assembly from the top of the control valve [Figure 20-40-15].

The chart below lists the correct torque specifications and tightening sequence when reinstalling the BICS™ valve assembly to the control valve. Thoroughly clean and dry bolts and threads in valve. Use liquid adhesive LOCTITE #242 or equivalent. STEP 1 2 3

TORQUE 110-130 in.-lb. (12,5-23,7N•m) 190-210 in.-lb. (21,5-23,7N•m) 190-210 in.-lb. (21,5-23,7 N•m)

SEQUENCE

1,2,3,4,5 & 6

*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for every bolt or repeat step 3.

20-40-5


Figure 20-40-19

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation Figure 20-40-18

1

N-18687

1

Figure 20-40-20

N-18686

Remove the fitting (Item 1) [Figure 20-40-18] from the valve. 1

N-18685

Using a flat blade screw driver, remove the lift arm bypass orifice (Item 1) [Figure 20-40-19] & [Figure 20-4020]. Orifice size is 0.078 inch. Reverse the removal procedure to install the lift arm bypass orifice.

20-40-6


Figure 20-40-23

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve, Check Valve Removal And Installation Figure 20-40-21

1

P-8956

1

Clean and inspect the screen (Item 1) [Figure 20-40-23] on the end of the valve. N-18683

Reverse the removal procedure to install the BICS™ check valve.

Remove the check valve (Item 1) [Figure 20-40-21]. Installation: Tighten the valve to 20 ft.-lb. (27 N•m) torque. Figure 20-40-22

3

2 1

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-22]. Install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-22] on the check valve. Check valve (Item 3) [Figure 20-40-22] has a rating of 5-10 PSI.

20-40-7


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)

Figure 20-40-26

BICS™ Valve Lock Valve Removal And Installation Figure 20-40-24

1

1 1

N-18689

N-18682

Remove the lock valves (Item 1) [Figure 20-40-24], [Figure 20-40-25] & [Figure 20-40-26] from the BICS™ valve. Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m) torque.

Figure 20-40-25

Figure 20-40-27

1

1 1

2

N-18688

2

2 N-18690

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-27] from both the tilt and lift lock valves. Install new O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-27] on the tilt and lift lock valves. Reverse the removal procedure to install the lock valve.

20-40-8


Figure 20-40-30

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve Solenoid Removal And Installation

1

Figure 20-40-28

1

N-18692

Remove the solenoid [Figure 20-40-30].

cartridge

(Item

1)

N-18691

Remove the mounting nut (Item 1) [Figure 20-40-28] from the solenoid cartridge.

Installation: Tighten the cartridge to 20 ft.-lb. (27 N•m) torque.

Installation: Tighten the mounting nut to 53 in.-lb. (6 N•m) torque. Figure 20-40-29

1 1

N-18693

Remove the O-rings (Item 1) [Figure 20-40-29] from both ends of the solenoid.

20-40-9


BICS™ Valve Solenoid Testing


Figure 20-40-32

BICS™ Valve Solenoid Removal And Installation (Cont’d) Figure 20-40-31

3 2

P9175

1

Use an Ohm meter to measure coil resistance [Figure 20-40-32].

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-31] from the cartridge. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and replace any showing excessive wear.

Coil wires do not have polarity. Correct resistance for the BICS™ is 9.7 ± 1 Ohm @ 20°C. Correct resistance for the tilt and lift lock coils is 7.7 ± 1 Ohm @ 20°C.

NOTE: The screen (Item 3) [Figure 20-40-31] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-40-29] & [Figure 20-40-31] and new back-up rings (Item 2) [Figure 20-4031] on the solenoid cartridge.

20-40-10



Figure 20-40-33 H3

Identification Chart ITEM

S175, S185 LOADER

A1

Lift Cylinder Base End/Restrictor

A2

Tilt Cylinder Base End

A3

Auxiliary Hydraulics

B1

Lift Cylinder Rod End

B2

Tilt Cylinder Rod End

B3


C1

Load Check Valve/Lift Function

C2

Load Check Valve/Tilt Function

C3

Orificed Load Check Valve Auxiliary Function

C4

Outlet Fluid Flow

D1

Lift Spool Centering Spring/Detent

D2

Tilt Spool Centering Spring

D3

Auxiliary Spool/Centering Springs

E1

Port Relief Valve-3500PSI

E2

Anti-Cavitation/Port Relief Valve-3500PSI

F1

Anti-Cavitation Valve

F2


G1

Lift Spool End

G2

Tilt Spool End

G3


H1

Auxiliary Electric Solenoid

H2

Plug/Port Relief (Optional)-3100PSI

H3


MR

Main Relief Valve-3300PSI

H1

H2

C4 G3

B3

A3

D3

C3 G2

B2

F2

A2

E2

A1

E1

D2

C2

G1

B1 F1

D1

C1 MR TS-1918

20-40-11


Figure 20-40-35

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Load Check Valve

IMPORTANT

1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-18698

Figure 20-40-34 Mark each valve section, spool and related parts so that they will be returned to its original valve section during assembly.

1

1

1

Use bolts to fasten the control valve to a work bench for easier disassembly and assembly procedures.

1

Loosen the load [Figure 20-40-35].

2

check

valve

plugs

(Item

1)

Installation: Always use new O-ring. tighten the plug to 35-40 ft.-lb. (47-54 N•m) torque. Figure 20-40-36 N-18697

Remove the BICS™ valve assembly from the control valve. (See BICS™ Valve Removal And Installation on Page 20-40-5.) Remove the four large O-rings (Item 1) and small O-ring (Item 2) [Figure 20-40-34]. Always replace these O-rings before installing the BICS™ valve assembly.

1

3 2

N-18699

Remove the load check plugs (Item 1) [Figure 20-40-36]. Remove the spring (Item 2) and poppet (Item 3) [Figure 20-40-36].

20-40-12


Figure 20-40-39

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Load Check Valve (Cont’d) Figure 20-40-37 1

1 N-19031

Remove the main relief valve (Item 1) [Figure 20-40-39].

2

Figure 20-40-40

N-18700

2 l

The auxiliary section (Item 1) uses an orifice load check poppet (Item 2) [Figure 20-40-37].

l 1

NOTE: For correct port locations and valve component values (See Identification Chart on Page 20-40-11.)

3 4 l l

5 l

B-06764

1. Relief Valve 2. O-ring 3. Sleeve 4. Glide Ring 5. O-ring

Main Relief Valve Figure 20-40-38

CD-15092

Remove the O-rings, sleeve, and glide ring from the main relief valve [Figure 20-40-40]. Installation: Always use new O-rings. sleeve, and glide ring. Tighten to 35-40 ft.-lb. (47-54 N•m) torque. 1

N-18923

Loosen the main relief valve (Item 1) [Figure 20-40-38].

20-40-13


Figure 20-40-43

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Port Relief Valve Figure 20-40-41

1

1 N-18977

Remove the port relief valve (Item 1) [Figure 20-40-43]. Figure 20-40-44

N-18976

Figure 20-40-42

4 3 2 1

1

1. O-ring 2. Backup Washer 3. O-ring 4. Relief Valve N-18844

Remove the O-rings and back-up washer from the port relief valve [Figure 20-40-44].

N-18923

Loosen the port relief valve (Item 1) [Figure 20-40-41] & [Figure 20-40-42] (Port E1 or F2). Installation: Always use new O-rings and back-up washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

20-40-14


Figure 20-40-47

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Anti-Cavitation Valve/Port Relief Valve Figure 20-40-45

1

1 N-18843

Remove the O-rings (Item 1) [Figure 20-40-47] from the anti-cavitation/port relief valve. N-18976

Anti-Cavitation Valve Loosen the anti-cavitation valve (Item 1) [Figure 20-4045].

Figure 20-40-48

Installation: Always use new O-rings and back-up washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

2

Figure 20-40-46

1 1 N-18923

Remove the lift lock solenoid (Item 1) [Figure 20-40-48] & [Figure 20-40-49]. Installation: Always use new O-rings and back-up washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

N-18978

Remove the anti-cavitation/port relief valve (Item 1) [Figure 20-40-46] from the control valve for the tilt section.

20-40-15


Rubber Boot


Figure 20-40-51

Anti-Cavitation Valve (Cont’d) Figure 20-40-49

2 1

1

N-18923

Remove the two screws (Item 1) [Figure 20-40-51] on the rubber boot retainer.

N-19032

Remove the anti-cavitation valve (Item 2) [Figure 20-40-48] & [Figure 20-40-49] from the control valve for the lift section.

Installation: Tighten the screws to 90-100 in.-lb. (10,211,3 N•m) torque. Figure 20-40-52

Figure 20-40-50 1

2

3

2

4 1

E-01509

1. Anti-Cavitation Valve 2. O-ring 3. Backup Washer 4. O-ring

1

2

N-18924 N-18839

Remove the O-rings and back-up washer from the anti-cavitation valve [Figure 20-40-50].

Remove the rubber boot (Item 1) and retainer (Item 2) [Figure 20-40-52].

20-40-16


Figure 20-40-55

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift And Tilt Lock Block Removal And Installation Figure 20-40-53

1

N-18926

2 1

Remove the block [Figure 20-40-55]. NOTE: The lock block must be clean and oil free. (Oil can cause the solenoids not to function properly.)

N-18923

Figure 20-40-54

Lift Spool and Detent The tool listed will be needed to do the following procedure:

1

MEL1278 - Detent Tool MEL1285 - Detent Spring Tool Figure 20-40-56

2 2

1 N-18925

1 Remove the lock solenoids (Item 1) [Figure 20-40-53] & [Figure 20-40-54] from the lock block. 2

Remove the rubber boot (Item 2) [Figure 20-40-53] & [Figure 20-40-54]. (See Identification Chart on Page 2040-11.)

1 N-18923

Remove the lift and tilt lock solenoids (Item 1) [Figure 20-40-56]. Remove the lift and tilt lock block (Item 2) [Figure 20-40-56] from the control valve. (See Lift And Tilt Lock Block Removal And Installation on Page 20-4017.)

20-40-17


Figure 20-40-59

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool and Detent (Cont’d) Figure 20-40-57

1

1

2

2 N-18971

Use safety glasses and a screwdriver to remove the snap ring (Item 1) [Figure 20-40-59]. N-18927

Remove the washer (Item 2) [Figure 20-40-59]. Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-57] from the lift spool.

Figure 20-40-60

Figure 20-40-58

1

2 1 1

N-18976

Remove the end cap (Item 1) [Figure 20-40-58].

N-18972

Remove the screws (Item 1) [Figure 20-40-60] from the detent bonnet. Remove the detent bonnet (Item 2) [Figure 20-40-60].

IMPORTANT The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly. I-2012-0284

20-40-18


Figure 20-40-63


1

N-18975

Remove the spool assembly and seal (Item 1) [Figure 20-40-63] from the control valve.

1 N-18973

Figure 20-40-64 Put a rag around the detent assembly (Item 1) [Figure 20-40-61]. This will prevent the detent balls and spring from being lost when the detent sleeve is removed. Figure 20-40-62

1

3

2 N-18930

1

Remove the spool seal (Item 1) [Figure 20-40-64] from the linkage end of the valve.

2 N-18974

Remove the detent sleeve (Item 1), detent balls (Item 2) and spring (Item 3) [Figure 20-40-62].

20-40-19


Figure 20-40-67


1

2 N-18916

Put a rag around the detent assembly [Figure 20-40-67]. This will prevent the detent balls and spring from being lost when the detent adapter is removed.

P-8988

Clamp the linkage end of the spool in a vise [Figure 20-40-65]. Figure 20-40-66

Remove the detent adapter with an allen wrench. Remove the back-up washer (Item 1) and spool seal (Item 2) [Figure 20-40-67]. Figure 20-40-68

2

1 1

N-18915 N-19004

Install the spring tool (Item 1) [Figure 20-40-66] over the centering spring. NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-40-66] from the centering spring, as it is under spring pressure.

Remove the detent adapter (Item 1) [Figure 20-40-68] from the spring assembly.

20-40-20


Figure 20-40-71

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool and Detent (Cont’d) Figure 20-40-69 1

N-18918

Remove the stud [Figure 20-40-71].

from

the

end

of

the

spool

N-19009

Figure 20-40-72 Remove spring tool (Item 1) [Figure 20-40-69] from the spring assembly. Figure 20-40-70

2

1 1

3 4

N-18920

Removal of the plastic plug: Make a center point in the plug using a 1/16 inch drill.

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-40-70].

Drill a hole all the way through the plug using a 7/64 inch tap drill. Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap. Clean all the debris from inside the spool bore. NOTE: DO NOT USE LOCTITE ON THE STUD THREADS.

20-40-21


Figure 20-40-75


O-ring

Lift Spool and Detent (Cont’d) Figure 20-40-73

2

Plastic Plug

1

.60 inch (15,2 mm) B-14712

Install the stud and tighten until the other end of the stud is out about 0.60 inch (15,2 mm) from the spool [Figure 20-40-75].

N-18961

Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-40-73].

Figure 20-40-76

Figure 20-40-74 1

N-18967

Clamp the collar (Item 1) [Figure 20-40-76] in a vice. N-18963

Install the plastic plug and O-ring in the spool [Figure 20-40-74].

20-40-22


Figure 20-40-79


1 2

1

N-19004

3 2

Install the spring tool (Item 1) [Figure 20-40-79] over the washer, spring, collar and detent adapter. N-18958

Figure 20-40-80 Apply grease on all the detent component surfaces before assembly [Figure 20-40-77]. Install the spring (Item 1) and detent balls (Item 2) into the adapter (Item 3) [Figure 20-40-77] and compress with the detent pliers [Figure 20-40-78].

2

Figure 20-40-78

1

N-18917

Install the spool seal (Item 1) and back-up washer (Item 2) [Figure 20-40-80].

N-18968

Install the detent adapter to the collar [Figure 20-40-78]. NOTE: The collar and the detent adapter are held together by spring pressure when assembled to the lift spool not the detent balls. Hold the detent adapter and collar together to prevent the detent balls and spring from falling out.

20-40-23


Figure 20-40-83


1

N-19007

Hold the detent balls in place with the detent pliers [Figure 20-40-83]. N-19005

Figure 20-40-84 Install the spring assembly to the lift spool hand tight [Figure 20-40-81]. Remove the spring tool. Check the alignment of the detent adapter and the washer.

1

Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m). NOTE: The adapter must fit in the center of the washer (Item 1) [Figure 20-40-81]. Figure 20-40-82

N-19008

Install the detent sleeve (Item 1) [Figure 20-40-84] to the detent adapter.

CD-15051

Install the detent balls and spring [Figure 20-40-82].

20-40-24


Figure 20-40-87


1

2 N-18976

1 Install the end cap (Item 1) [Figure 20-40-87]. 2

Figure 20-40-88

N-18972

Install the lift spool assembly in the spool bore [Figure 20-40-85]. Install the detent bonnet (Item 1) [Figure 20-40-85]. Install the mounting screws (Item 2) [Figure 20-40-85]. Installation: Tighten the screws to 90-100 in.-lb. 11,3 N•m) torque.

(10,21

Figure 20-40-86 N-18930

Install the spool seal (Item 1) [Figure 20-40-88] on the linkage end of the valve. 2

1 N-18971

Install the washer (Item 1) and snap ring (Item 2) [Figure 20-40-86].

20-40-25


Tilt Spool Removal And Installation


Figure 20-40-91

Lift Spool and Detent (Cont’d) Figure 20-40-89

1

2 1

N-18923

N-18927

Install the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-89] on the linkage end of the lift spool.

Remove the lift and tilt lock block (Item 1) [Figure 20-40-91] from the control valve. (See Lift And Tilt Lock Block Removal And Installation on Page 20-4017.) Figure 20-40-92

Figure 20-40-90

1

2

1

N-18928 N-18923

Install the lift and tilt lock block (Item 1) [Figure 20-40-90]. (See Lift And Tilt Lock Block Removal And Installation on Page 20-40-17.)

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-92] from the tilt spool.

20-40-26


Figure 20-40-95

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Tilt Spool Removal And Installation (Cont’d)

1

Figure 20-40-93

1

N-18942 N-18942

Put the linkage end of the spool in the vice [Figure 20-40-95]. N-18686

Remove the screws (Item 1) [Figure 20-40-93] from the end cap.

Install the spool tool (Item 1) [Figure 20-40-95] over the centering spring. Figure 20-40-96

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque. 1

Figure 20-40-94

N-19014

Remove the bolt (Item 1) [Figure 20-40-96] holding the centering spring to the spool. N-18816

Remove the spool, centering spring, back-up washer and spool seal [Figure 20-40-94].

Installation: Tighten the bolt to 90-100 in.-lb. 11,3 N•m) torque.

(10,2-

Remove spring tool from the spring assembly.

Assembly: Always use a new spool seal.

20-40-27


Auxiliary Spool Removal And Installation


Figure 20-40-99

Tilt Spool Removal And Installation (Cont’d) Figure 20-40-97 2

1

3 4 1

N-18976

Remove the screws (Item 1) [Figure 20-40-99] from the end cap (both sides).

N-18944A


Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque.

Figure 20-40-98

Figure 20-40-100 2 1

1

N-18930

N-18943

N-18990

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-40-98].

Remove the end cap, O-ring, springs and washer (both sides).


Assembly: Put grease on all the centering spring component parts.

20-40-28


Figure 20-40-103

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-40-101

1

2 1 N-18823

Remove the end plate (Item 1) and housing (Item 2) [Figure 20-40-103]. N-18989

Figure 20-40-104 Remove the spool (Item 1) [Figure 20-40-101]. Assembly: Always use a new spool seal. Auxiliary Electric Solenoid Figure 20-40-102

3

2 1

N-18992

1

Remove the coil (Item 1) and end plate (Item 2) [Figure 20-40-104].

1

Remove the solenoid valve (Item 3) [Figure 20-40-104]. Installation: Tighten valve to 96-144 in.-lb. (11-16 N•m) torque.

N-18822

Remove the nut (Item 1) [Figure 20-40-102] from both solenoids. Installation: Tighten the nut to 96-144 in.-lb. 16 N•m) torque.

(11-

20-40-29


Figure 20-40-107


Plug

Auxiliary Electric Solenoid (Cont’d) Figure 20-40-105 2

1 1 1 N-18800

Figure 20-40-108

Port Relief (Optional)

N-18795

Remove the O-rings (Item 1) [Figure 20-40-105] from the solenoid valves. 1

Port-Auxiliary Section

2

Figure 20-40-106 1

N-18843

Remove the O-rings (Item 1) [Figure 20-40-107] & [Figure 20-40-108] and back-up ring (Item 2) [Figure 20-40-107] & [Figure 20-40-108] from the plug or port relief.

1

N-18993

Remove the plug (Item 1) [Figure 20-40-106] or optional port relief valve from the control valve.

20-40-30


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Cleaning And Inspection Clean all components with clean solvent and dry with compressed air. Check the spools for wear or scratches. Check that the spools are not loose in their bore. Check that the centering springs are not broken. Check that the load check valve seats are not worn. Check the load check poppets for damage. Check the rubber boots and retainers. Replace the parts as needed. Use new O-rings and back-up rings. Apply oil to all new O-rings and back-up rings before installation.

20-40-31


20-40-32


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)

IMPORTANT



Lift and block the loader. (See Procedure Page 10-10-1.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device Page 10-20-1.) 1

Raise the operator cab. ((See Raising The Operator Cab Page 10-30-1.)

N-18695

Clean the area around the control valve. The hydraulic control valve (2 piece casting) (Advance Control System) (ACS) has a removable BICS™ section (Item 1) [Figure 20-41-1].

Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid Page 10-120-1.)

The BICS™ section and main control valve are in two seperate castings.

Remove the control panel. Installation Page 50-100-1.)

For identification of the hydraulic control valve (1 piece casting) (Advanced Control System) (ACS), (See Identification Chart (ACS) Page 20-43-9.)

Figure 20-41-2

Removal and Installation

((See

Removal

and

1

P-48872

WARNING

Remove the right rear tire.

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.

Locate and remove the access covers (Item 1) [Figure 20-41-2] on the right side of the machine.

W-2059-0598

20-41-1


Figure 20-41-5

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal and Installation (Cont’d) Figure 20-41-3 1

1

P-48881

Remove the tubeline clamp (Item 1) [Figure 20-41-5]. This will allow room to move the auxiliary tubelines away from the control valve.

P-31998

Figure 20-41-6

Mark all tubelines and hoses for correct installation. The fixed end main valve hose assembly (Item 1) [Figure 20-41-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.

4 1

NOTE: Remember the hose routing for ease of control valve installation. 3

Figure 20-41-4

2

P-48878

Disconnect the tubeline (Item 1) [Figure 20-41-6] from the lift arm by-pass valve. Disconnect the drain hose (Item 2) [Figure 20-41-6] from the control valve.

1

Disconnect the motor case drain hose (Item 3) [Figure 20-41-6] from the lift arm by-pass valve.

P-31999

Remove the tie - strap (Item 1) [Figure 20-41-4] from the fixed end main valve hose.

Remove the bolts (Item 4) [Figure 20-41-6] from the lift arm by-pass control valve. After removing the lift arm bypass valve mounting bolts move the wire harness and bypass valve towards the engine to give more room for control valve removal.

20-41-2


Figure 20-41-9

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal and Installation (Cont’d)

1

2

Figure 20-41-7 1

1

3 2

P-48884

Remove the drain tubeline (Item 1) [Figure 20-41-9] from the control valve and BICS™ valve. P-48879

Label and disconnect the electrical connectors (Item 1) [Figure 20-41-7]. Disconnect the outlet tubeline (Item 2) [Figure 20-41-7] from the control valve.

Disconnect the auxiliary tubelines (Item 2) [Figure 20-419]. Disconnect the drain hose (Item 3) [Figure 20-41-9] from the control valve. Figure 20-41-10

Figure 20-41-8 3

2 5

2 1

4

1 P-48883 P-48880

Label and disconnect the actuator electrical connectors (Item 1) [Figure 20-41-8]. Remove the bolt (Item 2) [Figure 20-41-8] from the wire harness clamp. Installation: Tighten the bolt to 25-28 ft.-lb. (34-38 N•m) torque.

Remove the tilt tubeline (Item 1) [Figure 20-41-10] from the bucket positioning valve (if so equipped) and the control valve. Disconnect the lift tubeline (Item 2) [Figure 20-41-10]. Disconnect the tilt tubeline (Item 3) [Figure 20-41-10]. Remove the tilt tubeline (Item 4) [Figure 20-41-10] from the bucket positioning valve and the control valve (if so equipped). Disconnect the tilt tubeline (Item 5) [Figure 20-41-10].

20-41-3


Figure 20-41-13

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal and Installation (Cont’d) Figure 20-41-11

1 1

2

P-48873

Locate and remove the two control valve mounting bolts (Item 1) [Figure 20-41-13] through the right side access panels.

P-48876

Disconnect the BICS valve electrical connector (Item 1) [Figure 20-41-11]. Disconnect the inlet hose (Item 2) [Figure 20-41-11] from the bottom of the control valve.

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the control valve from the loader.

Figure 20-41-12

1

P-48884

Connect a hoist (Item 1) [Figure 20-41-12] to the control valve.

20-41-4


Figure 20-41-16

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve Removal And Installation Figure 20-41-14

1

1

1 1 2

1

1

N-18697

1 1

Remove the four large O-rings (Item 1) and the small Oring (Item 2) [Figure 20-41-16] from the top of the control valve.

N-18679

Remove the control valve. (See Removal and Installation Page 20-41-1.)

Install the four large O-rings (Item 1) and the small O-ring (Item 2) [Figure 20-41-16] on the top of the control valve.

To remove the BICS™ from the control valve loosen and remove the six mounting bolts (Item 1) [Figure 20-4114]. Figure 20-41-15

N-18695

Remove the BICS™ valve assembly from the top of the control valve [Figure 20-41-15].

20-41-5


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS Valve Removal And Installation (Cont’d) Figure 20-41-17

6

3

2

1 5

4

N-18679

Install the six mounting bolts [Figure 20-41-17]. The chart below lists the correct torque specifications and tightening sequence when reinstalling the BICS valve assembly to the control valve. Thoroughly clean and dry bolts and threads in valve. Use liquid adhesive LOCTITE #242 or equivalent. STEP

TORQUE

1

110-130 in.-lb. (12,4-14,7 N•m)

2

190-210 in.-lb. (21,5-23,7 N•m)

3

190-210 in.-lb. (21,5-23,7 N•m)

SEQUENCE

1,2,3,4,5 & 6

*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for every bolt or repeat step 3.

20-41-6


Figure 20-41-19

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation Figure 20-41-18

1

N-18687

1

Figure 20-41-20

N-18686

Remove the fitting (Item 1) [Figure 20-41-18] from the valve.

1

N-18685

Using a flat blade screw driver, remove the lift arm bypass orifice (Item 1) [Figure 20-41-19] & [Figure 20-4120]. Orifice size is 0.078 inch. Reverse the removal procedure to install the lift arm bypass orifice.

20-41-7


Figure 20-41-23

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Check Valve Removal And Installation Figure 20-41-21

1

1

P-8956

Clean and inspect the screen (Item 1) [Figure 20-41-23] on the end of the valve. N-18683

Reverse the removal procedure to install the BICS™ check valve.

Remove the check valve (Item 1) [Figure 20-41-21]. Installation: Tighten the valve to 20 ft.-lb. (27 N•m) torque. Figure 20-41-22

3

2 1

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-22]. Install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-22] on the check valve. Check valve (Item 3) [Figure 20-41-22] has a rating of 510 PSI.

20-41-8


HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Figure 20-41-26

BICS™ Valve Lock Valve Removal And Installation Figure 20-41-24

1 1 1 N-18689

N-18682

Remove the lock valves (Item 1) [Figure 20-41-24], [Figure 20-41-25] & [Figure 20-41-26] from the BICS™ valve. Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m) torque.

Figure 20-41-25

1

N-18688

20-41-9



Figure 20-41-29

BICS Valve Lock Valve Removal And Installation (Cont’d)

1 1

Figure 20-41-27

1

1 N-18693

2 2

Remove the O-rings (Item 1) [Figure 20-41-29] from both ends of the solenoid.

2

Figure 20-41-30

N-18690

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-27] from both the tilt and lift lock valves.

1

Install new O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-27] on the tilt and lift lock valves. Reverse the removal procedure to install the lock valve. BICS™ Valve Solenoid Removal And Installation Figure 20-41-28

1

N-18692

Remove the solenoid cartridge (Item 1) [Figure 20-4130]. 2

Installation: Tighten the cartridge to 20 ft.-lb. (27 N•m) torque.

N-18691

Remove the mounting nut (Item 1) [Figure 20-41-28] from the solenoid cartridge. Installation: Tighten the mounting nut to 53 in.-lb. (6 N•m) torque. Remove the solenoid (Item 2) [Figure 20-41-28].

20-41-10


BICS™ Valve Solenoid Testing


Figure 20-41-32

BICS Valve Solenoid Removal And Installation (Cont’d) Figure 20-41-31

3 2

P9175

1 Use an Ohm meter to measure coil resistance [Figure 20-41-32].

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-31] from the cartridge. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and replace any showing excessive wear.

Coil wires do not have polarity. Correct resistance for the BICS™ is 9.7 ± 1 Ohm at 20°C. Correct resistance for the tilt and lift lock coils is 7.7 ± 1 Ohm at 20°C.

NOTE: The screen (Item 3) [Figure 20-41-31] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-41-29] & [Figure 20-41-31] and new back-up rings (Item 2) [Figure 20-4131] on the solenoid cartridge.

20-41-11


Figure 20-41-35

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation NOTE: Actuators can be removed with the control valve in the loader. Remove the lift arm bypass valve to allow room for actuator removal in the loader.

4

Figure 20-41-33 2

3

1

1

N-19114

Remove the actuator (Item 1) [Figure 20-41-35]. Remove the O-ring (Item 2) [Figure 20-41-35]. Remove the spacer block (Item 3) [Figure 20-41-35]. 1 2

Remove the O-ring (Item 4) [Figure 20-41-35]. N-19112

Figure 20-41-36 Remove the two screws (Item 1) [Figure 20-41-33] on the actuator retainer. Installation: Tighten the bolt and nut to 90-100 in.-lb. (10,2-11,3 N•m) torque. Pull the actuator (Item 2) [Figure 20-41-33] away from the control valve. Figure 20-41-34

N-18940

Repeat removal for the other actuator [Figure 20-41-36]. NOTE: The calibration procedure must be followed when replacing handle sensor, actuator or ACS controller. (See Calibration Procedure Page 60-120-16.)

1

N-19113

Use a drift pin and hammer to remove the actuator pin (Item 1) [Figure 20-41-34] from the actuator and the lift or tilt spool.

20-41-12



Figure 20-41-37 H1 H3

Identification Chart (ACS) ITEM

S175, S185 ACS LOADER

A1

Lift Cylinder Base End/Restrictor

A2

Tilt Cylinder Base End

A3


B1

Lift Cylinder Rod End

B2

Tilt Cylinder Rod End

B3


C1

Load Check Valve/Lift Function

C2

Load Check Valve/Tilt Function

C3

Orificed Load Check Valve/Auxiliary Function

C4

Outlet Fluid Flow

D1

Lift Spool Centering Spring

D2

Tilt Spool Centering Spring

D3


E1


E2

Anti-Cavitation/Port Relief Valve-3500PSI

F1


F2


G1

Lift Spool End

G2

Tilt Spool End

G3


H1


H2

Plug/Port Relief (Optional)-3100PSI

H3


MR

Main Relief Valve-3300PSI

H2

C4 G3 G2 F2

G1 F1

B3

A3

D3

C3 B2

A2

E2

A1

E1

C2 B1

D2 D1

C1 MR

PE1339

20-41-13



IMPORTANT

Lift Base End Restrictor Figure 20-41-38


1 Figure 20-41-40

N-21159

1

Remove the BICS™ valve assembly from the control valve. (See Removal and Installation Page 20-41-1.) Remove the restrictor (Item 1) [Figure 20-41-38] from the lift section base end port. N-19100

Load Check Valve Mark each valve section, spool and related parts so that they will be returned to their original valve section during assembly.

Figure 20-41-39

Use bolts to fasten the control valve to a work bench for easier disassembly and assembly procedures.

1

1

Loosen the load check valve plugs (Item 1) [Figure 2041-40]. 1

1

Installation: Always use new O-ring. tighten the plug to 35-40 ft.-lb. (47-54 N•m) torque.

2 N-19099

Remove the BICS™ valve assembly from the control valve. (See Removal and Installation Page 20-41-1.) Remove the four large O-rings (Item 1) and small O-ring (Item 2) [Figure 20-41-39]. Always replace these O-rings before installing the BICS™ valve assembly

20-41-14


Main Relief Valve


Figure 20-41-43

Load Check Valve (Cont’d) Figure 20-41-41

1

1

N-19034

3

2

Loosen the main relief valve (Item 1) [Figure 20-41-43].

N-19101

Remove the load check plugs (Item 1) [Figure 20-41-41].

Figure 20-41-44

Remove the spring (Item 2) and poppet (Item 3) [Figure 20-41-41]. Figure 20-41-42 1 1

N-19035

Remove the main relief valve (Item 1) [Figure 20-41-44]. 2

N-19102

The auxiliary section (Item 1) uses an orifice load check poppet (Item 2) [Figure 20-41-42].

20-41-15


Figure 20-41-47

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Main Relief Valve (Cont’d) Figure 20-41-45

1 2

3

4

5

1 B-06764

1. Relief Valve 2. O-ring 3. Sleeve 4. Glide Ring 5. O-ring

N-19034

Loosen the port relief valve (Item 1) [Figure 20-41-46] & [Figure 20-41-47] (Port E1 or F2). (See Identification Chart (ACS) Page 20-41-13.)

CD-15092

Remove the O-rings, sleeve, and glide ring from the main relief valve [Figure 20-41-45]. Installation: Always use new O-rings, sleeve, and glide ring. TIghten to 35-40 ft.-lb. (47-54 N•m) torque.

Installation: Always use new O-rings and back-up washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque. Figure 20-41-48

Port Relief Valve Figure 20-41-46

1

1 N-18981

Remove the port relief valve (Item 1) [Figure 20-41-48].

N-19000

20-41-16


Figure 20-41-51

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Port Relief Valve (Cont’d) Figure 20-41-49 4

1

3 2 1 1. O-ring 2. Backup Washer 3. O-ring 4. Relief Valve

N-18980

Remove the anti-cavitation/port relief valve (Item 1) from the control valve for the tilt section [Figure 20-41-51].

N-18844

Remove the O-rings and back-up washer from the port relief valve [Figure 20-41-49].

Installation: Always use new O-rings and back-up washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque. Figure 20-41-52

Anti-Cavitation Valve/Port Relief Valve Figure 20-41-50 1

1

N-18843

Remove the O-rings (Item 1) [Figure 20-41-52] from the anti-cavitation/port relief valve.

N-19003

Loosen the anti-cavitation valve (Item 1) [Figure 20-4150].

20-41-17



Figure 20-41-55 1


2

3

4

Figure 20-41-53 E-1509A

1 1. Anti-Cavitation Valve 2. O-ring 3. Backup Washer 4. O-ring N-18839

Remove the O-rings and back-up washer from the anticavitation valve [Figure 20-41-55]. N-19034

Tilt Spool Removal And Installation Figure 20-41-54

Figure 20-41-56

1

1 N-19036

N-19112

Remove the anti-cavitation valve (Item 1) [Figure 20-4153] & [Figure 20-41-54] from the control valve.

Remove the actuator (Item 1) [Figure 20-41-56] from the control valve. (See Actuator Removal And Installation Page 20-41-12.)

20-41-18


Lift Spool Removal And Installation


Figure 20-41-59

Tilt Spool Removal And Installation (Cont’d) Figure 20-41-57

1

1

1 N-19112

N-19003

Remove the screws (Item 1) [Figure 20-41-57] from the cap.

Remove the actuator (Item 1) [Figure 20-41-59] from the control valve. (See Actuator Removal And Installation Page 20-41-12.) Figure 20-41-60

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque. Figure 20-41-58 1

1

1

N-19003

Remove the screws (Item 1) [Figure 20-41-60] from the end cap. N-18983

Remove the spool assembly (Item 1) [Figure 20-41-58] and seal from the control valve.



20-41-19


Figure 20-41-63

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation (Cont’d) Figure 20-41-61

1

1

N-19014

Remove the bolt (Item 1) [Figure 20-41-63] holding the centering spring to the spool. N-18985

Remove the spool assembly (Item 1) [Figure 20-41-61] and seal from the control valve. Assembly: Always use a new spool seal.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque. Remove spring tool from the spring assembly. Figure 20-41-64

Lift and Tilt Spool Disassembly And Assembly Figure 20-41-62

3

2

1

4 1

N-18944A


N-18942

Put the linkage end of the spool in the vice [Figure 2041-62]. Install the spool tool (Item 1) [Figure 20-41-62] over the centering spring.

20-41-20


Figure 20-41-67

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift and Tilt Spool Disassembly And Assembly (Cont’d)

4 3

Figure 20-41-65

2 2

1

1

N-18987

1 Remove the end cap (Item 1), O-ring (Item 2) springs (Item 3) and washer (Item 4) [Figure 20-41-67] (both sides). N-18930

N-18943

Assembly: Always use a new spool seal. Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-41-65].

Figure 20-41-68

Assembly: Always use a new spool seal. Auxiliary Spool Removal And Installation

1

Figure 20-41-66

N-18988

1 Remove the spool (Item 1) [Figure 20-41-68].

Assembly: Put grease on all the centering spring component parts. N-19003

Remove the screws (Item 1) [Figure 20-41-66] from the end cap (both sides). Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque.

20-41-21


Figure 20-41-71

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Auxiliary Electric Solenoid Figure 20-41-69

3

2 1

1

N-18992

Remove the coil (Item 1) and end plate (Item 2) [Figure 20-41-71].

1 N-18996

Remove the solenoid valve (Item 3) [Figure 20-41-71]. Remove the nut (Item 1) [Figure 20-41-69] from both solenoids.

Installation: Tighten valve to 96-144 in.-lb. (11-16 N•m) torque.

Installation: Tighten the nut to 96-144 in.-lb. (11-16 N•m) torque.4

Figure 20-41-72

Figure 20-41-70

2

1 1

N-18795

Remove the O-rings (Item 1) [Figure 20-41-72] from the solenoid valves.

N-18823

Remove the end plate (Item 1) and housing (Item 2) [Figure 20-41-70].

Installation: Always use new O-rings and apply oil to the O-rings prior to installation.

20-41-22


Figure 20-41-75

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Port-Auxiliary Section Figure 20-41-73

2

1

1

N-18843

1

Remove the O-rings (Item 1) [Figure 20-41-74] & [Figure 20-41-75] and back-up ring (Item 2) [Figure 2041-74] & [Figure 20-41-75] from the plug.

N-18996

Remove the plug (Item 1) [Figure 20-41-73] or optional port relief valve from the control valve. Figure 20-41-74

Cleaning And Inspection Clean all components with clean solvent and dry with compressed air. Check the spools for wear or scratches.

Plug

Check that the spools are not loose in their bore. Check that the centering springs are not broken.

2

Check that the load check valve seats are not worn. Check the load check poppets for damage. Check the rubber boots and retainers.

1

Replace the parts as needed.

1 N-18800

Use new O-rings and back-up rings. Apply oil to all new O-rings and back-up rings before installation.

20-41-23


20-41-24


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)

IMPORTANT



1

Lift and block the loader. ((See Procedure on Page 1010-1.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

P-51436

The hydraulic control valve (1 piece casting) (foot control) (Item 1) [Figure 20-42-1] does not have a removable BICS™ section. The BICS™ section and main control valve are in one casting. For identification of the hydraulic control valve (2 piece casting) (foot control), (See Identification on Page 20-401.)

Clean the area around the control valve. Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.) Figure 20-42-2

Removal And Installation

1

P-34004

WARNING




W-2059-0598

20-42-1


Figure 20-42-5


4

Removal and Installation (Cont’d) 2

Figure 20-42-3

1

3

1

1

P-51714

Mark and disconnect the four electric solenoid connectors for correct installation (Item 1) [Figure 20-425].

P-51710

Remove the outlet tubeline (Item 2) [Figure 20-42-5] from the control valve to the hydraulic oil cooler.

Mark all tubelines and hoses for correct installation. The fixed end main valve hose (Item 1) [Figure 20-42-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.

Disconnect and cap the supply hose (Item 3) and the supply hose clamp (Item 4) [Figure 20-42-5]. Figure 20-42-6 1

NOTE: Remember the hose routing for ease of control valve installation. Figure 20-42-4 2

P-51715

1

Disconnect and cap the tubeline (Item 1) [Figure 20-426] from the lift arm by-pass valve to the control valve. Disconnect and cap the hose (Item 2) [Figure 20-42-6] from the lift arm by-pass valve to the drive motor case drain.

P-31999

Remove the tie-strap (Item 1) [Figure 20-42-4] from the fixed end main valve hose.

20-42-2


Figure 20-42-9

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont'd) Figure 20-42-7

1

1

1

P-48287

Remove the connector pins (Item 1) [Figure 20-42-9]. Figure 20-42-10

P-51719

Remove the tie-strap (Item 1) [Figure 20-42-7] from the main valve mounting bracket. 1

Figure 20-42-8

2

P-51723

1

Remove the wire harness clamp bolt (Item 1) [Figure 2042-10]. P-51724

Disconnect the wire harness tie-strap mounts (Item 1) [Figure 20-42-8] from the lift arm by-pass bracket.

Remove the control pedal crossbar linkage and tilt linkage. (See Crossbar Linkage Removal and Installation on Page 50-90-2.)

Remove the lift arm by-pass tubeline (Item 2) [Figure 20-42-8] from the control valve drain.

20-42-3


Figure 20-42-13

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont'd) Figure 20-42-11

2

1

1

1

P-51714

Remove and cap both tubelines (Item 1) [Figure 20-4213] from the auxiliary section of the control valve. P-51721

Remove the two lift arm by-pass valve mounting bolts (Item 1) [Figure 20-42-11].

Disconnect and cap the drain hose (Item 2) [Figure 2042-13] from the control valve. Figure 20-42-14

Remove the lift arm by-pass valve and mounting bracket. Figure 20-42-12 1 1 2 3

P-51729

Disconnect and cap the tubelines (Item 1) and (Item 2) [Figure 20-42-14] from the tilt section of the control valve.

P-51727

Remove tubeline clamp bolt (Item 1) [Figure 20-42-12] from the auxiliary tubelines in the left rear upright.

Disconnect and cap the tubeline (Item 3) [Figure 20-4214] from the lift section of the control valve.

Installation: Tighten bolt to 15-20 ft.-lb. (20-27 N•m) torque.

20-42-4


Figure 20-42-17

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Removal And Installation (Cont'd) Figure 20-42-15

1

1

P-51726

1

Connect a hoist to the lifting brackets (Item 1) [Figure 20-42-17] on the control valve. P-51728

Figure 20-42-18 Remove the fixed-end main valve hose (Item 1) [Figure 20-42-15] from the main control valve fitting. Figure 20-42-16

1

1

P-34004PP-51713 51713

Remove the two mounting bolts (Item 1) [Figure 20-4218] fastening the control valve and bracket to the side of the loader.

P-51722

Mark and disconnect the BICS™ electric solenoid connector (Item 1) [Figure 20-42-16].

Remove the control valve from the loader. Reverse procedure for installation.

20-42-5


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Identification Chart Figure 20-42-19

C2 D5

J4

J2

C3

B3

E3 G1

F2 D4

F4

G2

E3

A3

B2

D3 E2

A2 D1

D2 A1 F1

F3

H2

B1 MR

C1

H1

E1 H3

J3

J1

MS1926

ITEM

S175/S185 LOADER

ITEM

S175/S185 LOADER

A1 A2 A3

Lift Cylinder Base End Tilt Cylinder Base End

E1 E2 E3 F1 F2 F3 F4 G1 G2 H1

Lift Spool Detent Tilt Spool Centering Spring Auxiliary Spool/Centering Springs LIft Spool Tilt Spool Lift Spool Lock Solenoid Tilt Spool Lock Solenoid Auxiliary Solenoid Stem Auxiliary Solenoid Stem

H2

BICS™ Lock Valve (Tilt)

H3

BICS™ Lock Valve (Lift)

J1 J2 J3 J4

Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm By-Pass Orifice

B1 B2 B3 C1 C2 C3 D1 D2 D3 D4 D5

Auxiliary Hydraulic Rod End Lift Cylinder Rod End Tilt Cylinder Rod End Auxiliary Hydraulics Base End Load Check/BICS™ Valve Lift Load Check Valve Tilt Function Load Check Valve Auxiliary Function Anti-Cavitation Valve Lift (Rod End) Port Relief/Anti-Cavitation Valve – 3500 PSI Lift (Base End) Port Relief/Anti-Cavitation Valve – 3500 PSI Tilt (Base End) Port Relief/Anti-Cavitation Valve – 3500 PSI Tilt (Rod End) Port Relief/Anti-Cavitation Valve (Auxiliary) 3500 PSI (Optional)

MR

20-42-6

BICS™ Valve Solenoid

Drain (Case) Main Relief Valve – 3300 PSI


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)

BICS™ Valve, Lift Load Check Valve Removal And Installation

Mount Bracket Removal and Installation

Figure 20-42-22

Figure 20-42-20

1

P-51438

1 P-51690

Remove the control valve and mount bracket (Item 1) [Figure 20-42-20] from the loader. Figure 20-42-21

Remove the lift load check valve (Item 1) [Figure 20-4222]. Installation: Lubricate the o-ring and tighten the valve to 55-65 ft.-lb. (75-88 N•m) torque. Figure 20-42-23

1

2 1 2

2 P-51435

P-51439

Disconnect the tubeline (Item 1) [Figure 20-42-21] from the inlet fitting on the control valve. Remove the two mount bolts (Item 2) [Figure 20-42-21] from the control valve mount plate. Remove the mount plate and tubeline.

Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-42-23].

20-42-7


Figure 20-42-26

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lift Load Check Valve Removal And Installation (Cont’d)

4

Figure 20-42-24 1

1 3

2

P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-26]. Check the orifice (Item 3) [Figure 20-42-26] in the poppet to be sure it is not plugged.

P-51440

Check for free movement of the load check valve (Item 1) [Figure 20-42-24]. Load Check Valve Removal And Installation (Tilt & Auxiliary)

Installation: Install a new O-ring (Item 4) [Figure 20-4226] on the plug and lightly lubricate with oil before installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m) torque.

Figure 20-42-25

2

1

P-51691

At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-42-25]. At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-42-25]. NOTE: The tilt and auxiliary load check valves are interchangeable.

20-42-8


Figure 20-42-29

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Anti-Cavitation Valve (Lift, Rod End)

4

Figure 20-42-27

1 3

1

2

P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-29]. P-51692

Check the orifice (Item 3) [Figure 20-42-29] in the poppet to be sure it is not plugged.

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-42-27].


WARNING 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 20-42-28

1 P-51693

Installation: Always use new O-ring (Item 1) [Figure 2042-28] on the anti-cavitation valve plug. Tighten the plug to 35-40 ft.-lb. (47-54 N•m) torque. 20-42-9


Port Relief/Anti-Cavitation Valve (Tilt, Base End)


Figure 20-42-32

Port Relief/Anti-Cavitation Valve (Lift, Base End) Figure 20-42-30

1

1 P-51692

Remove the tilt port relief/anti cavitation valve (Item 1) [Figure 20-42-32] from the base end of the tilt section.

P-51692

Loosen the lift circuit port relief/anti cavitation valve (Item 1) [Figure 20-42-30].

Figure 20-42-33

Figure 20-42-31

1

P-51454

1

Replace the O-ring (Item 1) [Figure 20-42-33] before installation.

P-51451


Installation: Tighten to 38-45 ft.-lb. (52-61 N•m) torque.


20-42-10


Port Relief Valve


Figure 20-42-36

Port Relief/Anti-Cavitation Valve (Tilt, Rod End) Figure 20-42-34

1

1

P-51692

Remove the port relief plug (Item 1) [Figure 20-42-36] from the auxiliary circuit of the control valve.

P-51692

Remove the tilt port relief/anti cavitation valve (Item 1) [Figure 20-42-34] from the rod end of the tilt section.

Figure 20-42-37

Figure 20-42-35

1 1

P-51695

Installation: Always use new O-rings (Item 1) [Figure 20-42-37]. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

P-51694

Replace the O-ring (Item 1) [Figure 20-42-35] before installation. Installation: Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

20-42-11


Plug Removal


Figure 20-42-40

Port Relief Valve (Cont’d) Figure 20-42-38

1

1

P-51459

At the top side of the control valve, remove the plug (Item 1) [Figure 20-42-40].

P-51696

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-42-38].

Figure 20-42-41

Remove the auxiliary port relief valve. Figure 20-42-39

1

1 P-51460

Installation: Always use new O-rings (Item 1) [Figure 20-42-41]. Tighten to 40 ft.-lb. (54 N•m) torque. P-51640

Installation: Always use new O-rings (Item 1) [Figure 20-42-39]. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

20-42-12


Rubber Boot Removal and Installation


Figure 20-42-44

Plug Removal (Cont’d)

1

Figure 20-42-42

1

1 P-51506

1 Remove the three screws (Item 1) [Figure 20-42-44] on the rubber boot retainer plate.

P-51461

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-42-42].

Installation: Tighten the screws to 90-100 in.-lb. (10, 11,3 N•m) torque.

Figure 20-42-43

Figure 20-42-45

1

2

1 1

P-51462

P-51701

Installation: Always use new O-rings (Item 1) [Figure 20-42-43]. Tighten to 40 ft.-lb. (54 N•m) torque.

Remove the rubber boots (Item 1) from the retainer plate (Item 2) [Figure 20-42-45].

20-42-13


Figure 20-42-48

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) End Cap/Spool Lock Block Removal and Installation Figure 20-42-46

1

1

2 1 P-51699

1

Remove the four end cap/spool lock block mount screws (Item 1) [Figure 20-42-48]. P-51697

Remove the lift spool lock solenoid (Item 1) and the tilt spool lock solenoid (Item 2) [Figure 20-42-46] from the end cap/spool lock block. Figure 20-42-47

Installation: Tighten the screws to 90 in.-lb. (10-11,3 N•m) torque. Remove the rubber boots and retainer plate from the lift and tilt spools. Figure 20-42-49

1

1 P-51698

P-51700

Disconnect the tube line (Item 1) [Figure 20-42-47] from the end cap/spool lock block.

Remove the end cap/spool lock block (Item 1) [Figure 20-42-49] from the control valve.

20-42-14


Figure 20-42-52

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool and Detent Removal and Installation The tool listed will be needed to do the following procedure: MEL1278 - Detent Tool MEL1285 - Detent Spring Tool

1

Remove the end cap/spool lock block from the control valve. Figure 20-42-50 P-51513

Remove the end cap (Item 1) [Figure 20-42-52]. Figure 20-42-53

1

P-51511

1 2

Remove the O-ring (Item 1) [Figure 20-42-50]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap/spool lock block.

P-51514

Figure 20-42-51 Use a screwdriver to remove the snap ring (Item 1) [Figure 20-42-53]. Remove the washer (Item 2) [Figure 20-42-53].

2 1

P-51512

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-51] from the lift spool.

20-42-15


Figure 20-42-56

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool and Detent Removal and Installation (Cont'd) Figure 20-42-54

2 3

1

1

2

1

P-51517

Remove the detent sleeve (Item 1), detent balls (Item 2) and spring (Item 3) [Figure 20-42-56].

2 P-51515

Figure 20-42-57

Remove the screws (Item 1) [Figure 20-42-54] from the detent bonnet. Remove the detent bonnet (Item 2) [Figure 20-42-54]. Installation: Lubricate the screws and tighten to 90-100 in.-lb. (10-11,3 N•m) torque.

IMPORTANT 1

The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly.

P-51518

I-2012-0284

Figure 20-42-55

Remove the lift spool assembly and seal (Item 1) [Figure 20-42-57] from the control valve.

P-51516

Put a rag around the detent assembly [Figure 20-42-55]. This will prevent the detent balls and spring from being lost when the detent sleeve is removed. 20-42-16


Figure 20-42-60


2

Lift Spool and Detent Removal and Installation (Cont'd) Figure 20-42-58

1 3

N-18915

1

Install the spring tool (Item 1) [Figure 20-42-60] over the centering spring. P-51519

Remove the lift spool seal (Item 1) [Figure 20-42-58] from the linkage end of the valve. Figure 20-42-59

NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-42-60] from the centering spring, as it is under spring pressure. NOTE: The centering spring (Item 3) [Figure 20-42-60] is white on all 700 series loaders. Figure 20-42-61

1

P-8988

2 N-18916

Clamp the linkage end of the spool in a vise [Figure 2042-59]. NOTE: Protect spool before clamping in vise.

Put a rag around the detent assembly [Figure 20-42-61]. This will prevent the detent balls and spring from being lost when the detent adapter is removed. Remove the detent adapter with an Alan wrench. Remove the back-up washer (Item 1) and spool seal (Item 2) [Figure 20-42-61].

20-42-17


Figure 20-42-64

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool and Detent Removal and Installation (Cont'd)

2

1

3

Figure 20-42-62 4

1

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-64]. Figure 20-42-65

N-19004

Remove the detent adapter (Item 1) [Figure 20-42-62] from the spring assembly. Figure 20-42-63 1

N-18918

Remove the stud from the end of the spool [Figure 2042-65]. N-19009

Remove spring tool (Item 1) [Figure 20-42-63] from the spring assembly.

20-42-18


Figure 20-42-68


N-18963

1

Install the plastic plug and O-ring in the spool [Figure 2042-68]. Figure 20-42-69

N-18920

Removal of the plastic plug:

O-Ring

Make a center point in the plug using a 1/16 inch drill. Drill a hole all the way through the plug using a 7/64 inch tap drill Turn a 6-32 tap (Item 1) [Figure 20-42-66] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap.

Plastic Plug

Clean all the debris from inside the spool bore. NOTE: DO NOT USE LOCTITE ON THE STUD THREADS. Figure 20-42-67

0.60 inch (15,2 mm) B-14712

Install the stud and tighten until the other end of the stud is out about 0.600 inch (15,2 mm) from the spool [Figure 20-42-69]. 2 1

N-18961

Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-42-67].

20-42-19


Figure 20-42-72


1 1

N-18968

Install the detent adapter to the collar [Figure 20-42-72].

Clamp the collar (Item 1) [Figure 20-42-70] in a vice.

NOTE: The collar and the detent adapter are held together by spring pressure when assembled to the lift spool not the detent balls. Hold the detent adapter and collar together to prevent the detent balls and spring from falling out.

Figure 20-42-71

Figure 20-42-73

N-18967

2 1

1

3 2 N-18958

N-19004

Apply grease on all the detent component surfaces before assembly [Figure 20-42-71].

Install the spring tool (Item 1) [Figure 20-42-73] over the washer, spring, collar and detent adapter.

Install the spring (Item 1) and detent balls (Item 2) into the adapter (Item 3) [Figure 20-42-71] and compress with the detent pliers (Item 1) [Figure 20-42-72].

20-42-20


Figure 20-42-76


2

CD-15051

1

Install the detent balls and spring [Figure 20-42-76]. Figure 20-42-77 N-18917

Install the spool seal (Item 1) and back-up washer (Item 2) [Figure 20-42-74]. Figure 20-42-75

1 N-19007

Hold the detent balls in place with the detent pliers [Figure 20-42-77].

N-19005

Install the spring assembly to the lift spool hand tight [Figure 20-42-75]. Remove the spring tool. Check the alignment of the detent adapter and the washer. Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m). NOTE: The adapter must fit in the center of the washer (Item 1) [Figure 20-42-75].

20-42-21


Figure 20-42-80


2 1 1 P-51514

Install the washer (Item 1) and snap ring (Item 2) [Figure 20-42-80]. Figure 20-42-81

N-19008

Install the detent sleeve (Item 1) [Figure 20-42-78] to the detent adapter. Figure 20-42-79 1

2 P-51513

1 Install the end cap (Item 1) [Figure 20-42-81]. 2 P-51515

Install the lift spool assembly in the spool bore [Figure 20-42-79]. Install the detent bonnet (Item 1) [Figure 20-42-79]. Install the mounting screws (Item 2) [Figure 20-42-79]. Installation: Lubricate the screws and tighten to 90-100 in.-lb. (10-11,3 N•m) torque.

20-42-22


Figure 20-42-84


1

Figure 20-42-82

1

P-51511

Install the O-ring (Item 1) [Figure 20-42-84] on the control valve. Figure 20-42-85

P-51520

Install the spool seal (Item 1) [Figure 20-42-82] on the linkage end of the valve.

2

Figure 20-42-83 1

3 4

1

P-51701

Install the end cap/spool lock block (Item 1) and the mount bolt (Item 2) [Figure 20-42-85].

2 P-51512

Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-42-83] on the lift spool.

Install the lift and tilt spool rubber boots and mount plate (Item 3) and install the three mounting screws (Item 4) [Figure 20-42-85]. Installation: Tighten the screws to 90-100 in.-lb. (1011,3 N•m) torque.

20-42-23


Tilt Spool Removal and Installation


Remove the lift and tilt end cap/spool lock block. (See End Cap/Spool Lock Block Removal and Installation on Page 20-40-14.)

Figure 20-42-86

Figure 20-42-88

1 1

2

P-51698

P-51521

Connect the tubeline (Item 1) [Figure 20-42-86].

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-88] from the tilt spool.

Figure 20-42-87

Figure 20-42-89

2 1 1

1

P-51697

P-51522

Use an Ohm meter to measure the lock solenoid coils resistance. The correct resistance for the coil is 5.5 ± .28 Ohms. Installation: Install the lift spool (Item 1) and tilt spool (Item 2) [Figure 20-42-87] lock solenoids and tighten to 35-45 ft.-lb. (52-61 N•m) torque.

Remove the three screws (Item 1) [Figure 20-42-89] from the spool centering block. Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3 N•m) torque.

20-42-24


Figure 20-42-92

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Tilt Spool Removal And Installation (Cont'd)

1

Figure 20-42-90

2

N-18942

Put the linkage end of the spool in the vice [Figure 2042-92].

1 P-51543

Remove the spool centering block (Item 1) [Figure 2042-90] from the control valve.

Install the spool tool (Item 1) [Figure 20-42-92] over the centering spring. Figure 20-42-93

Check and replace the O-ring (Item 2) [Figure 20-42-90] before replacing the spool centering block. 1

Figure 20-42-91

N-19014

Remove the bolt (Item 1) [Figure 20-42-93] holding the centering spring to the spool. P-51544

Remove the tilt spool, centering spring, back-up washer and spool seal [Figure 20-42-91].

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque. Remove spring tool from the spring assembly.


20-42-25


Auxiliary Spool Removal And Installation


Figure 20-42-96

Tilt Spool Removal And Installation (Cont'd) Figure 20-42-94

2 2

1 1

3 4 1

P-51522

Remove the three screws (Item 1) [Figure 20-42-96] from the spool centering block.

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-94].

Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3 N•m) torque.

Figure 20-42-95

Remove the spool centering block (Item 2) [Figure 2042-96] from the control valve. 2

Figure 20-42-97

1

1

2 1

P-51545

N-18943

Remove the spool seal(s) (Item 1) [Figure 20-42-95] and the back-up washer (Item 2) [Figure 20-42-95]. Assembly: Always use a new spool seal.

P-51546

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-97] from the auxiliary spool. Note:

20-42-26

If the centering spring retainer (Item 2) [Figure 20-42-97] must be replaced, replace the retainer on the opposite end also.


Figure 20-42-100

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-42-98

1

2

1 2

P-51550

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-100] from the auxiliary spool. P-51547

Figure 20-42-101 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-98] from the auxiliary spool. Figure 20-42-99 1

2

1 P-51551

Remove the spool (Item 1) [Figure 20-42-101]. P-51549

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-99] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-42-99] must be replaced, replace the retainer on the opposite end also.

20-42-27


Figure 20-42-104

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Auxiliary Solenoid Disassembly and Assembly Figure 20-42-102

1

1 1

P-51703

Remove the solenoid stem (Item 1) [Figure 20-42-104]. Installation: Tighten the stem to 10-14 ft.-lb. (14-19 N•m) torque.

P-51702

Remove the nut (Item 1) [Figure 20-42-102] from both solenoids.

Figure 20-42-105

Installation: Tighten the nut to 48-72 in.-lb. (5-8 N•m) torque. Figure 20-42-103 1

1 2

2

P-51555

Remove the O-rings (Item 1) [Figure 20-42-105] from the solenoid stem. Check and clean the screen (Item 2) [Figure 20-42-105].

P-51553

Remove the nut (Item 1) and solenoid coil (Item 2) [Figure 20-42-103]. Use an Ohm meter to measure the solenoid coil resistance. The correct resistance for the coil is 4.9 ± .25 Ohms.

20-42-28


Figure 20-42-108

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve Solenoid Disassembly And Assembly Figure 20-42-106

1 1

2 P-51445

Remove the solenoid stem (Item 1) [Figure 20-42-108]. Installation: Lubricate the O-rings and tighten the stem to 20-24 ft.-lb. (27-33 N•m) torque.

P-51444

Remove the nut (Item 1) [Figure 20-42-106] from the solenoid stem.

Figure 20-42-109

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque. Remove the solenoid coil (Item 2) [Figure 20-42-106]. 2

Figure 20-42-107

3

1 1 1 N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-109] from the cartridge. Clean all parts in solvent and dry with compressed air. N-18693A

Remove the O-rings (Item 1) [Figure 20-42-107] from both ends of the solenoid coil. Use an Ohm meter to measure the solenoid coil resistance. The correct resistance for the coil is 9.79 ± .29 Ohms.

Inspect all parts for wear and replace any showing excessive wear. NOTE: The screen (Item 3) [Figure 20-42-109] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-42-107] & [Figure 20-42-109] and new back-up rings (Item 2) [Figure 20-42-109] on the solenoid stem.

20-42-29


Figure 20-42-112

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lock Valve Removal And Installation Figure 20-42-110

1 1 1 2

1

1 2 2 2 P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-112] from the lift lock valve, and replace with new.

P-51704

Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-42-110] is for the lift circuit. Figure 20-42-111

1

P-51443

Remove the lift lock valve (Item 1) [Figure 20-42-111] from the back of the control valve. Installation: Lightly lubricate the lock valve o-rings and tighten to 20-24 ft.-lb. (27-33 N•m) torque.

20-42-30


Figure 20-42-115

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lock Valve Removal And Installation (Cont’d) Figure 20-42-113

1 1

P-51706

Remove the tilt lock valve (Item 1) [Figure 20-42-115] from the front of the control valve. Installation: Lightly lubricate the lock valve o-rings and tighten to 20-24 ft.-lb. (27-33 N•m) torque.

P-51705

Locate the tilt circuit lock valve (Item 1) [Figure 20-42113].

Figure 20-42-116

Figure 20-42-114 1 1 1

2

1 2 1

2 2 P-51564

P-51697P51504

Remove the lift spool lock solenoid (Item 1) [Figure 2042-114].

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-116] from the tilt lock valve, and replace with new.

Remove the tilt spool lock solenoid (Item 2) [Figure 2042-114]. Installation: Lubricate the O-rings and tighten the spool lock solenoids to 38-45 ft.-lb. (52-61 N•m) torque.

20-42-31


Figure 20-42-119


1

BICS™ Valve, Check Valve Removal And Installation Figure 20-42-117

2 3

1

4 P-51447

Check that there is no blockage in the orifice (Item 1) [Figure 20-42-119]. P-51438

Inspect the check valve (Item 2) and spring (Item 3) [Figure 20-42-119].

Remove the BICS™ valve (Item 1) [Figure 20-42-117]. Installation: Lubricate the o-ring and tighten the valve to 55-65 ft.-lb. (75-88 N•m) torque.

Replace the O-ring (Item 4) [Figure 20-42-119] on the plug before installation.

Figure 20-42-118

1

P-51446

Remove the plug (Item 1) [Figure 20-42-118] from the top of the BICS™ valve.

20-42-32


Main Relief Valve


Figure 20-42-122

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly Figure 20-42-120

1

P-51707

1

Remove the main relief valve (Item 1) [Figure 20-42122].

P-51436


Figure 20-42-123

Figure 20-42-121

1

1 P-51463

Remove the O-rings from the main relief valve (Item 1) [Figure 20-42-123].

P-51437

Check the lift arm by-pass orifice (Item 1) [Figure 20-42121].

Installation: Always use new O-rings. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

NOTE: This orifice is not removable from the valve casting.

20-42-33


20-42-34


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)

IMPORTANT



Lift and block the loader. ((See Procedure on Page 1010-1.)

1

Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

P-51730

The hydraulic control valve (1 piece casting) (ACS) (Item 1) [Figure 20-43-1] does not have a removable BICS™ section. The BICS™ section and main control valve are in one casting. For identification of the hydraulic control valve (2 piece casting) (ACS), (See Identification on Page 20-41-1.)

Clean the area around the control valve. Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.) Figure 20-43-2


1

P-34004

WARNING




W-2059-0598

20-43-1


Figure 20-43-5


4

Removal and Installation (Cont’d) Figure 20-43-3

1

1

2

3

1

P-51975

Mark and disconnect the two auxilliary electric solenoid connectors (Item 1) [Figure 20-43-5] for correct installation.

P-51710

Remove the outlet tubeline (Item 2) [Figure 20-43-5] from the control valve to the hydraulic oil cooler.

Mark all tubelines and hoses for correct installation. The fixed end main valve hose (Item 1) [Figure 20-43-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.

Disconnect and cap the supply hose (Item 3) and the supply hose clamp (Item 4) [Figure 20-43-5]. Figure 20-43-6 1

NOTE: Remember the hose routing for ease of control valve installation. Figure 20-43-4

3 2

P-51976

1

Disconnect and cap the tubeline (Item 1) [Figure 20-436] from the lift arm by-pass valve to the control valve. Disconnect and cap the hose (Item 2) [Figure 20-43-6] from the lift arm by-pass valve to the drive motor case drain.

P-31999

Remove the tie-strap (Item 1) [Figure 20-43-4] from the fixed end main valve hose.

Remove the lift arm by-pass tubeline (Item 3) [Figure 20-43-6] from the control valve drain.

20-43-2


Figure 20-43-9

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont'd) Figure 20-43-7

1 1 P-51983

Disconnect the connectors (Item 1) [Figure 20-43-9] from the lift and tilt actuators. P-51719

Remove the tie-strap (Item 1) [Figure 20-43-7] from the main valve mounting bracket. Figure 20-43-8

1

P-51977

Disconnect the wire harness tie-strap mounts (Item 1) [Figure 20-43-8] from the lift arm by-pass bracket.

20-43-3


Figure 20-43-12


1

1

2

1

P-51980

Remove and cap both tubelines (Item 1) [Figure 20-4312] from the auxiliary section of the control valve. P-51721

Remove the two lift arm by-pass valve mounting bolts (Item 1) [Figure 20-43-10].

Disconnect and cap the drain hose (Item 2) [Figure 2043-12] from the control valve. Figure 20-43-13

Remove the lift arm by-pass valve and mounting bracket. Figure 20-43-11 2 1 1

3

P-51982

Disconnect and cap the tubelines (Item 1) and (Item 2) [Figure 20-43-13] from the tilt section of the control valve.

P-51727

Remove tubeline clamp bolt (Item 1) [Figure 20-43-11] from the auxiliary tubelines in the left rear upright.

Disconnect and cap the tubeline (Item 3) [Figure 20-4313] from the lift section of the control valve.

Installation: Tighten bolt to 15-20 ft.-lb. (20-27 N•m) torque.

20-43-4


Figure 20-43-16


1

1

P-51726

1

Connect a hoist to the lifting brackets (Item 1) [Figure 20-43-16] on the control valve. P-51728

Figure 20-43-17 Remove the fixed-end main valve hose (Item 1) [Figure 20-43-14] from the main control valve fitting. Figure 20-43-15 1

1

P-31999 P-34004P51713

Remove the two mounting bolts (Item 1) [Figure 20-4317] fastening the control valve and bracket to the side of the loader.

P-51722

Mark and disconnect the BICS™ electric solenoid connector (Item 1) [Figure 20-43-15].

Remove the control valve from the loader. Reverse procedure for installation.

20-43-5


Figure 20-43-20

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out of Loader) Remove the control valve from the loader. Figure 20-43-18

1 1

P-51734

1

Using a drift pin and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-20] from the actuator and the tilt spool. Remove the actuator and linkage pin from the valve.

P-51732

Remove the two mount bolts (Item 1) [Figure 20-43-18] from the tilt actuator.

Figure 20-43-21

Installation: Tighten the mounting bolts to 90-100 in.-lb. (10,2-11,3 N•m) torque. 1

Figure 20-43-19

2 1

P-51736

Inspect the O-ring (Item 1) [Figure 20-43-21] on the face of the actuator, and replace as needed. Check the linkage pin (Item 2) [Figure 20-43-21] and replace as needed.

P-51733

Slide the actuator mount bracket (Item 1) [Figure 20-4319] away from the control valve. Pull the actuator away from the control valve [Figure 2043-19].

20-43-6


Figure 20-43-24

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out of Loader) (Cont’d) Figure 20-43-22

1 1 P-51800

Using a drift pin and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-24] from the actuator and the tilt spool.

1 P-51737

Remove the actuator and linkage pin from the valve. Remove the two mount bolts (Item 1) [Figure 20-43-22] from the lift actuator.

Figure 20-43-25

Installation: Tighten the mounting bolts to 90-100 in.-lb. (10,2-11,3 N•m) torque. Figure 20-43-23

1

1 2 P-51736

Inspect the O-ring (Item 1) [Figure 20-43-25] on the face of the actuator, and replace as needed. Check the linkage pin (Item 2) [Figure 20-43-25] and replace as needed.

P-51799

Slide the actuator mount bracket (Item 1) [Figure 20-4323] away from the control valve. Pull the actuator away from the control valve [Figure 2043-23].

20-43-7


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out of Loader) (Cont’d) Figure 20-43-26 1 4

1

2 3 P-51738

NOTE: The two longer bolts (Item 1) are used to mount the lift actuator and end cap (Item 2) [Figure 20-43-26] to the control valve. The two shorter mount bolts (Item 3) are used to mount the tilt actuator to the end cap (Item 4) [Figure 20-43-26]. Installation: Tighten the mounting bolts to 90-100 in.-lb. (10,2-11,3 N•m) torque (Item 1) [Figure 20-43-26]

20-43-8


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Identification Chart (ACS) Figure 20-43-27

C2 D5

J2 J4

C3

B3

E3 G1

F2 D4

G2

E3

A3

B2

D3 E2

A2 D1

D2 A1 F1

H2

B1 MR H1

E1 H3

C1 J1

J3 MS1929

ITEM

S175/S185 LOADER

ITEM

S175/S185 LOADER

A1 A2 A3

Lift Cylinder Base End Tilt Cylinder Base End

E1 E2 E3 F1 F2 G1 G2 H1

Lift Spool Centering Spring Tilt Spool Centering Spring Auxiliary Spool/Centering Springs LIft Spool Tilt Spool Auxiliary Solenoid Stem Auxiliary Solenoid Stem

H2

BICS™ Lock Valve (Tilt)

H3

BICS™ Lock Valve (Lift)

J1 J2 J3 J4

Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm By-Pass Orifice Drain (Case) Main Relief Valve – 3300 PSI

B1 B2 B3 C1 C2 C3 D1 D2 D3 D4 D5

Auxiliary Hydraulic Rod End Lift Cylinder Rod End Tilt Cylinder Rod End Auxiliary Hydraulics Base End Load Check/BICS™ Valve Lift Load Check Valve Tilt Function Load Check Valve Auxiliary Function Anti-Cavitation Valve Lift (Rod End) Port Relief/Anti-Cavitation Valve – 3500 PSI Lift (Base End) Port Relief/Anti-Cavitation Valve – 3500 PSI Tilt (Base End) Port Relief/Anti-Cavitation Valve – 3500 PSI Tilt (Rod End) Port Relief/Anti-Cavitation Valve (Auxiliary) 3500 PSI (Optional)

MR

20-43-9

BICS™ Valve Solenoid



BICS™ Valve, Lift Load Check Valve Removal And Installation

Mount Bracket Removal and Installation

Figure 20-43-30

Figure 20-43-28

1

P-51740

1 P-51730

Remove the control valve and mount bracket (Item 1) [Figure 20-43-28] from the loader. Figure 20-43-29

Remove the lift load check valve (Item 1) [Figure 20-4330]. Installation: Lubricate the O-ring and tighten the valve to 55-65 ft.-lb. (75-88 N•m) torque. Figure 20-43-31

1 1

2 2 P-51731 P-51439

Disconnect the tubeline (Item 1) [Figure 20-43-29] from the inlet fitting on the control valve. Remove the two mount bolts (Item 2) [Figure 20-43-29] from the control valve mount plate. Remove the mount plate and tubeline.

Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-43-31].

20-43-10


Figure 20-43-34

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lift Load Check Valve Removal And Installation (Cont’d)

4

Figure 20-43-32 1

1 3

2

P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-34]. Check the orifice (Item 3) [Figure 20-43-34] in the poppet to be sure it is not plugged.

P-51440

Check for free movement of the load check valve (Item 1) [Figure 20-43-32]. Load Check Valve Removal And Installation (Tilt & Auxiliary)


Figure 20-43-33

2 1

P-51741

At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-43-33]. At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-43-33]. NOTE: The tilt and auxiliary load check valves are interchangeable.

20-43-11


Figure 20-43-37

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Anti-Cavitation Valve (Lift, Rod End)

4

Figure 20-43-35

1 3

2

P-51453

1 Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-37]. P-51742

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-43-35].

Check the orifice (Item 3) [Figure 20-43-37] in the poppet to be sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4337] on the plug and lightly lubricate with oil before installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m) torque.

WARNING 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 20-43-36

1 P-51452

Always use new O-ring (Item 1) [Figure 20-43-36] on the anti-cavitation valve plug.

20-43-12


Port Relief/Anti-Cavitation Valve (Tilt, Base End)


Figure 20-43-40

Port Relief/Anti-Cavitation Valve (Lift, Base End) Figure 20-43-38

1

1 P-51742

Remove the tilt port relief/anti cavitation valve (Item 1) [Figure 20-43-40] from the base end of the tilt section.

P-51742

Loosen the lift circuit port relief/anti cavitation valve (Item 1) [Figure 20-43-38].

Figure 20-43-41

Figure 20-43-39

1

1

P-51454


P-51451


Installation: Lightly lubricate with oil and tighten to 38-45 ft.-lb. (52-61 N•m) torque.


20-43-13


Port Relief Valve


Figure 20-43-44

Port Relief/Anti-Cavitation Valve (Tilt, Rod End) Figure 20-43-42

1

1

P-51742

Remove the port relief plug (Item 1) [Figure 20-43-44] from the auxiliary circuit of the control valve.

P-51742

Remove the tilt port relief/anti cavitation valve (Item 1) [Figure 20-43-42] from the rod end of the tilt section.

Figure 20-43-45

Figure 20-43-43

1 1

P-51801

P-51455


Installation: Always use new O-rings (Item 1) [Figure 20-43-45]. Lightly lubricate with oil and tighten to 38-45 ft.-lb. (52-61 N•m) torque.


20-43-14


Plug Removal


Figure 20-43-48

Port Relief Valve (Cont’d) Figure 20-43-46

1

1

P-51459

At the top side of the control valve, remove the plug (Item 1) [Figure 20-43-48].

P-51743

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-43-46].

Figure 20-43-49

Remove the auxiliary port relief valve. Figure 20-43-47

1

1 P-51460

Installation: Always use new O-rings (Item 1) [Figure 20-43-49]. Tighten to 40 ft.-lb. (54 N•m) torque. P-51640

Installation: Always use new O-rings (Item 1) [Figure 20-43-47]. Lightly lubricate with oil and tighten to 38-45 ft.-lb. (52-61 N•m) torque.

20-43-15


End Cap Block Removal and Installation


Remove the lift and tilt actuators from the control valve. (See Actuator Removal And Installation (Out of Loader) on Page 20-43-6.)

Plug Removal (Cont’d) Figure 20-43-50

Figure 20-43-52

1 1 2

P-51461

P-51744

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-43-50]. Figure 20-43-51

Disconnect the tube line (Item 1) [Figure 20-43-52] from the end cap block. Remove the two end cap block mount screws (Item 2) [Figure 20-43-52]. Installation: Tighten the screws to 90-100 in.-lb. (1011,3 N•m) torque. Figure 20-43-53

1

P-51462

1

Installation: Always use new O-rings (Item 1) [Figure 20-43-51]. Tighten to 40 ft.-lb. (54 N•m) torque.

P-51745

Remove the end cap block (Item 1) [Figure 20-43-53] from the control valve.

20-43-16


Figure 20-43-56

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal and Installation

1

The tool listed will be needed to do the following procedure: MEL 1285 - Spring Tool Remove the end cap block from the control valve. Figure 20-43-54

1 P-51748

Remove the two screws (Item 1) [Figure 20-43-56] from the lift spool end cap. 1

Installation: Lubricate the screws and tighten to 90-100 in.-lb. (10-11,3 N•m) torque. Figure 20-43-57

P-51746

Remove the O-ring (Item 1) [Figure 20-43-54]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap block. 1

Figure 20-43-55

P-51749

Remove the lift spool end cap (Item 1) [Figure 20-43-57] from the control valve.

2 1

P-51747

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-55] from the lift spool.

20-43-17


Figure 20-43-60

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal and Installation (Cont'd) Figure 20-43-58

P-51772

Clamp the linkage end of the spool in a vise [Figure 2043-60].

1 P-51770

NOTE: Protect spool before clamping in vise. Remove the lift spool assembly and seal (Item 1) [Figure 20-43-58] from the control valve.

Figure 20-43-61

Figure 20-43-59

1

1

P-51773

Install the spring tool (Item 1) [Figure 20-43-61] over the centering spring.

P-51771

Remove the lift spool seal (Item 1) [Figure 20-43-59] from the linkage end of the valve.

20-43-18


Figure 20-43-64

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal and Installation (Cont'd)

1

Figure 20-43-62

2

1

1

P-51771

P-51775

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-43-64]. N-190146

Assembly: Always use a new spool seal. Remove the bolt (Item 1) [Figure 20-43-62] holding the centering spring to the spool.

Figure 20-43-65


1

Remove spring tool from the spring assembly. Figure 20-43-63 3

3

2 3

2 4

1

P-51749

Install the lift spool assembly (Item 1) [Figure 20-43-65] in the spool bore. Install the end cap (Item 2) [Figure 20-43-65]. Install the mounting screws (Item 3) [Figure 20-43-65].

P-51776

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-43-63].

Installation: Lubricate the screws and tighten to 90-100 in.-lb. (10-11,3 N•m) torque.

20-43-19


Figure 20-43-68

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal and Installation (Cont'd) Figure 20-43-66

1

1

P-51746

Install the O-ring (Item 1) [Figure 20-43-68] on the control valve. P-51777

Figure 20-43-69 Install the spool seal (Item 1) [Figure 20-43-66] on the linkage end of the valve. Figure 20-43-67

3 2 1

2

1 P-51744

2

Install the end cap block (Item 1) and the two mount bolts (Item 2) [Figure 20-43-69]. P-51747

Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-43-67] on the lift spool.

Installation: Tighten the screws to 90-100 in.-lb. (1011,3 N•m) torque. Connect the tube line (Item 3) [Figure 20-43-69] to the end cap block. Install the lift and tilt actuators to the control valve.

20-43-20


Figure 20-43-72

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Tilt Spool Removal and Installation Remove the end cap block. (See End Cap Block Removal and Installation on Page 20-43-16.) Figure 20-43-70

2

1 P-51780

Remove the spool centering block (Item 1) [Figure 2043-72] from the control valve.

2

1

Check and replace the O-ring (Item 2) [Figure 20-43-72] before replacing the spool centering block. P-51778

Figure 20-43-73 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-70] from the tilt spool. Figure 20-43-71

1

1 2 P-51781

2

Remove the tilt spool, centering spring, back-up washer and spool seal (Item 1) [Figure 20-43-73]. P-51779

Assembly: Always use a new spool seal. Disconnect the tubeline (Item 1) [Figure 20-43-71]. Remove the three screws (Item 2) [Figure 20-43-71] from the spool centering block. Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3 N•m) torque.

20-43-21


Figure 20-43-76

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Tilt Spool Removal And Installation (Cont'd)

2

Figure 20-43-74

1

3 4 1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-43-76]. N-18942

Figure 20-43-77 Put the linkage end of the spool in the vice [Figure 2043-74].

2 1

Install the spring tool (Item 1) [Figure 20-43-74] over the centering spring. Figure 20-43-75

1

1

P-51545

N-18943

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-43-77]. Assembly: Always use a new spool seal. N-19014

Remove the bolt (Item 1) [Figure 20-43-75] holding the centering spring to the spool. Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 N•m) torque. Remove spring tool from the spring assembly.

20-43-22


Figure 20-43-80

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Auxiliary Spool Removal And Installation Figure 20-43-78

2

1

1 2

P-51783

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-80] from the auxiliary spool.

2

P-51779

Figure 20-43-81 Disconnect the tubeline (Item 1) [Figure 20-43-78] from the spool centering block. Remove the three screws (Item 2) [Figure 20-43-78] from the spool centering block. Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3 N•m) torque. 1

Remove the spool centering block from the control valve. 2

Figure 20-43-79

P-51784

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-81] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-43-81] must be replaced, replace the retainer on the opposite end also. 2 1 P-51782

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-79] from the auxiliary spool. Note:

If the centering spring retainer (Item 2) [Figure 20-43-79] must be replaced, replace the retainer on the opposite end also.

20-43-23


Auxiliary Solenoid Disassembly and Assembly


Figure 20-43-84

Auxiliary Spool Removal And Installation (Cont’d) Figure 20-43-82

1

1

1 2 P-51552

Remove the nut (Item 1) [Figure 20-43-84] from both solenoids.

P-51785

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-82] from the auxiliary spool.

Installation: Tighten the nut to 48-72 in.-lb. (5-8 N•m) torque.

Figure 20-43-83

Figure 20-43-85

1

2

1

P-51786

Remove the auxiliary spool (Item 1) [Figure 20-43-83].

P-51553

Remove the nut (Item 1) and solenoid coil (Item 2) [Figure 20-43-85]. Use an Ohm meter to measure the solenoid coil resistance. The correct resistance for the coil is 4.9 ± .25 Ohms.

20-43-24


BICS™ Valve Solenoid Disassembly And Assembly


Figure 20-43-88

Auxiliary Solenoid Disassembly and Assembly (Cont’d) Figure 20-43-86

1

1 2

P-51788

Remove the nut (Item 1) [Figure 20-43-88] from the solenoid stem.

P-51787

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Remove the solenoid stem (Item 1) [Figure 20-43-86]. Installation: Tighten the stem to 10-14 ft.-lb. (14-19 N•m) torque.

Remove the solenoid coil (Item 2) [Figure 20-43-88]. Figure 20-43-89

Figure 20-43-87 1 1

1

2 N-18693A P-51555

Remove the O-rings (Item 1) [Figure 20-43-87] from the solenoid stem. Check and clean the screen (Item 2) [Figure 20-43-87].

Remove the O-rings (Item 1) [Figure 20-43-89] from both ends of the solenoid coil. Use an Ohm meter to measure the solenoid coil resistance. The correct resistance for the coil is 9.79 ± .29 Ohms.

20-43-25



Use only new O-rings and apply oil to all O-rings and back-up rings before installation.

BICS™ Valve Solenoid Disassembly And Assembly (Cont’d)

Install new O-rings (Item 1) [Figure 20-43-89] & [Figure 20-43-91] and new back-up rings (Item 2) [Figure 20-4391] on the solenoid stem.

Figure 20-43-90

BICS™ Valve, Lock Valve Removal And Installation Figure 20-43-92

1 2

1

P-51789

Remove the solenoid stem (Item 1) [Figure 20-43-90].

P-51790

Installation: Lubricate the O-rings and tighten the stem to 20-24 ft.-lb. (27-33 N•m) torque. Figure 20-43-91

2

Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-43-92] is for the lift circuit. Figure 20-43-93

3

1 1 N-18694 P-51791

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-91] from the stem. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and replace any showing excessive wear.

Remove the lift lock valve (Item 1) [Figure 20-43-93] from the back of the control valve. Installation: Lightly lubricate the lock valve o-rings and tighten to 20-24 ft.-lb. (27-33 N•m) torque.

NOTE: The screen (Item 3) [Figure 20-43-91] may be cleaned with solvent. If it is torn or worn it needs to be replaced.

20-43-26


Figure 20-43-96

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lock Valve Removal And Installation (Cont’d)

1

Figure 20-43-94

1 1 1

1 2

1 1

2 2 P-51564

1 2

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-96] from the tilt lock valve, and replace with new.

2 2 P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-94] from the lift lock valve, and replace with new. Figure 20-43-95

1

P-51792

Remove the tilt lock valve (Item 1) [Figure 20-43-95] from the back of the control valve. Installation: Lightly lubricate the lock valve o-rings and tighten to 20-24 ft.-lb. (27-33 N•m) torque.

20-43-27


Figure 20-43-99


1

BICS™ Valve, Check Valve Removal And Installation Figure 20-43-97

2 3

4 P-51447

1

Check that there is no blockage in the orifice (Item 1) [Figure 20-43-99]. P-51788

Inspect the check valve (Item 2) and spring (Item 3) [Figure 20-43-99].

Remove the BICS™ valve (Item 1) [Figure 20-43-97]. Installation: Lubricate the o-ring and tighten the valve to 55-65 ft.-lb. (75-88 N•m) torque.

Replace the O-ring (Item 4) [Figure 20-43-99] on the plug before installation.

Figure 20-43-98

1

P-51446

Remove the plug (Item 1) [Figure 20-43-98] from the top of the BICS™ valve.

20-43-28


Main Relief Valve


Figure 20-43-102

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly Figure 20-43-100

1

1

P-51794

Remove the main relief valve (Item 1) [Figure 20-43102].

P-51793


Figure 20-43-103

Figure 20-43-101

1 1 P-51463

Remove the O-rings from the main relief valve (Item 1) [Figure 20-43-103].

P-51437

Check the lift arm by-pass orifice (Item 1) [Figure 20-43101].

Installation: Always use new O-rings. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

NOTE: This orifice is not removable from the valve casting.

20-43-29


20-43-30


Figure 20-50-1

LIFT ARM BY-PASS CONTROL VALVE Raise the lift arms 6 feet (2 m) off the ground. Stop the engine. Turn the Lift Arm By-Pass Control Knob clockwise 1/4 turn. Then pull the Lift Arm By-Pass Control Knob until the lift arms slowly lower.

1


3

4

1 P-31990A

The Lift Arm By-Pass valve (Item 1) [Figure 20-50-1] is located under the right side of the control panel.


Hold the Lift Arm By-Pass Control knob (Item 2) and loosen the jam nut (Item 3) on the Lift Arm By-Pass valve shaft [Figure 20-50-1]. Remove the Lift Arm By-Pass Control knob (Item 2) and the jam nut (Item 3) from the Lift Arm By-Pass valve shaft [Figure 20-50-1]. Remove the rubber washer (Item 4) [Figure 20-50-1].

Install jack stands under the rear corners of the loader. Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.)

20-50-1


LIFT ARM BY-PASS CONTROL VALVE (CONT'D)

Disassembly And Assembly


Figure 20-50-3

Figure 20-50-2

1

1 4

2 3 P-26065 P-48431

Disconnect the base end lift tubeline (Item 1) [Figure 2050-2] from the Lift Arm By-Pass valve. Disconnect the drain hose (Item 2) [Figure 20-50-2] from the Lift Arm By-Pass valve. Disconnect the motor case drain hose (Item 3) [Figure 20-50-2].

Remove the by-pass valve (Item 1) [Figure 20-50-3] from the valve block. Inspect the by-pass valve for damage and replace if necessary. Installation: Tighten the valve to 33-37 ft.-lb. (45-50 N•m) torque. Inspect the hydraulic fittings on the valve block for damage and replace if necessary.

Remove the two mounting bolt/nuts (Item 4) [Figure 2050-2]. Installation: Tighten the mounting bolts to 180-200 in. lb. (21-23 N•m) torque. Remove the lift arm by-pass control valve.

20-50-2


Figure 20-60-1

HYDRAULIC PUMP Check The Output Of The Hydraulic Pump Without Power Bob-Tach

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

1 P-26071

WARNING

Disconnect the OUTLET hose (Item 1) [Figure 20-60-1] from the pump.


Figure 20-60-2

W-2059-0598


2

1

MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit 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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

P-24594

Connect the INLET hose (Item 1) [Figure 20-60-2] from the tester to the OUTLET fitting (Item 2) [Figure 20-60-1] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-60-2] from the tester to the hose (Item 1) [Figure 20-60-1] which was disconnected from the pump.

Open the rear door of the loader. Connect the remote start tool. (See Procedure on Page 10-60-1.)

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284

20-60-1


HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump Without Power Bob-Tach (Cont'd) Figure 20-60-3 Reservoir

Hydraulic Pump Out In

EXAMPLE: TESTER CONNECTION

Hydraulic Control Valve

1 B-16277

Sample tester connection shown [Figure 20-60-3]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-60-3] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

X100

A low percentage may indicate a failed pump. *Refer to SPECIFICATIONS Section SPEC-01 for system relief pressure and full RPM.

20-60-2


Figure 20-60-4

HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach.

1

2


P-26682

WARNING

Disconnect the OUTLET hose (Item 1) [Figure 20-60-4] from the top of the Power Bob-Tach block.


Figure 20-60-5

W-2059-0598


1

2


P-24594

Connect the INLET hose (Item 1) [Figure 20-60-5] from the tester to the OUTLET fitting (Item 2) [Figure 20-60-4] on the top of the Power Bob-Tach block. Connect the OUTLET hose (Item 2) [Figure 20-60-5] from the tester to the hose (Item 1) [Figure 20-60-4] which was disconnected from the Power Bob-Tach block.



20-60-3


HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach. (Cont'd) Figure 20-60-6 Reservoir




1 B-16277

Sample tester connection shown [Figure 20-60-6]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-60-6] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=


X100


20-60-4


Remove the Power Bob-Tach block if equipped. (See Removal And Installation on Page 20-120-1.)

HYDRAULIC PUMP (CONT'D) Removal And Installation

Disconnect and cap the outlet hose (Item 1) [Figure 20-60-7] from the back of the hydraulic pump. Figure 20-60-8


Figure 20-60-7

1 P-26068

Disconnect and cap the inlet hose (Item 1) [Figure 20-60-8] from the front of the hydraulic pump. Figure 20-60-9

1

2 1

P-26071 P-26069

Raise the lift arms and install an approved lift arm support device. (See Procedure on Page 10-10-1.) Stop the engine. Raise the seat bar.

Remove the two mounting bolts [Figure 20-60-9] from the hydraulic pump.

(Item

1)

Lift and block the rear of the loader. (See Installing Lift Arm Support Device on Page 10-20-1.)

Installation: Tighten the mounting bolts to 27-37 in.-lb. (37-50 N•m) torque.


Remove the hydraulic pump (Item 2) [Figure 20-60-9] from the hydrostatic pump.

Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Open the rear door of the loader.

20-60-5


HYDRAULIC PUMP (CONT'D) Removal And Installation (Cont’d) Figure 20-60-10

P-26347

1

2

P-26347

Remove the O-ring (Item 1) [Figure 20-60-10]. Remove the coupler (Item 2) [Figure 20-60-10] from the hydraulic pump shaft. Reverse the removal procedure to install the hydraulic pump. Installation: Use a new O-ring (Item 1) [Figure 20-60-10] when installing the hydraulic pump. (See Disassembly And Assembly on Page 20-60-8.)

20-60-6


HYDRAULIC PUMP (CONT'D) Identification

15

7

8

6 14

11

1

3

4

5

7

9

13

12

10

2

B-16050A

REF.

DESCRIPTION

REF.

1

RETAINING RING

2

PUMP END SECTION

10

PUMP CENTER SECTION

3

PRE-LOAD SEAL

11

WEAR PLATE

4

LOAD SEAL

12

SECTION SEAL

5

SECTION SEAL

13

PUMP END SECTION

6

WEAR PLATE

14

BOLTS (4)

7

PINS

15

BOLTS (4)

8

DRIVE GEAR

9

20-60-7

DESCRIPTION IDLER GEAR


HYDRAULIC PUMP (CONT'D)

Figure 20-60-12


1

Figure 20-60-11

1 P-26352

2

2

P-26353

1 Remove the pump [Figure 20-60-12].

P-26351

Mark the pump [Figure 20-60-11].

sections

for

correct

end

section

(Item

1)

assembly

Remove the four smaller pump housing bolts (Item 1) [Figure 20-60-11]. Remove the four larger pump housing bolts (Item 2) [Figure 20-60-11]. Installation: Tighten the four smaller bolts (Item 1) to 30 ft.-lb. (40,7 N•m) torque. Tighten the four larger bolts (Item 2) [Figure 20-60-11] to 54 ft.-lb. (73,2 N•m) torque.


20-60-8


Figure 20-60-15

HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd)

1

Figure 20-60-13

1

P-26358

2

Figure 20-60-16 P-26354

1

Figure 20-60-14

4

3

1

P-26359

2

Remove the pump center section (Item 1) [Figure 20-60-15] & [Figure 20-60-16] from the pump end section.

P-26355

Remove the wear plate (Item 1) [Figure 20-60-13] & [Figure 20-60-14] and section seal (Item 2) [Figure 20-60-13] & [Figure 20-60-14] from the pump end section.

NOTE: Inspect the pump center section (Item 1) [Figure 20-60-16]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Position wear plate (Item 1) [Figure 20-60-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) and bushings (Item 4) [Figure 20-60-14]. If excessive wear or damage is visible, the pump must be replaced.

20-60-9


Figure 20-60-19

HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-60-17

1

1 P-26391

Figure 20-60-20 P-26389

Figure 20-60-18 2 P-26362

1

1 P-26362

P-26390

Remove the idler gear (Item 1) [Figure 20-60-17] & [Figure 20-60-18].

To remove the drive gear (Item 1) [Figure 20-60-19] from the pump end section, locate and remove the retaining ring (Item 2) (Inset) [Figure 20-60-20] from the spline end of the drive gear.

NOTE: Inspect the idler gear (Item 1) [Figure 20-6018]. If excessive wear or damage is visible, the pump must be replaced.

20-60-10


Figure 20-60-23

HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-60-21

1 2 1

P-26394

NOTE: Position wear plate (Item 1) [Figure 20-60-23] inlets and traps as shown with bronze side toward gears.

P-26392

Remove the drive gear (Item 1) [Figure 20-60-21] from the pump end section.

Figure 20-60-24 1

NOTE: Inspect the drive gear (Item 1) [Figure 20-60-21]. If excessive wear or damage is visible, the pump must be replaced.

P-26396

Figure 20-60-22

1

P-26395

1 Remove the load seal (Item 1) [Figure 20-60-24]. 2

P-26393


20-60-11


HYDRAULIC PUMP (CONT'D)

Figure 20-60-26

Disassembly And Assembly (Cont'd) 1 Figure 20-60-25

1 2 P-26398

1 P-26374

P-26397

Remove the pre-load seal (Item 1) [Figure 20-60-25].

NOTE: Inspect the pump end section (Item 1) and bushings (Item 2) [Figure 20-60-26]. If excessive wear or damage is visible, the pump must be replaced.

20-60-12


Figure 20-61-1

HYDRAULIC PUMP (HIGH FLOW) Check The Output Of The Hydraulic Pump Without Power Bob-Tach

2


1 P-26753

WARNING

Disconnect the OUTLET hose (Item 1) [Figure 20-61-1] from the pump.


Figure 20-61-2

W-2059-0598


1

2


P-24594

Connect the INLET hose (Item 1) [Figure 20-61-2] from the tester to the OUTLET fitting (Item 2) [Figure 20-61-1] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-61-2] from the tester to the hose (Item 1) [Figure 20-61-1] which was disconnected from the pump.



20-61-1


HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump Without Power Bob-Tach (Cont'd) Figure 20-61-3 Reservoir




1 B-16277

Sample tester connection shown [Figure 20-61-3]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-61-3] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics, the light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=


X100


20-61-2


Figure 20-61-4

HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach.

1 2

WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-26754

WARNING

Disconnect the OUTLET hose (Item 1) [Figure 20-61-4] from the top of the Power Bob-Tach block.


Figure 20-61-5

W-2059-0598

2


1


P-24594

Connect the INLET hose (Item 1) [Figure 20-61-5] from the tester to the OUTLET fitting (Item 2) [Figure 20-61-4] on the top of the Power Bob-Tach block. Connect the OUTLET hose (Item 2) [Figure 20-61-5] from the tester to the hose (Item 1) [Figure 20-61-4] which was disconnected from the Power Bob-Tach block.



20-61-3


HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach. (Cont'd) Figure 20-61-6 Reservoir




1 B-16277

Sample tester connection shown [Figure 20-61-6]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-61-6] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics, the light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=


X100


20-61-4


Remove the Power Bob-Tach block if equipped. (See Removal And Installation on Page 20-120-1.)

HYDRAULIC PUMP (HI FLOW) (CONT'D) Removal And Installation

Disconnect and cap the outlet hoses (Item 1) [Figure 20-61-7] from the back of the hydraulic pump. Figure 20-61-8


Figure 20-61-7

1

1

P-26739

Disconnect and cap the inlet hoses (Item 1) [Figure 20-61-8] from the front of the hydraulic pump. Figure 20-61-9

1 2 1 P-26741 P-26740

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device 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.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

Remove the two mounting bolts [Figure 20-61-9] from the hydraulic pump.

(Item

1)

Installation: Tighten the mounting bolts to 27-37 ft.-lb. (37-50 N•m) torque. Remove the hydraulic pump (Item 2) [Figure 20-61-9] from the hydrostatic pump.

Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Open the rear door of the loader. 20-61-5


HYDRAULIC PUMP (HI FLOW) (CONT'D) Removal And Installation (Cont’d) Figure 20-61-10

P-26684

1

2

P-26684

Remove the O-ring (Item 1) [Figure 20-61-10]. Remove the coupler (Item 2) [Figure 20-61-10] from the hydraulic pump shaft. Reverse the removal procedure to install the hydraulic pump. Installation: Use a new O-ring (Item 1) [Figure 20-61-10] when installing the hydraulic pump. (See Disassembly And Assembly on Page 20-61-8.)

20-61-6


HYDRAULIC PUMP (HI FLOW) (CONT'D) Identification

26

22 23

19

27

17 18 15 16 14

20

23 21

25

24

7 8

2

13

11

1 3 4

5

6

7

9

12

10

B-16051a

REF.

DESCRIPTION

REF.

DESCRIPTION

1

RETAINING RING

14

PUMP CENTER SECTION

2

PUMP END SECTION

15

PRE-LOAD SEAL

3

PRE-LOAD SEAL

16

LOAD SEAL

4

LOAD SEAL

17

SECTION SEAL

5

SECTION SEAL

18

WEAR PLATE

6

WEAR PLATE

19

DRIVE GEAR

7

PINS

20

IDLER GEAR

8

DRIVE GEAR

21

PUMP SECTION

9

IDLER GEAR

22

WEAR PLATE

10

PUMP SECTION

23

PINS

11

WEAR PLATE

24

SECTION SEAL

12

SECTION SEAL

25

PUMP END SECTION

13

SPLINE SHAFT

26

BOLT (4)

27

BOLT (4)

20-61-7


HYDRAULIC PUMP (HI FLOW) (CONT'D)

IMPORTANT

Disassembly And Assembly Figure 20-61-11

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

I-2003-0888 P-26622

Figure 20-61-12 2 1

2 1 Mark the pump [Figure 20-61-11].

P-26622

sections

for

correct

assembly

Remove the four smaller pump housing bolts (Item 1) [Figure 20-61-11]. P-26624

Remove the four larger pump housing bolts (Item 2) [Figure 20-61-11]. Installation: Tighten the four smaller bolts (Item 1) to 30 ft.-lb. (40,7 N•m) torque. Tighten the four larger bolts (Item 2) [Figure 20-61-11] to 54 ft.-lb. (73,2 N•m) torque.

Remove the pump [Figure 20-61-12].

20-61-8

end

section

(Item

1)


Figure 20-61-15

HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-13

1

1

P-26627

2

Figure 20-61-16 P-26625

Figure 20-61-14

4 1

3 1

P-26628

Remove the pump section (Item 1) [Figure 20-61-15] & [Figure 20-61-16] from the pump center section.

2 P-26626


NOTE: Inspect the pumps center section (Item 1) [Figure 20-61-16]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Position wear plate (Item 1) [Figure 20-61-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) and bushings (Item 4) [Figure 20-61-14]. If excessive wear or damage is visible, the pump must be replaced.

20-61-9


Figure 20-61-19


1 1

P-26631

Figure 20-61-20 P-26629

Remove the idler gear (Item 1) [Figure 20-61-17] & [Figure 20-61-18]. Figure 20-61-18 1

P-26632

1 Remove the drive gear (Item 1) [Figure 20-61-19] & [Figure 20-61-20].

P-26630

NOTE: Inspect the idler gear (Item 1) [Figure 20-61-18]. If excessive wear or damage is visible, the pump must be replaced.


20-61-10


Figure 20-61-23

HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd)

1

Figure 20-61-21

P-26636A

1 1

P-26635

2 Remove the load seal (Item 1) [Figure 20-61-23]. P-26633

Figure 20-61-24

Figure 20-61-22

1

P-26638A

1 2 1

P-26637 P-26634


Remove the wear plate (Item 1) [Figure 20-61-21] & [Figure 20-61-22] and section seal (Item 2) [Figure 20-61-21] & [Figure 20-61-22] from the pump center section. NOTE: Position wear plate (Item 1) [Figure 20-61-22] inlets and traps as shown with bronze side toward gears.

20-61-11


Figure 20-61-27

HYDRAULIC PUMP (HI FLOW) (CONT'D)

3

Disassembly And Assembly (Cont'd) Figure 20-61-25

4 1 1 2 P-26657


P-26654

Remove the pump center section [Figure 20-61-25] from the pump sections.

(Item

1)

Figure 20-61-26

NOTE: Inspect the pump center section (Item 3) and bushings (Item 4) [Figure 20-61-27]. If excessive wear or damage is visible, the pump must be replaced. Figure 20-61-28

1

1 2 P-26655

Remove the wear plate (Item 1) [Figure 20-61-26] & [Figure 20-61-27] and section seal (Item 2) [Figure 20-61-26] & [Figure 20-61-27] from the pump section.

P-26659

Remove the pump section (Item 1) [Figure 20-61-28] from the pump end section.

20-61-12


Figure 20-61-31

HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-29 1

1

P-26662

P-26660

NOTE: Inspect the pump section (Item 1) [Figure 20-61-29]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Inspect the idler gear (Item 1) [Figure 20-61-31]. If excessive wear or damage is visible, the pump must be replaced.

Figure 20-61-30

1

P-26661

Remove the idler gear (Item 1) [Figure 20-61-30] & [Figure 20-61-31].

20-61-13


Figure 20-61-34


1

1

P-26666

Remove the drive gear (Item 1) [Figure 20-61-34] from the pump end section.

P-26663


Figure 20-61-33

Figure 20-61-35 1 P-26665

1 1

P-26664

To remove the drive gear (Item 1) [Figure 20-61-32] from the pump end section, locate and remove the retaining ring (Item 1) [Figure 20-61-33] from the spline end of the drive gear.

P-26674

Remove the spline shaft (Item 1) [Figure 20-61-35] from the end of the drive gear. NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-35]. If excessive wear or damage is visible, the pump must be replaced.

20-61-14


Figure 20-61-38

HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd)

1

Figure 20-61-36

P-26670A

1

1 P-26669

2

Remove the load seal (Item 1) [Figure 20-61-38]. P-26667

Figure 20-61-39

Figure 20-61-37 1

1

1

P-26672A

2

P-26671 P-26668


Remove the wear plate (Item 1) [Figure 20-61-36] & [Figure 20-61-37] and section seal (Item 2) [Figure 20-61-36] & [Figure 20-61-37] from the pump end section. NOTE: Position wear plate (Item 1) [Figure 20-61-37] inlets and traps as shown with bronze side toward gears.

20-61-15


HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-40 1

2

P-26673

NOTE: Inspect the pump end section (Item 1) and bushings (Item 2) [Figure 20-61-40]. If excessive wear or damage is visible, the pump must be replaced.

20-61-16


Figure 20-62-2

HYDRAULIC PUMP (SJC) Test The Output Of The Hydraulic Auxiliary Pump

WARNING

1

2 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

Figure 20-62-1

P-48256

Connect the INLET hose (Item 1) [Figure 20-62-2] from the tester, to the OUTLET hose (Item 1) [Figure 20-62-1] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-62-2] from the tester, to the INLET tubeline (Item 2) [Figure 20-62-1] leading to the control valve.

1

2

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine.

P-64570

I-2024-0284

The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit 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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See Procedure on Page 10-60-1.) Disconnect the OUTLET hose (Item 1) [Figure 20-62-1].

20-62-1


Test The Output Of The Hydraulic Charge Pump

HYDRAULIC PUMP (SJC) (CONT'D) Test The Output Of The Hydraulic Auxiliary Pump (Cont'd)

WARNING

Figure 20-62-3 Reservoir



Figure 20-62-4 Hydraulic Pump Out In


1

1 B-16277

Sample tester connection shown [Figure 20-62-3]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-62-3] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=


2 P-64315

The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit 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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

X100

Open the rear door of the loader.

A low percentage may indicate a failed pump. *Refer to SPECIFICATIONS Section, Contents Page SPEC-01 for system relief pressure and full RPM.

Connect the remote start tool. (See Procedure on Page 10-60-1.) Disconnect the charge pump OUTLET hose (Item 1) from the INLET fitting (Item 2) [Figure 20-62-4] at the charge filter housing.

20-62-2


HYDRAULIC PUMP (SJC) (CONT'D)

Turn the restrictor down to 2000 PSI. DO NOT EXCEED 2000 PSI. The high pressure flow must be at least 80% of free flow.

Test The Output Of The Hydraulic Charge Pump (Cont’d)

%=

Figure 20-62-5


X100

A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics for pump flow and full RPM. 2

1

P-48256

Connect the INLET hose (Item 1) [Figure 20-62-5] from the tester, to the charge pump OUTLET hose (Item 1) [Figure 20-62-4] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-62-5] from the tester, to the INLET fitting (Item 2) [Figure 20-62-4] at the charge filter housing.


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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-62-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed 2000 PSI. Open the restrictor control and record the free flow (GPM) at full RPM.

20-62-3



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 20-62-7

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.

1

I-2003-0888

1 Figure 20-62-6 P-64547

Disconnect and cap the inlet hoses (Item 1) [Figure 2062-7] from the front of the hydraulic pump. 1

Figure 20-62-8

2

1

P-64546

Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Open the rear door of the loader. Disconnect and cap the outlet hose (Item 1) [Figure 2062-6] from the back of the hydraulic pump.

P-64549

Remove the two mounting bolts (Item 1) [Figure 20-628] from the hydraulic pump. Installation: Tighten the mounting bolts to 55-60 ft.-lb. (75-85 N•m) torque.

Remove the Power Bob-Tach block (Item 2) [Figure 2062-6] if equipped. (See Removal And Installation on Page 20-120-1.) 20-62-4


Figure 20-62-10

HYDRAULIC PUMP (SJC) (CONT'D) Removal And Installation (Cont’d) Figure 20-62-9

1

3 1

P-64446

2 Replace the O-ring (Item 1) [Figure 20-62-10] in the hydrostatic pump.

P-64343

Remove the bracket mounting bolt (Item 1) from the pump mounting bracket (Item 2) [Figure 20-62-9]. Note:

Reverse the removal procedure to install the hydraulic pump.

The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts.

Installation: Apply a medium strength threadlocker to mounting bolt and tighten to 90-100 ft.-lb. (122-136 N•m) torque. Remove the mounting bracket (Item 2) [Figure 20-62-9]. Remove the hydraulic pump (Item 3) [Figure 20-62-9] from the hydrostatic pump.

20-62-5


HYDRAULIC PUMP (SJC) (CONT'D) Identification

15 14

12

3

4

5

6

8

7 5

13

7 9 7

8

11

5 10

6

9

3

4

1 2

5

6

7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Shaft Seal Pump Flange Section Pre-Load Seal Load Seal O-ring Wear Plate Pins Drive Gear Idler Gear Auxiliary Pump Section Spline Shaft Pump Center Section Charge Pump Section Pump End Section Bolt (8) B-21259A

20-62-6



Figure 20-62-12


1

Figure 20-62-11 2 P-26352 P-64507

1

1

P-64509

1

Remove the pump end section (Item 1) [Figure 20-6212].

P-64508

Mark the pump sections for correct assembly [Figure 2062-11]. Remove the eight pump housing bolts (Item 1) [Figure 20-62-11]. Installation: Tighten the bolts (Item 2) [Figure 20-62-11] to 54 ft.-lb. (73,2 N•m) torque.


20-62-7


Figure 20-62-15

HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-13

1 1

P-64511

2

Figure 20-62-16 P-64509

1

Figure 20-62-14

3 4

1

P-64512

2

Remove the charge pump section (Item 1) [Figure 2062-15] & [Figure 20-62-16] from the pump center section.

P-64510

Remove the wear plate (Item 1) and section seal (Item 2) [Figure 20-62-13] & [Figure 20-62-14] from the pump end section.

NOTE: Inspect the pump section (Item 1) [Figure 2062-16]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Position wear plate (Item 1) [Figure 20-62-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) [Figure 20-62-14] and bushings (Item 4) [Figure 20-6214]. If excessive wear or damage is visible, the pump must be replaced.

20-62-8


Figure 20-62-19


1 1

P-64515

Figure 20-62-20 P-64513

Figure 20-62-18

1

1

P-64516

Remove the idler gear (Item 1) [Figure 20-62-19] & [Figure 20-62-20] from the pump center section.

P-64514

Remove the drive gear (Item 1) [Figure 20-62-17] & [Figure 20-62-18].


NOTE: Inspect the drive gear (Item 1) [Figure 20-6218]. If excessive wear or damage is visible, the pump must be replaced.

20-62-9


Figure 20-62-23


1

P-64519

1 Figure 20-62-24

2 P-64517

2

Figure 20-62-22

1 2

1 P-64520

Remove the load seal (Item 1) [Figure 20-62-23] & [Figure 20-62-24]. Inspect for damage and replace as needed.

P-64518

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-21] & [Figure 20-62-22] from the pump center section. Inspect for damage and replace as needed.



20-62-10


Figure 20-62-27


2

2

3 1 1 P-64526

Figure 20-62-28 P-64521

3

Inspect the pre-load seal (Item 1) [Figure 20-62-25] for damage and replace as needed.

4

NOTE: Inspect the pump center section (Item 2) and bushings (Item 3) [Figure 20-62-25]. If excessive wear or damage is visible, the pump must be replaced.

1

Figure 20-62-26 2

1

P-64527

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-27] & [Figure 20-62-28] from the pump center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-62-28] inlets and traps as shown with bronze side toward gears. P-64525

Remove the pump center section (Item 1) [Figure 20-6226].

NOTE: Inspect the pump center section (Item 3) and bushings (Item 4) [Figure 20-62-28]. If excessive wear or damage is visible, the pump must be replaced.

20-62-11


Figure 20-62-31


1

P-64530

1

Remove the drive gear (Item 1) [Figure 20-62-31] from the pump flange section.

P-64528

Figure 20-62-32

Figure 20-62-30

1

1

P-64531 P-64529

Remove the auxiliary pump section (Item 1) [Figure 2062-29] & [Figure 20-62-30] from the pump flange section.


NOTE: Inspect the pump section (Item 1) [Figure 2062-30]. If excessive wear or damage is visible, the pump must be replaced.

20-62-12


Figure 20-62-35


1 2 1

2

P-64535

Figure 20-62-36 P-64532

Remove the spline shaft (Item 1) [Figure 20-62-33] from the end of the drive gear. Remove the idler gear (Item 2) [Figure 20-62-33]. Figure 20-62-34 1

2 P-64536

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-35] & [Figure 20-62-36] from the pump flange section. Inspect for damage and replace as needed.

1


P-64534


20-62-13


Figure 20-62-39


3

2 1

1

P-64540


P-64537

NOTE: Inspect the pump flange section (Item 2) and bushings (Item 3) [Figure 20-62-39]. If excessive wear or damage is visible, the pump must be replaced.

Figure 20-62-38

Figure 20-62-40

1 2 2

1

P-30188A

P-64538

Remove the load seal (Item 1) [Figure 20-62-37] & [Figure 20-62-38]. Inspect for damage and replace as needed. Remove the pre-load seal (Item 2) [Figure 20-62-38].

P-64541

Remove the shaft seal (Item 1) [Figure 20-62-40] from the pump flange section. Installation: The shaft seal flush surface (Item 2) [Figure 20-62-40] must be facing out away from the pump.

20-62-14


Figure 20-63-2

HYDRAULIC PUMP (HIGH FLOW) (SJC) Test The Output Of The Hydraulic Auxiliary Pump

WARNING

1

2 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

Figure 20-63-1

P-48256

Connect the INLET hose (Item 1) [Figure 20-63-2] from the tester, to the OUTLET hose (Item 1) [Figure 20-63-1] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-63-2] from the tester, to the INLET tubeline (Item 2) [Figure 20-63-1] leading to the hydraulic control valve.

1

2

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine.

P-64570

I-2024-0284

The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit 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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See Procedure on Page 10-60-1.) Disconnect the OUTLET hose (Item 1) [Figure 20-63-1].

20-63-1


Test The Output Of The Hydraulic Charge Pump

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Auxiliary Pump (Cont'd)

WARNING

Figure 20-63-3 Reservoir



Figure 20-63-4 Hydraulic Pump Out In


1

1 B-16277

Sample tester connection shown [Figure 20-63-3]. 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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-63-3] 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. Push the maximum/variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=


2 P-64315

The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit 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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

X100


A low percentage may indicate a failed pump. *Refer to SPECIFICATIONS Section, Contents Page SPEC-01 for system relief pressure and full RPM.

Connect the remote start tool. (See Procedure on Page 10-60-1.) Disconnect the charge pump OUTLET hose (Item 1) from the INLET fitting (Item 2) [Figure 20-63-4] at the charge filter housing.

20-63-2


HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)

Turn the restrictor down to 2000 PSI. DO NOT EXCEED 2000 PSI. The high pressure flow must be at least 80% of free flow.

Test The Output Of The Hydraulic Charge Pump (Cont’d)

%=

Figure 20-63-5


X100

A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics for pump flow and full RPM. 2

1

P-48256

Connect the INLET hose (Item 1) [Figure 20-63-5] from the tester, to the charge pump OUTLET hose (Item 1) [Figure 20-63-4] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-63-5] from the tester, to the INLET fitting (Item 2) [Figure 20-63-4] at the charge filter housing.


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 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-63-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed 2000 PSI. Open the restrictor control and record the free flow (GPM) at full RPM.

20-63-3


Figure 20-63-6

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Pump (High Flow)

1


P-48463

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.

Install a jumper hose (Item 1) [Figure 20-63-6] onto the front auxiliary quick couplers. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

W-2059-0598


The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10103 - Hydraulic Tester MEL10106 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See Procedure on Page 10-60-1.)

20-63-4


Figure 20-63-9

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Pump (High Flow) (Cont'd)

Reservoir


Figure 20-63-7


High Flow Valve

1 1

B-16277

Sample tester connection shown [Figure 20-63-9].

2 P-48235

Disconnect the high flow pump OUTLET hose (Item 1) from the high flow valve INLET fitting (Item 2) [Figure 2063-7]. Figure 20-63-8

Start the engine and run at low idle RPM. Press the front auxiliary button. Press the High Flow button. Push the button (on the right control lever) for fluid flow to the quick coupler. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full RPM*. Warm the fluid to 140°F. (60°C.) by turning the restrictor control (Item 1) [Figure 20-63-9] on the tester to about 1000 PSI (6895 kPa). NOTE: DO NOT EXCEED 3300 PSI.

2

Open the restrictor control and record the free flow (GPM) at full RPM. Turn the restrictor control on the tester to 3300 PSI and the flow should go to zero GPM.

1

If pressure readings are not obtained go to the High Flow Valve, relief valve adjustment procedure.(See High Flow Relief Valve Adjustment Procedure on Page 20-100-3.) Record the highest pressure (PSI) and flow (GPM). The high pressure flow must be at least 80% of free flow.

P-48256

Connect the INLET hose (Item 1) [Figure 20-63-8] from the tester, to the high flow pump OUTLET hose (Item 1) [Figure 20-63-7]. Connect the OUTLET hose (Item 2) [Figure 20-63-8] from the tester, to the high flow valve INLET fitting (Item 2) [Figure 20-63-7] on the High Flow valve. Lower the cab.

%=


X100

A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics Legend for system relief pressure and full RPM.

20-63-5


Figure 20-63-11

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Removal And Installation

1

2 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.)

P-64546

Disconnect and cap the outlet hoses (Item 1) [Figure 2063-10] and [Figure 20-63-11] from the back of the hydraulic pump. Remove the Power Bob-Tach block (Item 2) [Figure 2063-11] if equipped. (See Removal And Installation on Page 20-120-1.) Figure 20-63-12



1

1

W-2059-0598

Figure 20-63-10

P-64544

Disconnect and cap the inlet hoses (Item 1) [Figure 2063-12] from the front of the hydraulic pump.

1 P-64545

20-63-6


Figure 20-63-14

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Removal And Installation (Cont’d) Figure 20-63-13

3 1

1

2 P-64343

Remove the bracket mounting bolt (Item 1) from the pump mounting bracket (Item 2) [Figure 20-63-14].

P-64549

Remove the two mounting bolts (Item 1) [Figure 20-6313] from the hydraulic pump. Installation: Tighten the mounting bolts to 55-60 ft.-lb. (75-85 N•m) torque.

NOTE: The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts. Installation: Apply a medium strength threadlocker to mounting bolt and tighten to 90-100 ft.-lb. (122-136 N•m) torque. Remove the mounting bracket (Item 2) [Figure 20-6314]. Remove the hydraulic pump (Item 3) [Figure 20-63-14] from the hydrostatic pump. Figure 20-62-15

1

P-64446

Replace the O-ring (Item 1) [Figure 20-62-15] in the hydrostatic pump. Reverse the removal procedure to install the hydraulic pump.

20-63-7


HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Identification

17

16 8

12

2

15

4

7 3

14 8

7

6

13

4 5

5

9

6

7

12

7

8 7

9

3

6

3 4

1

5

6

9

5

4

5

6

11

10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

2

Shaft Seal Pump Flange Section Pre-Load Seal Load Seal O-Ring Valve Plate Pin Drive Gear Idler Gear Auxiliary Pump Section Auxiliary Center Section Splined Shaft Charge Pump Section Charge Center Section High Flow Pump Section High Flow End Section Bolt

B-18248

20-63-8


HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)

Figure 20-63-17


1

Figure 20-63-16

1 P-64553

P-64554

1 1

Remove the high flow end section (Item 1) [Figure 2063-17].

P-64552

Mark the pump sections for correct assembly [Figure 2063-16]. Remove the eight pump housing bolts (Item 1) [Figure 20-63-16]. Installation: Tighten the bolts (Item 2) [Figure 20-63-16] to 54 ft.-lb. (73,2 N•m) torque.


20-63-9


Figure 20-63-20

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd)

1

Figure 20-63-18

1

P-64556

2

Figure 20-63-21 P-64554

1 Figure 20-63-19 3

4

1 P-64557

2

Remove the high flow pump section (Item 1) [Figure 2063-20] & [Figure 20-63-21] from the charge center section.

P-64555

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-18] & [Figure 20-63-19] from the high flow end section. NOTE: Position wear plate (Item 1) [Figure 20-63-19] inlets and traps as shown with bronze side toward gears.

NOTE: Inspect the high flow pump section (Item 1) [Figure 20-63-21]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Inspect the high flow end section (Item 3) and bushings (Item 4) [Figure 20-63-19]. If excessive wear or damage is visible, the pump must be replaced.

20-63-10


Figure 20-63-24

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-22

1 1

P-64560

Figure 20-63-25 P-64558

Figure 20-63-23

1 1

P-64561

Remove the idler gear (Item 1) [Figure 20-63-24] & [Figure 20-63-25] from the charge center section.

P-64559

Remove the drive gear (Item 1) [Figure 20-63-22] & [Figure 20-63-23].



20-63-11


Figure 20-63-28


1

1

P-64564

2

Figure 20-63-29 P-64562

2 Figure 20-63-27

1 2

1 P-64565


P-64563

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-26] & [Figure 20-63-27] from the charge center section. Inspect for damage and replace as needed.



20-63-12


Figure 20-63-32


2

2

3 1 1 P-64569

Figure 20-63-33 P-64567

3


4

NOTE: Inspect the charge center section (Item 2) and bushings (Item 3) [Figure 20-63-30]. If excessive wear or damage is visible, the pump must be replaced.

1

Figure 20-63-31 2 1

P-64571

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-32] & [Figure 20-63-33] from the charge center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-63-33] inlets and traps as shown with bronze side toward gears. P-64568

Remove the charge center section (Item 1) [Figure 2063-31].

NOTE: Inspect the charge center section (Item 3) and bushings (Item 4) [Figure 20-63-33]. If excessive wear or damage is visible, the pump must be replaced.

20-63-13


Figure 20-63-36

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-34 1

1

P-64574

Remove the drive gear (Item 1) [Figure 20-63-36] from the auxiliary center section.

P-64572

Figure 20-63-37

Figure 20-63-35 1

1

P-64575 P-64573

Remove the charge pump section (Item 1) [Figure 2063-34] & [Figure 20-63-35] from the auxiliary pump center section.


NOTE: Inspect the charge pump section (Item 1) [Figure 20-63-35]. If excessive wear or damage is visible, the pump must be replaced.

20-63-14


Figure 20-63-40


1

1

2

2

P-64578

Figure 20-63-41 P-64576

Remove the spline shaft (Item 1) [Figure 20-63-38] from the end of the drive gear. Inspect for damage and replace as needed. Remove the idler gear (Item 2) [Figure 20-63-38].

1 2

Figure 20-63-39

P-64579

1

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-40] & [Figure 20-63-41] from the auxiliary center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-63-41] inlets and traps as shown with bronze side toward gears.

P-64577


20-63-15


Figure 20-63-44

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd)

2

Figure 20-63-42 3 1 1

P-64521


P-64519

NOTE: Inspect the auxiliary center section (Item 2) and bushings (Item 3) [Figure 20-63-44]. If excessive wear or damage is visible, the pump must be replaced.

Figure 20-63-43

2

Figure 20-63-45 1

1 P-64520

Remove the load seal (Item 1) [Figure 20-63-42] & [Figure 20-63-43]. Inspect for damage and replace as needed. Remove the pre-load seal (Item 2) [Figure 20-63-43].

P-64525

Remove the auxiliary center section (Item 1) [Figure 2063-45].

20-63-16


Figure 20-63-48


2

1 P-64528

1 Figure 20-63-49 P-64526

Figure 20-63-47 3

4

1

1 P-64529

2

Remove the auxiliary pump section (Item 1) [Figure 2063-48] & [Figure 20-63-49] from the pump flange section.

P-64527

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-46] & [Figure 20-63-47] from the auxiliary center section. Inspect for damage and replace as needed.

NOTE: Inspect the auxiliary pump section (Item 1) [Figure 20-63-49]. If excessive wear or damage is visible, the pump must be replaced.

NOTE: Position wear plate (Item 1) [Figure 20-63-47] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the auxiliary center section (Item 3) and bushings (Item 4) [Figure 20-63-47]. If excessive wear or damage is visible, the pump must be replaced.

20-63-17


Figure 20-63-52


1 1 2

P-64532

Remove the spline shaft (Item 1) [Figure 20-63-52] from the end of the drive gear.

P-64530

Remove the drive gear (Item 1) [Figure 20-63-50] from the pump flange section.

Remove the idler gear (Item 2) [Figure 20-63-52]. Figure 20-63-53

Figure 20-63-51

1

1

P-64534 P-64531


Remove the idler gear (Item 1) [Figure 20-63-53] from the pump flange section. NOTE: Inspect the idler gear (Item 1) [Figure 20-6353]. If excessive wear or damage is visible, the pump must be replaced.

20-63-18


Figure 20-63-56


1

1 2 P-64537

Figure 20-63-57 P-64535

Figure 20-63-55

2 1 1

P-64538


2 P-64536

Remove the wear plate (Item 1) and section seal (Item 2) [Figure 20-63-54] & [Figure 20-63-55] from the pump flange section. Inspect for damage and replace as needed.



20-63-19


Figure 20-63-59


1 2

P-30188A

3

2

P-64541

1

Remove the shaft seal (Item 1) [Figure 20-63-59] from the pump flange section.

P-64540


Installation: The shaft seal flush surface (Item 2) [Figure 20-63-59] must be facing out away from the pump.

NOTE: Inspect the pump flange section (Item 2) and bushings (Item 3) [Figure 20-63-58]. If excessive wear or damage is visible, the pump must be replaced.

20-63-20


Figure 20-70-2

HYDRAULIC/HYDROSTATIC FILTER HOUSING Removal And Installation

IMPORTANT

1


2

3 P-48260

Implement Filter Housing

Disconnect the wires from the charge pressure sender (Item 1) [Figure 20-70-2] from the filter housing.

Figure 20-70-1

Disconnect the temperature sender connector (Item 2) [Figure 20-70-2] from the filter housing. Disconnect the wire connector (Item 3) [Figure 20-70-2] from the differential pressure switch on the filter housing.

1

Figure 20-70-3 3 2 P-48259

1

Stop the engine and open the rear door. Drain the hydraulic fluid. (See Replacing Hydraulic Fluid on Page 10-120-1.) Remove the two mounting bolts (Item 1) and remove the hydraulic filter drip pan (Item 2) [Figure 20-70-1]. Disconnect the tubeline (Item 3) [Figure 20-70-1] from the filter housing.

P-48257

Using MEL 1558 tool disconnect the oil cooler tubeline (Item 1) [Figure 20-70-3] from the filter housing.

20-70-1


Charge Filter Housing

HYDRAULIC/HYDROSTATIC FILTER HOUSING (CONT’D)

Stop the engine and open the rear door.


Drain the hydraulic fluid. (See Replacing Hydraulic Fluid on Page 10-120-1.)

Figure 20-70-4

Figure 20-70-5 1 1 1

P-48258

P-64317

Remove the two mounting screws (Item 1) [Figure 2070-4] from the filter housing mounting bracket. Installation: Tighten the mounting screws to 15-20 ft.-lb. (20-27 N•m) torque.

Disconnect the hoses (Item 1) [Figure 20-70-5] from the filter housing.

Remove the hydraulic filter housing and filter.

Disconnect the hose (Item 2) [Figure 20-70-5] from the filter housing.

Reverse the removal procedure to install the filter housing and filter.

Figure 20-70-6

2

1 2 P-64317

Disconnect the wire connector (Item 1) [Figure 20-70-6] from the differential pressure switch on the filter housing. Remove the four mounting bolts (Item 2) [Figure 20-706] from the filter housing. Remove the hydraulic filter housing and filter. Reverse the removal procedure to install the filter housing and filter. 20-70-2


HYDRAULIC FLUID RESERVOIR

IMPORTANT

Fluid Removal Figure 20-80-1


1

I-2003-0888

Stop the engine. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the fluid from the hydraulic reservoir. Remove the control panel.(See Removal and Installation on Page 50-100-1.)

P-34037

Remove the plug (Item 1) [Figure 20-80-1] from the hydraulic reservoir. Remove the fluid from the tank with pump.

Remove Bucket position valve if so equipped. (See Removal And Installation on Page 20-90-3.) Remove the crossbar linkage. (See Crossbar Linkage Removal and Installation on Page 50-90-2.)

Removal And Installation Lift and block the loader. (See Procedure on Page 10-101.)

Figure 20-80-2

Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

2

1 P-34113

Remove the left rear tire assembly (Item 1) [Figure 2080-2].


Remove the two access panels (Item 2) [Figure 20-802].

W-2059-0598

20-80-1


Figure 20-80-5

HYDRAULIC FLUID RESERVOIR (CONT’D) Removal And Installation (Cont’d) Figure 20-80-3

1

1 2

3

2

P-34040

Remove the drive motor drain hose (Item 1) [Figure 2080-5] at the drain filter

P-34037

Remove the two mounting bolts (Item 1) [Figure 20-803] and remove the plate (Item 2) [Figure 20-80-3] from the loader. Figure 20-80-4

Remove the auxiliary pressure relief drain hose (Item 2) [Figure 20-80-5] at the drain filter. Remove the drive motor supply hose (Item 3) [Figure 2080-5]. Figure 20-80-6

2 1 3 1

2 P-34038N19059

P-34039

Remove the tie-straps (Item 1) [Figure 20-80-4] from the breather hose. Remove the hose clamp (Item 2) [Figure 20-80-4]. Remove the hydraulic fill hose (Item 3) [Figure 20-80-4] from the hydraulic reservoir.

Remove the two control valve drain hoses (Item 1) [Figure 20-80-6]. Remove the fitting (Item 2) [Figure 20-80-6] from the reservoir.

20-80-2


Figure 20-80-9


2 1 1

2 P-34044

Remove the hose clamp (Item 1) [Figure 20-80-9] from the fitting.

P-34042

Remove the hose clamp (Item 1) [Figure 20-80-7] from the tank outlet. Remove the hydrostatic supply hose (Item 2) [Figure 2080-7] from the bottom of the reservoir.

Remove the breather hose (Item 2) [Figure 20-80-9] from the hydraulic reservoir. Figure 20-80-10

Figure 20-80-8 1

1 2

P-34053

If the loader is equipped with rear auxiliaries remove the auxiliary tubeline (Item 1) [Figure 20-80-10] to allow the hydraulic reservoir to roll out from under the fender.

P-34043

Remove the bolt and nut (Item 1) [Figure 20-80-8]. Loosen the bolt and nut (Item 2) [Figure 20-80-8] to allow the hydraulic reservoir mount to drop down.

NOTE: Standard loaders without rear auxiliaries and all high flow loaders will have a one-piece auxiliary tubeline from the control valve to the rear upright hoses. Disconnect the tubeline (Item 1) [Figure 20-80-10] from the control valve and loosen the fitting in the left rear upright to allow movement of the tubeline for the hydraulic reservoir removal.

20-80-3



1

P-34052

Remove the hydraulic reservoir (Item 1) [Figure 20-8011] from the loader.

20-80-4


Figure 20-90-3

BUCKET POSITION VALVE Solenoid Removal And Installation Figure 20-90-1

1

2

1 P-26312A

Remove the solenoid stem (Item 1) [Figure 20-90-3] from the bucket position valve.

P-26310A

Disconnect the wire harness connector (Item 1) [Figure 20-90-1] from the bucket position shut-off solenoid. NOTE: Loosening the two mounting bolts (Item 2) [Figure 20-90-1] on the Bucket Positioning Valve Bracket may aid in the solenoid removal.

Installation: Put oil on O-rings and back-up washers and tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 N•m) torque. Figure 20-90-4

Figure 20-90-2

1

2

2

N-18191

1

Inspect the solenoid stem and replace the O-rings (Item 1) [Figure 20-90-4] and the back-up washer (Item 2) [Figure 20-90-4].

P-26311A

Remove the solenoid nut (Item 1) [Figure 20-90-2]. Installation: Tighten the solenoid nut to 4-6 ft.-lb. max. (5-8 N•m max.) torque. Overtightening may cause valve failure. Remove the solenoid coil (Item 2) [Figure 20-90-2].

20-90-1


BUCKET POSITION VALVE (CONT'D) Solenoid Testing Figure 20-90-5

P9175

Use a test meter to measure coil resistance [Figure 2090-5]. Coil wires do not have polarity. Correct resistance for the coil is 9.8 ohm. Replace the test meter with 12 volt power. You can see and hear the spool shift.

20-90-2


BUCKET POSITION VALVE (CONT'D) Removal And Installation


Figure 20-90-6

1

P-26310A

Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Stop the engine. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the electric solenoid connector (Item 1) [Figure 20-90-6].

20-90-3


Figure 20-90-9

BUCKET POSITION VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-90-7

1

2

1

P-26313A

1 Disconnect the two tubelines (Item 1) [Figure 20-90-9] from the tee fitting.

P-26311A

Figure 20-90-10

Figure 20-90-8

1 4 1

2

3

P-26314

P-26312A

Remove the solenoid nut (Item 1) [Figure 20-90-7].

Remove the tubeline (Item 1) [Figure 20-90-10] from the B port to the control valve.

Installation: Tighten the nut to 4-6 ft.-lb. max. (5-8 N•m max.) torque. Overtightening may cause valve failure.

Disconnect the tubeline (Item 2) [Figure 20-90-10] from the C port (tilt rod end) on the BPV.

Remove the solenoid (Item 2) [Figure 20-90-7] and the solenoid stem (Item 1) [Figure 20-90-8].

Disconnect the tubeline (Item 3) [Figure 20-90-10] from the D port (tilt base end) on the BPV.

Installation: Put oil on the O-rings and back-up washers and tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 N•m) torque.

Remove the mounting screws (Item 4) [Figure 20-9010]. Installation: Tighten the mounting screws to 15 ft.-lb. (20 N•m) torque. Remove the bucket position valve and bracket from the loader.

20-90-4


Figure 20-90-13

BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly Figure 20-90-11

1 1 N-19072

Remove the flow adjustment valve and O-ring (Item 1) [Figure 20-90-13]

N-19069

Remove the solenoid nut (Item 1) [Figure 20-90-11]. Installation: Tighten the nut to 4-6 ft.-lb. max. (5-8 N•m max.) torque. Overtighten may cause valve failure.

NOTE: Always install new O-rings before any parts are installed into the valve. Check the parts for wear or damage and replace as needed. Figure 20-90-14

Figure 20-90-12

2

1

1

N-19041 N-19070

Remove the plug (Item 1) [Figure 20-90-14].

Remove the solenoid (Item 1) and the solenoid stem (Item 2) [Figure 20-90-12]. Installation: Tighen the solenoid stem to 30-35 ft.-lb. (40,8-47,6 N•m) torque.

20-90-5


Figure 20-90-17

BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-90-15

2 1 N-19045

Remove the plug [Figure 20-90-17]. N-18339

Figure 20-90-18

Remove the plug (Item 1), and flow control spool (Item 2) [Figure 20-90-15]. Check the flow control spool for wear, check the O-ring on the plug and replace as needed. 3

Figure 20-90-16

2 1 N-19046

1

Remove the plug (Item 1), spring (Item 2) and unloading spool (Item 3) [Figure 20-90-18].

2

Check all parts and replace as needed. Install a new Oring on the plug before installing.

3 N-19042

Remove the tilt cylinder check valve (item 1) spring (Item 2) and plug (Item 3) [Figure 20-90-16]. Check for wear, check the O-ring and replace as needed.

20-90-6


HIGH FLOW VALVE

WARNING

Checking The High Flow Relief Valve Figure 20-100-1

2

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

1

W-2017-0286

Figure 20-100-2

3

1

P-34480

2 The tools listed will be needed to do the following procedure: MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit

N-18409

Lift and block the loader. (See Procedure on Page 10-101.) NOTE: Check the Main Relief Valve (See Removal and Installation on Page 20-30-3.) for proper flow and pressure before checking the High Flow Relief Valve. Connect the IN port of the hydraulic tester to the female quick coupler (Item 1) [Figure 20-100-1] on the loader.

Start the engine and run at low idle RPM. Push the flow switch (Item 1) once (on the instrument panel) to engage the front auxiliary hydraulics variable flow, the light (Item 2) will come ON [Figure 20-100-2]. Push the high flow switch (Item 3) [Figure 20-100-2] and the High Flow light will come ON.

Connect the OUT port of the hydraulic tester to the male quick coupler (Item 2) [Figure 20-100-1] on the loader.


20-100-1


HIGH FLOW VALVE (CONT'D) Checking The High Flow Relief Valve (Cont’d) Figure 20-100-3 Right Steering Lever Control

1

P-31833

•

Push the front switch (Item 1) [Figure 20-100-3] to give the front quick couplers a constant flow of fluid.

•

To release from continuous operation, press the front switch (Item 1) [Figure 20-100-3] a second time.

Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full RPM. Warm the fluid to 140°F. (60°C.) by turning the restrictor control on the tester to about 1000 PSI (6895 kPa). DO NOT exceed system relief pressure. NOTE: DO NOT EXCEED 3300 PSI. Turn the restrictor control on the tester counter clockwise, to obtain free flow, the flow should be at 27 GPM. Start turning the restrictor clockwise, causing more restriction on the flow. The GPM should drop off slightly until the pressure reaches approximately 3100 PSI. At approximately 3100 PSI the flow should start decreasing rapidly until the pressure reaches 3250-3350 PSI. At 3250-3350 PSI the flow should be at 0 GPM. Turn the restrictor control counter clockwise to free flow. Shut the front auxiliary hydraulics off. If the specs from above are reached, the high flow relief valve is OK. If the high flow relief pressure is not correct, stop the engine and adjust the high flow relief valve. (See High Flow Relief Valve Adjustment Procedure on Page 20100-3.)

20-100-2


Figure 20-100-5

HIGH FLOW VALVE (CONT'D) High Flow Relief Valve Adjustment Procedure NOTE: The high flow relief valve is located between the control valve and the hydraulic reservoir. Figure 20-100-4

1

1

P-45469

To increase the high flow relief valve PSI turn the screw (Item 1) [Figure 20-100-5] clockwise a 1/4 turn and recheck the high flow relief valve. (1/4 turn equals approximately 200 PSI.) P-48231

If the relief pressure is not correct, stop the engine and raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.) Remove the high flow relief valve adjustment plug (Item 1) [Figure 20-100-4].

To decrease the high flow relief valve PSI turn the screw (Item 1) [Figure 20-100-5] counterclockwise a 1/4 turn and recheck the high flow relief valve. (1/4 turn equals approximately 200 PSI.) NOTE: If the relief screw (Item 1) [Figure 20-100-5] has been turned in 1/4 turn and the pressure remains the same, remove and inspect the high flow relief valve, replace as needed. Install the plug into the high flow relief valve.

20-100-3


HIGH FLOW VALVE (CONT'D)

Figure 20-100-7

Removal And Installation Figure 20-100-6

2

2

1

1

P-48236

1 Disconnect the electrical connector (Item 1) [Figure 20100-7] from the solenoid.

P-48235

Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 20-100-6] which are connected to the steering shaft on the control panel.

Figure 20-100-8

Remove the four steering linkage mounting bolts (Item 2) [Figure 20-100-6].

2

Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 2528 ft.-lb. (34-38 N•m) torque. The high flow valve is located between the control valve and the hydraulic reservoir.

1 P-48238

IMPORTANT

Mark all tubelines and hoses for correct installation.


Disconnect and cap the hose (Item 1) [Figure 20-100-8] from the pump outlet to the high flow valve. Disconnect and cap the hose (Item 2) [Figure 20-100-8] from the high flow valve to the pump inlet.

20-100-4


HIGH FLOW VALVE (CONT'D) Removal And Installation (Cont’d) Figure 20-100-9

1 1 2

P-48232

Disconnect and cap the tubelines (Item 1) [Figure 20100-9] to the tilt cylinders. Remove the two mounting bolts (Item 2) [Figure 20-1009]. Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque.

20-100-5


Figure 20-100-12

HIGH FLOW VALVE (CONT'D) Disassembly And Assembly Figure 20-100-10

2

1 2

1 P-48110

Inspect O-rings (Item 1) and back-up washer (Item 2) on the solenoid stem [Figure 20-100-12].

P-48108

Remove the solenoid nut (Item 1) and solenoid (Item 2) from the solenoid valve [Figure 20-100-10].

Installation: Put oil on O-rings and back-up washer. Install and tighten to 25 ft.-lb. (39,9 N•m) torque. Figure 20-100-13

Installation: Tighten to 4-6 ft.-lb. (5-8 N•m) torque. Figure 20-100-11

1

1

P-48111

Remove the relief valve (Item 1) [Figure 20-100-13].

P-48109

Remove the solenoid valve (Item 1) [Figure 20-100-11] from the valve.

Installation: Apply to oil to the O-rings and back-up washers. Tighten to 30-35 ft.-lb. (41-47 N•m) torque.


20-100-6


Figure 20-100-16

HIGH FLOW VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-100-14

1

1 P-48113

2 Remove the check valve (Item 1) [Figure 20-100-16] from the high flow valve.

P-48112

Inspect the relief valve and replace the two o-rings (Item 1) and washer (Item 2) [Figure 20-100-14].

Figure 20-100-17

Figure 20-100-15 1 2

1

P-48114

Inspect the check valve, O-rings & back-up washers for wear and replace as needed [Figure 20-100-17].

P-45469

Inspect the O-ring (Item 1) [Figure 20-100-15] on the relief valve adjustment plug for damage and replace as needed.

Installation: Apply oil to the O-rings (Item 1) and backup washers (Item 2) [Figure 20-100-17]. Tighten to 3035 ft.-lb. (41-47 N•m) torque.

Installation: Tighten to 20 ft.-lb. (27,1 N•m) torque.

20-100-7


HIGH FLOW VALVE (CONT'D) Solenoid Testing Figure 20-100-18

P9175

Use a test meter to measure coil resistance [Figure 20100-18]. Coil terminals do not have polarity. Correct resistance for the pressure relief coil is 7.5 ohms. Replace the test meter with 12 volt power. You can see and hear the spool shift.

20-100-8


Figure 20-110-1

REAR AUXILIARY DIVERTER VALVE Removal And Installation

1

P-48301


The rear auxiliary valve (Item 1) [Figure 20-110-1] is located between the control valve and the gear pump on the right side of the loader.

IMPORTANT

W-2059-0598



Figure 20-110-2

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 Lift Arm Support Device on Page 10-20-1.)

1

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the negative battery cable. (See Removal And Installation on Page 60-20-1.)

2 P-48302

Remove the speed control lever. (See Control Lever Removal And Installation on Page 50-100-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.) Remove the right rear tire. (See TIRE MAINTENANCE on Page 10-170-1.)

Disconnect the base and rod end tubelines (Item 1) [Figure 20-110-2]. Remove the fittings (Item 2) [Figure 20-110-2] from the valve.

20-110-1


Figure 20-110-5

REAR AUXILIARY DIVERTER VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-110-3

1

1

P-48304

Disconnect the drain tubeline (Item 1) [Figure 20-110-5] from the lift arm by pass valve.

P-48872

Remove the three access covers (Item 1) [Figure 20110-3] on the right side of the machine.

Figure 20-110-6

Figure 20-110-4

1

1

P-48303

Disconnect and remove the drain tubeline (Item 1) [Figure 20-110-6] from the rear auxiliary valve.

P-48300

Disconnect the four solenoid connectors (Item 1) [Figure 20-110-4] from the rear auxiliary valve.

20-110-2


Figure 20-110-9

REAR AUXILIARY DIVERTER VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-110-7

1

2 P-48870

1 P-48305

Disconnect the pump outlet hose (Item 1) [Figure 20110-7] from the rear auxiliary valve. Disconnect the tubeline (Item 2) [Figure 20-110-7] from the bottom of the control valve and the rear auxiliary vavle.

Remove the rear auxiliary valve (Item 1) [Figure 20-1109] by moving the valve to the rear access hole which allows enough room for the valve to be removed from the loader. The valve needs to be tilted as shown in [Figure 20-1109] for it to be removed through the hole.

Figure 20-110-8

1

1

P-48869

Loosen and remove the two bolts and nuts (Item 1) [Figure 20-110-8] that hold the rear auxiliary valve.

20-110-3


REAR AUXILIARY DIVERTER VALVE (CONT'D)

IMPORTANT



Figure 20-110-12 1 1 1 P-48751

Figure 20-110-11

P-48755

1 Figure 20-110-13

2 P-48752

2

2

1

Clean the diverter valve to remove dirt before disassembly. Valve ports are labeled for correct assembly. Several plugs (Item 1) [Figure 20-110-10] & [Figure 20110-11] are located all over the diverter valve and can be removed for cleanout purposes. Installation: Put oil on O-rings and back-up washers.Tighten to 10 ft.-lb. (13,6 N•m) torque.

P-48756

Remove the shuttle valve (Item 1) [Figure 20-110-12] & [Figure 20-110-13] from diverter valve and inspect the O-rings and back-up washers (Item 2) [Figure 20-11013] for damage. Installation: Put oil on the O-rings and back-up washers. Tighten to 10-12 ft.-lb. (14-16 N•m) torque.

20-110-4


Figure 20-110-16

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-110-14

1

P-48753

1 Figure 20-110-17 P-48755

1

Figure 20-110-15

2

2 2

1 P-48754

P-48757

Remove the differential sensing valve (Item 1) [Figure 20-110-14] & [Figure 20-110-15] from diverter valve and inspect the O-rings and back-up washers (Item 2) [Figure 20-110-15] for damage.

Remove the relief valve (Item 1) [Figure 20-110-16] & [Figure 20-110-17] from the diverter valve and inspect the O-rings and back-up washers (Item 2) [Figure 20110-17] for damage. Installation: Put oil on O-ring and back-up washers. Tighten to 20-25 ft.-lb. (27-34 N•m) torque.

Installation: Put oil on O-ring and back-up washers. Tighten to 50-55 ft.-lb. (68-75 N•m) torque.

20-110-5


Figure 20-110-20


1

1

P-48761

NOTE: Before removing the solenoid coils mark the coils for proper alignment.

P-48759

Remove the nuts (Item 1) [Figure 20-110-20] from the solenoid valve stems.

Figure 20-110-19

Installation: Tighten the nut to 4-6 ft.-lb. (5-8 N•m) torque.

3

1 2

P-48760

NOTE: Before removing the solenoid coils mark the coils for proper alignment. Remove the nut (Item 1) [Figure 20-110-18] & [Figure 20-110-19] from the solenoid valve stem. Installation: Tighten the nut to 4-6 ft.-lb. (5-8 N•m) torque. Remove the spacer (Item 2) and solenoid valve coils (Item 3) [Figure 20-110-19].

20-110-6


Figure 20-110-23

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd)

1

Figure 20-110-21

1

P-48763A

Figure 20-110-24 P-48762

Figure 20-110-22

1

1

2

2

1

2

P-48764

P-48763

Remove the solenoid valve stems (Item 1) [Figure 20110-21] & [Figure 20-110-22] and inspect the O-rings and back-up washers (Item 2) [Figure 20-110-22] for damage.

Remove the solenoid valve stem (Item 1) [Figure 20110-23] & [Figure 20-110-24] and inspect the O-rings and back-up washers (Item 2) [Figure 20-110-24] for damage. Installation: Put oil on O-rings and back-up washers. Tighten to 30-35 ft.-lb. (41-47 N•m) torque.

Installation: Put oil on O-rings and back-up washers. Tighten to 20-25 ft.-lb. (27-34 N•m) torque.

20-110-7


Figure 20-110-27


1 1

P-48765

Remove the plug (Item 1) [Figure 20-110-27]. P-48765

Installation: Tighten the plug to 10 ft.-lb. (13,6 N•m) torque.

Remove the plug (Item 1) [Figure 20-110-25]. Installation: Tighten the plug to 38 ft.-lb. (51,5 N•m) torque.

Figure 20-110-28

Figure 20-110-26

1

P-48786

Remove the orifice (Item 1) [Figure 20-110-28].

1 P-48766

Remove and inspect the orifice (Item 1) [Figure 20-11026] for dirt and debris.

Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m) torque.

Installation: Tighten the orifice to 22 ft.-lb. (29,8 N•m) torque.

20-110-8


REAR AUXILIARY DIVERTER VALVE (CONT'D)

Solenoid Testing

Disassembly And Assembly (Cont'd)

Figure 20-110-30

Figure 20-110-29

1

P9137 P-48758

Remove the plugs (Item 1) [Figure 20-110-29].

Use a test meter to measure coil resistance [Figure 20110-30]. Coil wires do not have polarity. Correct resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.

Installation: Tighten the plug to 14 ft.-lb. (19 N•m) torque.

Replace the test meter with 12 volt power. You can see and hear the spool shift. Inspection Inspect cartridges, check valves, solenoid valves and sealing washers for contamination or damage. Wash all parts in clean solvent. Use air pressure for drying them. Install new O-rings and back-up washers. Inspect diverter valve cavities for contamination. Wash valve in clean solvent. Use air pressure to dry.

20-110-9


20-110-10


POWER BOB-TACH BLOCK

Figure 20-120-1


3


1 2

W-2059-0598

3 P-48229

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 Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door.


Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Remove the nut from the speed control linkage (Item 1) and unplug the rear lights electrical connector (Item 2) [Figure 20-120-1]. Remove the fuel fill bracket mounting bolts (Item 3) [Figure 20-120-1].

20-120-1


Figure 20-120-4

POWER BOB-TACH BLOCK (CONT'D) Removal And Installation (Cont'd) Figure 20-120-2

1

1 1

P-48227

Remove the four mounting bolts (Item 1) [Figure 20-1204].

P-48230

Installation: The harness connectors are marked with Red or Black tie straps. Be sure the connectors with the same color are connected. Disconnect the power Bob-Tach harness from the solenoid connectors (Item 1) [Figure 20-120-2] by the hydraulic pump.

Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the power Bob-Tach block. NOTE: There is an O-ring in-between the power BobTach block and the hydraulic pump. Inspect and replace as needed.

Figure 20-120-3

4 1

2 3 P-48226

Disconnect the hose (Item 1) [Figure 20-120-3] from the "DR" port fitting on the block. Disconnect the hose (Item 2) [Figure 20-120-3] from the power Bob-Tach cylinder rod end fitting on the block. Disconnect the hose (Item 3) [Figure 20-120-3] from the power Bob-Tach cylinder base end fitting on the block. Disconnect the outlet hose (Item 4) [Figure 20-120-3] from the fitting on top of the block. 20-120-2


POWER BOB-TACH BLOCK (CONT'D)

Figure 20-120-6


3

1 4

2 2 1 P-48120

Remove the spring guide (Item 1), spring (Item 2) and the spool (Item 3) [Figure 20-120-6].

P-48115

Clean the block (Item 1) [Figure 20-120-5] to remove dirt before disassembly. Block ports are labeled for correct assembly.

Check the O-ring (Item 4) [Figure 20-120-6] on the plug and replace as needed. Figure 20-120-7

Remove the plug (Item 2) [Figure 20-120-5]. Installation: Tighten the plug to 25-30 ft.-lb. (34-40,6 N•m) torque.

IMPORTANT

1


P-48116

I-2003-0888

NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced. Do not remove the plug (Item 1) [Figure 20-120-7]. Installation: Tighten the plug to 12-14 ft.-lb. (16,3-19 N•m) torque.

20-120-3


Figure 20-120-10

POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-120-8

1 1 P-48122

Do not remove the plugs (Item 1) [Figure 20-120-10]. P-48382

NOTE: Do not remove plugs. If the plugs are removed the internal pressure relieving spring setting will be altered.

Remove the check valve (Item 1) [Figure 20-120-8]. Installation: Oil the check valve and O-rings and tighten the check valve to to 20-25 ft.-lb. (27,1-34 N•m) torque.

Figure 20-120-11

Figure 20-120-9

1 2 1 P-48384

3

Remove the plug (Item 1) [Figure 20-120-11], inspect the O-ring and replace as needed.

P-48119

Inspect the check valve (Item 1) and piston assembly (Item 2) [Figure 20-120-9].

Installation: Tighten the plug (Item 1) [Figure 20-12011] to 12-14 ft.-lb. (16,3-19 N•m) torque.

Check the O-rings and back up washers (Item 3) [Figure 20-120-9] on the check valve and piston assembly and replace as needed.

20-120-4


Figure 20-120-14

POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd)

3

Figure 20-120-12 2 1

2 1 P-48106

Remove the first solenoid coil (Item 1), spacer (Item 2) and the second solenoid coil (Item 3) [Figure 20-12014].

P-48664

Remove the orifice screw (Item 2) located behind the plug (Item 1) [Figure 20-120-11].

NOTE: Remember the solenoid coil orientation for ease of installation.

Installation: Tighten the orifice screw (Item 2) [Figure 20-120-11] to 6-8 ft.-lb. (8,1-10,8 N•m) torque.

Figure 20-120-15

Figure 20-120-13

1

1 2

P-48386

Remove the the solenoid stem (Item 1) [Figure 20-12015].

P-48127

NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced.

Installation: Tighten the solenoid stem to to 20-25 ft.-lb. (27,1-34 N•m) torque.

Do not remove the plug (Item 1) [Figure 20-120-13]. Remove the solenoid nut (Item 2) [Figure 20-120-13]. Installation: Tighten the solenoid valve stem nut to 1545 in.-lb. (1,7-5,1 N•m) torque.

20-120-5


Figure 20-120-18

POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-120-16

1

P-48174

1

Remove the screened orifice plug (Item 1) [Figure 20120-18].

P-48175

Remove the armature rod assembly (Item 1) [Figure 20120-16].

Installation: Tighten the screened orifice plug to to 1112 ft.-lb. (14,9-16,3 N•m) torque. Figure 20-120-19

Figure 20-120-17

3 2

2 1

1 P-48138 P-48173

Inspect the solenoid stem (Item 1), armature assembly (Item 2) and the spool (Item 3) for damage [Figure 20120-17]. NOTE: If the solenoid stem is damaged (Item 1) check the armature assembly (Item 2) for damage.

Inspect the screened orifice plug (Item 1) [Figure 20120-19] for damage replace as needed. If the screened orifice plug is blocked replace with a new plug. Check the O-ring (Item 2) [Figure 20-120-19] and replace as needed.

The armature assembly (Item 2) and spool (Item 3) are non-serviceable parts. If they are damaged, order a new power Bob-Tach block assembly from Bobcat parts [Figure 20-12017].

20-120-6


FRONT AUXILIARY HYDRAULIC COUPLER BLOCK



Figure 20-130-2

IMPORTANT

1


2 4 3

I-2003-0888

Figure 20-130-1 P-34661

Figure 20-130-3 2 1

1 3 6

2

4 5

3

P-48464

Disconnect the auxiliary tubelines (Item 1) and drain tubeline (Item 2) from the coupler block [Figure 20-1301]. Remove the two mounting bolts (Item 3) [Figure 20-1301].

P-34760

Remove the male coupler (Item 1) [Figure 20-130-2] & [Figure 20-130-3]. Installation: Tighten the male coupler (Item 1) [Figure 20-130-2] & [Figure 20-130-3] to 59 ft.lb. (80 N•m) Remove the drain coupler (Item 2) [Figure 20-130-2] & [Figure 20-130-3]. Installation: Tighten the drain coupler (Item 2) [Figure 20-130-2] & [Figure 20-130-3] to 37 ft.lb. (50 N•m) Remove the female coupler (Item 3) [Figure 20-130-2] & [Figure 20-130-3]. Installation: Tighten the female coupler (Item 3) [Figure 20-130-2] & [Figure 20-130-3] to 59 ft.lb. (80 N•m) Remove the fittings (Item 4) [Figure 20-130-2] & [Figure 20-130-3] check the O-rings (Item 5) [Figure 20-130-3] and replace as needed. Remove the springs (Item 6) [Figure 20-130-3].

20-130-1


Figure 20-130-6

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (CONT’D) Disassembly And Assembly (Cont’d)

1

Figure 20-130-4

1 2 P-34665

Check the O-rings (Item 1) backup O-rings (Item 2) for damage and replace as needed [Figure 20-130-6]. P-34663

Figure 20-130-7 Check the O-ring (Item 1) [Figure 20-130-4] for damage and replace as needed.

1

Figure 20-130-5

1

2 P-34664

Check the O-rings (Item 1) backup O-rings (Item 2) for damage and replace as needed [Figure 20-130-7]. P-34701

Press center of male couplers down and check the O-ring (Item 1) [Figure 20-130-5] for damage and replace as needed. .

20-130-2


HYDROSTATIC SYSTEM CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . Adjusting (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . Sender Removal And Installation (Non SJC Machines) . . Sender Removal And Installation (SJC Machines) . . . . . . Testing (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . Testing (SJC Machines). . . . . . . . . . . . . . . . . . . . . . . . . . .

30-30-1 30-30-2 30-30-4 30-30-1 30-30-3 30-30-1 30-30-3

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Disassembly. . . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . Tensioner Pulley Removal And Installation . . . . . . . . . . . .

30-50-1 30-50-1 30-50-3 30-50-1 30-50-7 30-50-6 30-50-5 30-50-4

HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Assembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Disassembly and Assembly (Dry Bolt). . . . . . . . . . . . . . . 30-20-16 Disassembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 Parts Identification (Dry Bolt) . . . . . . . . . . . . . . . . . . . . . . 30-20-15 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

30-21-1 30-21-6 30-21-5 30-21-3 30-21-1

HYDROSTATIC MOTOR CARRIER (SJC). . . . . . . . . . . . . . . Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

30-22-1 30-22-6 30-22-5 30-22-3 30-22-1


HYDROSTATIC SYSTEM

DRIVE SYSTEM


SPECIFICATIONS

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9 Hydraulic Pump Removal And Installation. . . . . . . . . . . . . 30-40-8 Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6 Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2 Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-1 CONTINUED ON NEXT PAGE

30-01


HYDROSTATIC SYSTEM (CONT’D) HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1 Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9 High Pressure Relief and By-Pass Valve. . . . . . . . . . . . . . 30-41-7 Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . 30-41-28 Hydraulic Controller Removal And Installation. . . . . . . . . . 30-41-2 Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . 30-41-25 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-4 HYDROSTATIC SYSTEM INFORMATION. . . . . . . . . . . . . . . 30-10-1 Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

30-02


HYDROSTATIC SYSTEM INFORMATION

WARNING



PROBLEM

CAUSE 1, 2 2, 3, 4, 5 2, 3, 5, 6, 7 8, 9

No drive on one side, in one direction. No drive on one side in both directions. The loader does not move in a straight line. The hydrostatic system is overheating.

KEY TO CORRECT THE CAUSE 1. The hydrostatic pump replenishing valves not seating. 2. 3. 4. 5. 6. 7. 8. 9.

The steering linkage needs adjustment. The hydrostatic pump has damage. The final drive chains are broken. The hydrostatic motor has damage. The tires do not have the correct tire pressure. The tires are not the same size. The hydrostatic fluid is not at the correct level. The oil cooler has a restriction.

30-10-1


HYDROSTATIC SYSTEM INFORMATION


Replenishing Valve Function Figure 30-10-1 CHARGE OIL

FUNCTION 1

FUNCTION 2

Valve Moves for Charge Oil Replacement

Valve Stays on Seat to Hold High Pressure for Drive B-2804

The functions of the replenishing valves are: 1. 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; Function 1 [Figure 30-10-1]. 2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [Figure 30-10-1].

30-10-2



HYDROSTATIC MOTOR Description Two types of hydrostatic drive motors have been used on this model loader. Both designs remove and install the same. Figure 30-20-1


1

W-2059-0598 N-00621

The early design is identified by the tie bolts (Item 1) [Figure 30-20-1] mounting from the inside of the hydrostatic drive motor with the heads of the tie bolts immersed in the hydraulic oil. The tie bolts are not visible when the hydrostatic drive motor is installed on the loader. This type is called the “wet bolt” design.


Figure 30-20-2

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the front and rear wheel/tire assemblies. (See TIRE MAINTENANCE on Page 10-170-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.)

1

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.)

P-39894

The later design has the tie bolts (Item 1) [Figure 30-202] mounting from the outside of the hydrostatic drive motor. The tie bolt heads are not immersed in hydraulic oil and are visible when the hydrostatic drive motor is installed on the loader. This type is called the “dry bolt” design.

30-20-1


Figure 30-20-5

HYDROSTATIC MOTOR (CONT’D) Removal And Installation (Cont’d) Figure 30-20-3

1

1

1

1

N-19240

Remove the four drive motor mounting bolts (Item 1) [Figure 30-20-5].

P-34004

Remove the four motor cover mounting bolts (Item 1) [Figure 30-20-3] .

Installation: Tighten the drive motor mounting bolts to 90-100 ft.-lb. (122-136 N•m) torque. Figure 30-20-6

Figure 30-20-4

2

1

1

2

P-4141 N-19238

Mark the two hoses (Item 1) [Figure 30-20-4] before disconnecting them from the HYDROSTATIC MOTOR for correct installation. Remove the two hoses (Item 1) [Figure 30-20-4] from the drive motor. Remove the drain hose (Item 2) [Figure 30-20-4] from the drive motor.

Remove the drive motor from the access hole in the loader frame [Figure 30-20-6]. Inspect drive motor o-ring (Item 1) and carrier shaft seal (Item 2) [Figure 30-20-6]. Reverse the removal procedure HYDROSTATIC MOTOR.

30-20-2

to

install

the


HYDROSTATIC MOTOR (CONT’D) Parts Identification (Wet Bolt) 3 10

11

9 8 13

4 16

3 5 11

6 15 21

14

3 7

6

22 20

17

19 18

19

17

20

1

3

12

24 23

26 25

2

Ref.

Description

Ref.

Description

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

HOUSING O-RING SEAL, square VALVE, plate GEROLER BALL PLATE, balance RING, back-up SEAL RING, back-up O-RING PLUG FLANGE, mounting SEAL, face

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

SHAFT, drive BOLT SPRING PISTON POPPET SLEEVE PLUG O-RING O-RING SPRING SHIM POPPET

30-20-3

D-3431B


Figure 30-20-9

HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt)

1

IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-00623

Figure 30-20-7

Lift and remove the mounting flange (Item 1) [Figure 3020-9] from the motor. NOTE: Do not scratch or damage the surfaces of the motor sections. Always put them on a soft surface. Figure 30-20-10 1 2 N-00621

Drain the oil from the motor. Seal all open ports and clean the motor with solvent. Put a mark across the sections of the motor for correct assembly [Figure 30-20-7]. Figure 30-20-8 N-00624

1

Turn the mounting flange over and remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 30-20-10].

N-00622

Remove the nine bolts (Item 1) [Figure 30-20-8] from the motor. 30-20-4


Figure 30-20-13

HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d)

1

Figure 30-20-11

1

N-00627

Remove the main drive (Item 1) [Figure 30-20-13] from the gerolor assembly.

N-00625

Turn the mounting flange backover and remove the seal (Item 1) [Figure 30-20-11] from the mounting flange.

Figure 30-20-14

Figure 30-20-12 1 1 1

N-00628

Remove the two check balls (Item 1) [Figure 30-20-14] from the gerolor.

N-00626

Remove the balance plate (Item 1) [Figure 30-20-12] from the gerolor assembly.

30-20-5


Figure 30-20-17

HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d) Figure 30-20-15

1

N-00631

1

Carefully turn the gerolor assembly over and remove the square cut seal (Item 1) [Figure 30-20-17].

N-00629

Remove the square cut seal (Item 1) [Figure 30-20-15] from the gerolor.

Figure 30-20-18 1

Figure 30-20-16

1

N-00632

Remove the valve plate (Item 1) [Figure 30-20-18] from the end cap.

N-00630

Remove the gerolor assembly (Item 1) [Figure 30-2016]. NOTE: Care should be taken to keep the gerolor assembly together. NOTE: If rollers are removed, put them back in their original bore.

30-20-6


Figure 30-20-21

HYDROSTATIC MOTOR (Wet Bolt) (CONT’D) Disassembly (Wet Bolt) (Cont’d)

1

Figure 30-20-19 1 2

N-00635

Remove the poppet and shuttle valve (Item 1) [Figure 30-20-21].

N-00633

Remove the square cut seal (Item 1) and small O-ring (Item 2) [Figure 30-20-19] from the end cap.

Figure 30-20-22

Figure 30-20-20

1 2

N-00636

Turn the end cover over and remove the shuttle valve plug from the end cover [Figure 30-20-22].

N-00634

Remove the spring seat (Item 1) and spring (Item 2) [Figure 30-20-20].

30-20-7


Figure 30-20-25

HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d)

3

Figure 30-20-23 2 1

1 2 3

N-00640

Remove the spring (Item 1) and poppet (Item 2) from the end cover (Item 3) [Figure 30-20-25].

N-00637

Remove the spring seat (Item 1), spring (Item 2) and poppet (Item 3) [Figure 30-20-23]. Figure 30-20-24

NOTE: The relief pressure is factory set and must not be changed. Shims may or may not have been used at the factory for setting the pressure. If shims are present, make sure they are reinstalled during assembly. Figure 30-20-26

3 2

1

N-00639

N-00641

Remove the low pressure relief valve plug from the side of the end cover [Figure 30-20-24].

The low pressure relief valve is made up of the poppet (Item 1), the spring (Item 2) and the plug assembly (Item 3) [Figure 30-20-26].

30-20-8


Figure 30-20-28

HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt)


Prior to assembly:

Install the new O-ring on the plug and tighten to 300 in.lb. (34 N•m) torque [Figure 30-20-28].

Clean all parts with solvent and dry with compressed air. Put grease on O-rings.

Figure 30-20-29

Lubricate parts with oil. Figure 30-20-27

3

2

2 1 1

N-00644

Install the poppet (Item 1), the spring (Item 2) and the spring seat (Item 3) [Figure 30-20-29] in the end cover.

N-00642

Install the poppet (Item 1) and spring (Item 2) [Figure 3020-27] in the low pressure relief port in the end cover.

NOTE: The tapered end of the poppet must face towards the shuttle valve.

30-20-9


Figure 30-20-32

HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d) Figure 30-20-30

1

2

N-00648

Install the square cut seal (Item 1) and small O-ring (Item 2) [Figure 30-20-32] in the end cover.

N-00646

Install a new O-ring on the plug [Figure 30-20-30] and tighten to 260 in.-lb. (41 N•m) torque.

Figure 30-20-33

NOTE: Always use new O-rings and seals when assembling the motor. Put a small amount of grease on all the O-rings and seals for easier installation. Figure 30-20-31 4 2

3

1

N-00649

Mark the case drain port location on the outside of the end cover for ease of assembly [Figure 30-20-33].

N-00647

Install the shuttle valve (Item 1), poppet (Item 2), spring (Item 3) and spring seat (Item 4) [Figure 30-20-31] in the port hole in the end cap. NOTE: The tapered end of the poppet must face towards the shuttle valve.

30-20-10


Figure 30-20-36


N-00652

Mark the case drain port location on the outside edge of the valve plate as shown [Figure 30-20-36].

N-00650

Align the case drain ports in the valve plate with the case drain port in the end cover [Figure 30-20-34].

Figure 30-20-37 1

Figure 30-20-35 1

N-00653

Install the gerolor assembly (Item 1) [Figure 30-20-37] by aligning the case drain hole with the case drain hole in the valve plate.

N-00651

Install the large square cut seal (Item 1) [Figure 30-2035] in gerolor assembly.

30-20-11


Figure 30-20-40

HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d)

1

Figure 30-20-38

1

N-00656

Install the main drive (Item 1) [Figure 30-20-40] in the gerolor (as shown).

N-00654

Install the square cut seal (Item 1) [Figure 30-20-38] in the gerolor outer ring.

NOTE: Whenever the main drive is not symmetrical, the smallest end of the main drive must be installed into the gerolors.

Figure 30-20-39

Figure 30-20-41

1

N-00655

N-00657

Install the two check balls (Item 1) [Figure 30-20-39] in their bores in the gerolor.

Mark the case drain hole on the outer ring of the gerolor (as shown) [Figure 30-20-41].

30-20-12


Figure 30-20-44

HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d)

1

Figure 30-20-42

2

3 4 5

N-00660

Install the square cut seal (Item 1), seal (Item 2), back-up seal (Item 3), seal (Item 4) and back-up ring (Item 5) [Figure 30-20-44] in the mounting flange.

1 N-00658

Align the case drain holes and install the balance plate (Item 1) [Figure 30-20-42] on the gerolor assembly.

Figure 30-20-45

Figure 30-20-43

1

N-00661

N-00659

Mark the case drain holes on the side of the balance plate [Figure 30-20-45].

Install the seal (Item 1) [Figure 30-20-43] (as shown).

30-20-13


Figure 30-20-48


1

N-00664

Install the nine bolts into the motor. Make sure all the parts are in correct alignment [Figure 30-20-48].

N-00662

Align the case drain port (Item 1) [Figure 30-20-46] in the mounting flange with the case drain port in the balance plate (as shown).

Figure 30-20-49

Figure 30-20-47

1

MC-2230

1. Tighten the bolts to 45-55 ft.-lb. (61-75 N•m) torque as shown in figure [Figure 30-20-49]. N-00663

Align the two case drain port (Item 1) [Figure 30-20-47] and install the mounting flange on the balance plate. Be careful not to displace the seals and back-up rings.

2. Tighten the bolts to 55-65 ft.-lb. (75 -88 N•m) torque as shown in figure [Figure 30-20-49]. NOTE: To prevent damage to the balance plate, never lift or support the motor by the center shaft.

30-20-14


HYDROSTATIC MOTOR (CONT’D) Parts Identification (Dry Bolt) 16

14

3 15

20 14 16

3

19

14

18 18

13

19 17

5

3

12 5 11 10 5

9

8 10

7 6

3 3 5 4 3 2 1

PE2620T

Ref.

Description

Ref.

Description

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SHAFT, drive SEAL, face O-RING FLANGE, mounting SEAL, square cut RING, back-up SPRING, belleville PLATE, outer balance PLATE, inner balance BALL

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

GEROLER PLATE, valve END CAP POPPET SPRING PLUG BOLT SLEEVE SPRING VALVE, shuttle

30-20-15


HYDROSTATIC MOTOR (CONT’D)

Figure 30-20-51

Disassembly and Assembly (Dry Bolt)

1

IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 P-39894

Figure 30-20-50

Remove the nine tie bolts (Item 1) [Figure 30-20-51] from the motor. Figure 30-20-52

1

9 6

4

3

7

P-64267

Drain the oil from the motor.

8

Seal all open ports and clean the motor with solvent.

2 5

Put a mark across the sections of the motor for correct assembly [Figure 30-20-50].

P-39894

Assembly: 1. Tighten the bolts to 45-55 ft.-lb. (61-75 N•m) torque in the order shown in figure [Figure 30-20-52]. 2. Tighten the bolts to 55-65 ft.-lb. (75 -88 N•m) torque in the order shown in figure [Figure 30-20-52]. NOTE: To prevent damage to the balance plate, never lift or support the motor by the drive shaft.

30-20-16


Figure 30-20-55

HYDROSTATIC MOTOR (CONT’D) Disassembly and Assembly (Dry Bolt) (Cont’d) Figure 30-20-53

3 1

2

1 P-63785

P-64267

Once the tie bolts have been removed and the motor begins to separate, the drive shaft can be removed. (Item 1) [Figure 30-20-53]. Assembly: Install drive shaft before tightening tie bolts.

Remove the plug (Item 1) spring (Item 2) and poppet (Item 3) [Figure 30-20-55] that make up the relief valve assembly. Inspect for scoring on poppet. Ensure it can operate freely in the bore. Inspect o-ring on plug. Installation: Lubricate relief valve assembly with hydraulic oil and tighten plug to 260 in.-lb. (41 N•m) torque. Figure 30-20-56

Figure 30-20-54

1

2 1

P-39896 P-39895

Lift and remove the end cap (Item 1) [Figure 30-20-54] from the motor.

Remove the plug (Item 1) and shuttle valve assembly (Item 2) [Figure 30-20-56]. Inspect for scoring on shuttle valve. Ensure it can operate freely in the bore.

NOTE: Do not scratch or damage the surfaces of the motor sections. Always put them on a soft surface.

Installation: Lubricate shuttle valve assembly with hydraulic oil and tighten plug to 260 in.-lb. (41 N•m) torque.

30-20-17


Figure 30-20-59

HYDROSTATIC MOTOR (CONT’D) Disassembly and Assembly (Dry Bolt) (Cont’d)

3

Figure 30-20-57 2

1

1

P-64274

Remove and inspect/replace seal (Item 1) [Figure 3020-59].

P-39897

Remove the remaining pieces to the shuttle valve assembly (Item 1) [Figure 30-20-57] from the inside of the end cap. Inspect for broken or damaged parts. Parts should move freely in bore. Assembly: Apply grease to shuttle valve parts to help hold in place during assembly. Figure 30-20-58

2

Remove the gerolor section as an assembly (Item 2) [Figure 30-20-59]. NOTE: There are two check balls on the backside of the gerolor section. Be carefull not to lose these check balls. See [Figure 30-20-60]. Note location of case drain hole (Item 3) [Figure 3020-59]. Align hole with other sections on drive motor.

3 1

1

P-39898

Remove and inspect/replace seals (Item 1) [Figure 3020-58]. Remove the valve plate (Item 2) [Figure 30-20-58]. Assembly: Apply grease to seals. Note location of case drain hole (Item 3) [Figure 30-20-58]. Align hole with other sections on drive motor.

30-20-18


Figure 30-20-61


4

Figure 30-20-60

1 2

3 1

1

P-64268

Remove the center piece of the balance plate (Item 1) [Figure 30-20-61].

P-39901

Remove the two check balls (Item 1) [Figure 30-20-60] from the gerolor. Assembly: Check for scoring and wear on the gerolor assembly. Apply grease to check balls to keep them from falling out of there seats when assembling. NOTE: Care should be taken to keep the gerolor assembly together.

Remove and inspect/replace the seal (Item 2) [Figure 30-20-61]. Remove the balance plate (Item 3) [Figure 30-20-61]. Assembly: Apply grease to seals. Note location of case drain hole (Item 4) [Figure 30-20-61]. Align hole with other sections on drive motor.

NOTE: If rollers are removed, put them back in their original bore.

30-20-19


Figure 30-20-64


1

Figure 30-20-62

1

P-64272

Remove the belleville spring. (Item 1) [Figure 30-20-64]. P-64270

Assembly: If the belleville spring is no longer cone shaped, replace with new.

Remove the back up ring (Item 1) [Figure 30-20-62]. Assembly: Apply grease to back up ring. One side of the back up ring is grooved to fit against the o-ring underneath.

Figure 30-20-65

Figure 30-20-63

1 1 P-64273

1

Carefully turn the mounting flange over and remove the seal (Item 1) [Figure 30-20-65].

1 P-64271

Assembly: Replace the seal.

Remove and inspect/replace the seals (Item 1) [Figure 30-20-63] from the gerolor. Assembly: Apply grease to seals.

30-20-20


Figure 30-21-2

HYDROSTATIC MOTOR CARRIER Shaft Seal Replacement The tool listed is necessary for the following procedure: MEL1420 - Carrier Seal Tool Remove the hydrostatic motor. (See Removal And Installation on Page 30-21-3.)


P-4456

Drill a .125 inch (3 mm) hole in the motor carrier seal [Figure 30-21-2]. Figure 30-21-3

Figure 30-21-1

1 P-4455

Use a slide hammer to remove the seal from the motor carrier shaft [Figure 30-21-3].

P-4153

The motor carrier seal (Item 1) [Figure 30-21-1] is located on the outside of the motor carrier shaft.

30-21-1


Figure 30-21-6

HYDROSTATIC MOTOR CARRIER (CONT’D) Shaft Seal Replacement (Cont’d) Figure 30-21-4

1

P-4149

Photo [Figure 30-21-6] shows the motor carrier seal correctly installed.

P-4454

Installation: Install a new seal over the motor carrier shaft [Figure 30-21-4]. Figure 30-21-5

NOTE: Before reinstalling the hydrostatic motor, check the plug (Item 1) [Figure 30-21-6] located in the center of the carrier shaft for tightness. If the plug becomes loosened, case drain lubrication oil from the hydrostatic motor can leak into the chaincase.

P-4150

Installation: Install MEL1420 Carrier Seal Tool over the carrier seal [Figure 30-21-5]. Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-21-5].

30-21-2


Figure 30-21-7

HYDROSTATIC MOTOR CARRIER (CONT’D) Removal And Installation

2


1

W-2059-0598

Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)

P-4152

Remove the parking brake disc (Item 1) [Figure 30-217]. (See Disk Removal And Installation on Page 40-101.) Remove the six motor carrier mounting bolts (Item 2) [Figure 30-21-7] from the inside of the chaincase. Installation: Tighten the motor carrier mounting bolts to 125-140 ft.-lb. (170-190 N•m) torque. Figure 30-21-8

Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.)

1

Remove the lift arm by-pass control valve. (See Removal and Installation on Page 20-50-1.) 2

Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the front chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) Remove the front axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.) Remove the hydrostatic motor. (See Removal And Installation on Page 30-21-3)

P-4167

For ease of removal, fasten the front drive chain (previously removed) to the chaincase as shown (Item 1) [Figure 30-21-8]. Tip the end of the sprocket toward the rear of the loader and remove the rear drive chain (Item 2) [Figure 30-218] from the sprocket.

30-21-3


HYDROSTATIC MOTOR CARRIER (CONT’D) Removal And Installation (Cont’d) Figure 30-21-9

1

P-4165

Slide the motor carrier out of the chaincase [Figure 3021-9]. Installation: Check the motor carrier gasket (Item 1) [Figure 30-21-9] for wear or damage and replace if necessary. Figure 30-21-10

1

P-4168

Use one of the motor carrier mounting bolts (Item 1) [Figure 30-21-10] and install partially into one mounting hole on the carrier. Fasten a chain hoist to the bolt on the motor carrier and remove the carrier from the loader. Reverse the removal procedure to install the motor carrier.

30-21-4


HYDROSTATIC MOTOR CARRIER (CONT’D) Parts Identification

1 8

2

3

4

5 4

3

7

6

MC-1937A

Ref.

Description

Ref.

Description

1.

MOUNT ASSY.

5.

HOUSING

2.

SHAFT

6.

SNAP RING

3.

BEARING

7.

SEAL

4.

RACE

8.

PLUG

30-21-5


Figure 30-21-13

HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly and Assembly Figure 30-21-11 3.000’’ O.D. Diameter (76,2 mm) 2.530’’ I.D. Diameter (64,26 mm) 7.000’’ Length (177,8 mm)

P-4176

Put the motor carrier in the hydraulic press as shown [Figure 30-21-13].

MC-2102

It is necessary to locate or fabricate a press tool for this procedure. Refer to photo [Figure 30-21-11] for the correct dimensions of the tool needed. Figure 30-21-12

Use 2-1/4 inch driver tool and press the sprocket shaft out of the motor carrier housing [Figure 30-21-13]. NOTE: The outer bearing will now be free from the sprocket shaft. Figure 30-21-14

2 1

1 P-4372 P-4365

A hydraulic press, slide hammer with puller end and snap ring pliers are also recommended for this procedure. Remove the motor carrier shaft seal. (See Disassembly and Assembly on Page 30-21-6). Remove the snap ring (Item 1) [Figure 30-21-12] from the motor carrier shaft using the snap ring pliers.

Remove the housing from the press and install a bearing puller (Item 1) [Figure 30-21-14] on the sprocket shaft. Put the assembly in the hydraulic press. Use the same tool driver and remove the bearing (Item 2) [Figure 3021-14] from the shaft.

30-21-6


Figure 30-21-17

HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly and Assembly (Cont’d) Figure 30-21-15 2

1

P-4369

Put the motor carrier housing in the press as shown [Figure 30-21-17].

P-4373

Fasten the carrier motor housing to the work surface securely with the inner bearing race (Item 1) [Figure 3021-15] facing up. Install the slide hammer with puller end (Item 2) [Figure 30-21-15] on the bottom side of the bearing race. Remove the bearing race from the carrier housing [Figure 30-21-15].

Use 4-5/16 inch driver tool and press the new inner bearing race into the motor carrier housing [Figure 3021-17]. Press the bearing race in until it is fully seated in the carrier housing. Figure 30-21-18

Figure 30-21-16

P-4368

Turn the motor carrier housing over as shown [Figure 30-21-18].

P-4370

Put the motor carrier housing in the hydraulic press as shown [Figure 30-21-16].

Use 4-5/16 inch driver tool and press the new outer bearing race into the motor carrier housing [Figure 3021-18].

Use a 3-7/8 inch driver tool and press the outer bearing race from the housing.

Press the bearing race in until it is fully seated in the carrier housing.

Check all parts for wear and damage. Replace the bearing race when new bearings are to be installed.

30-21-7


Figure 30-21-20

HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly and Assembly (Cont’d) Figure 30-21-19

1 1

2

P-4371

P-4366

Put the motor carrier housing (Item 1) [Figure 30-21-20] over the sprocket shaft as shown.

Use the fabricated press tool (Item 1) and 3.0 inch driver tool, install the new inner bearing (Item 2) [Figure 30-2119] on the sprocket shaft as shown. Remove the press and drive tools from the sprocket shaft.

Put the outer bearing over the end of the sprocket shaft and press the bearing on with the press tool and driver tool [Figure 30-21-20]. Remove the press and driver tools from the sprocket shaft.

30-21-8


Figure 30-21-23


1 1

P-4374

Put the snap ring (Item 1) [Figure 30-21-21] over the end of the sprocket shaft.

P-4375

NOTE: Use the snap ring pliers to spread the snap ring so it will fit over the sprocket shaft.

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-2123] and install the shaft seal.

Using the press and driver tools, press the snap ring (Item 1) [Figure 30-21-21] over the sprocket.

Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-21-23].

Press the snap ring on until it snaps into the groove on the shaft.

Figure 30-21-24

Figure 30-21-22

1

N-15088

Check the end play of the motor carrier as follows:

P-4376

Put a new shaft seal (Item 1) [Figure 30-21-22] on the sprocket shaft.

Use a rubber mallet [Figure 30-21-24], tap down on the cluster shaft.

30-21-9



1

N-15087

Install a dial indicator as shown in Photo [Figure 30-2125]. Use a pry bar (Item 1) [Figure 30-21-25] to lift the carrier shaft and read the end play on the dial indicator. The carrier shaft must turn freely with end play not to exceed 0.007 inch (0,17 mm).

30-21-10


Figure 30-22-2

HYDROSTATIC MOTOR CARRIER (SJC) Shaft Seal Replacement The tool listed is necessary for the following procedure: MEL1420 - Carrier Seal Tool Remove the hydrostatic motor. ((See Removal And Installation on Page 30-20-1.)


P-39783

Drill a .125 inch (3 mm) hole in the motor carrier seal [Figure 30-22-2]. Figure 30-22-3

Figure 30-22-1

1 P-39784

Use a slide hammer to remove the seal from the motor carrier shaft [Figure 30-22-3].

P-39780

The motor carrier seal (Item 1) [Figure 30-22-1] is located on the outside of the motor carrier shaft.

30-22-1


Figure 30-22-6

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Shaft Seal Replacement (Cont’d) Figure 30-22-4

1

P-39780

Photo [Figure 30-22-6] shows the motor carrier seal correctly installed.

P-4454A

Installation: Install a new seal over the motor carrier shaft [Figure 30-22-4]. Figure 30-22-5

NOTE: Before reinstalling the hydrostatic motor, check the plug (Item 1) [Figure 30-22-6] located in the center of the carrier shaft for tightness. If the plug becomes loosened, case drain lubrication oil from the hydrostatic motor can leak into the chaincase.

P-39786

Installation: Install MEL1420 Carrier Seal Tool over the carrier seal [Figure 30-22-5]. Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-22-5].

30-22-2


Figure 30-22-7

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Removal And Installation

WARNING 2


1

W-2059-0598

Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)

P-39781

Remove the parking brake disc (Item 1) [Figure 30-227]. (See Disk Removal And Installation on Page 40-101.) Remove the six motor carrier mounting bolts (Item 2) [Figure 30-22-7] from the inside of the chaincase. Installation: Tighten the motor carrier mounting bolts to 125-140 ft.-lb. (170-190 N•m) torque. Figure 30-22-8

Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)

1

Remove the control panel. (See Removal and Installation on Page 50-100-1.) Remove the lift arm by-pass control valve. (See Removal and Installation on Page 20-50-1.) 2

Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the front chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) Remove the front axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.) Remove the hydrostatic motor. (See Removal And Installation on Page 30-20-1.)

P-4167A

For ease of removal, fasten the front drive chain (previously removed) to the chaincase as shown (Item 1) [Figure 30-22-8]. Tip the end of the sprocket toward the rear of the loader and remove the rear drive chain (Item 2) [Figure 30-228] from the sprocket.

30-22-3


HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Removal And Installation (Cont’d) Figure 30-22-9

1

P-39812

Slide the motor carrier out of the chaincase [Figure 3022-9]. Installation: Check the motor carrier gasket (Item 1) [Figure 30-22-9] for wear or damage and replace if necessary. Figure 30-22-10

1

P-39813

Use one of the motor carrier mounting bolts (Item 1) [Figure 30-22-10] and install partially into one mounting hole on the carrier. Fasten a chain hoist to the bolt on the motor carrier and remove the carrier from the loader. Reverse the removal procedure to install the motor carrier.

30-22-4


HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Parts Identification

1

2

3 4

5 4 3 6

7 P-64693

Ref.

Description

Ref.

Description

1.

SHAFT

5.

HOUSING

2.

SENSOR DISC

6.

SNAP RING

3.

BEARING

7.

SEAL

4.

RACE

30-22-5


Figure 30-22-13

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly and Assembly Figure 30-22-11 3.000’’ O.D. Diameter (76,2 mm) 2.530’’ I.D. Diameter (64,26 mm) 7.000’’ Length (177,8 mm)

P-39816

Put the motor carrier in the hydraulic press as shown [Figure 30-22-13].

MC-2102

It is necessary to locate or fabricate a press tool for this procedure. Refer to photo [Figure 30-22-11] for the correct dimensions of the tool needed. Figure 30-22-12

Use 2-1/4 inch driver tool and press the sprocket shaft out of the motor carrier housing [Figure 30-22-13]. NOTE: The outer bearing will now be free from the sprocket shaft. Figure 30-22-14

2 1

1 P-39815 P-4365

A hydraulic press, slide hammer with puller end and snap ring pliers are also recommended for this procedure. Remove the motor carrier shaft seal. (See Shaft Seal Replacement on Page 30-22-1.) Remove the snap ring (Item 1) [Figure 30-22-12] from the motor carrier shaft using the snap ring pliers.

Remove the housing from the press and install a bearing puller (Item 1) [Figure 30-22-14] on the sprocket shaft. Put the assembly in the hydraulic press. Use the same tool driver and remove the bearing (Item 2) [Figure 3022-14] from the shaft.

30-22-6


Figure 30-22-17

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly and Assembly (Cont’d) Figure 30-22-15 2

1

P-39820

Put the motor carrier housing in the press as shown [Figure 30-22-17].

P-39817

Fasten the carrier motor housing to the work surface securely with the inner bearing race (Item 1) [Figure 3022-15] facing up. Install the slide hammer with puller end (Item 2) [Figure 30-22-15] on the bottom side of the bearing race. Remove the bearing race from the carrier housing [Figure 30-22-15].

Use a 4-5/16 inch driver tool and press the new inner bearing race into the motor carrier housing [Figure 3022-17]. Press the bearing race in until it is fully seated in the carrier housing. Figure 30-22-18

Figure 30-22-16

P-39819

Turn the motor carrier housing over as shown [Figure 30-22-18].

P-39818

Put the motor carrier housing in the hydraulic press as shown [Figure 30-22-16].

Use 4-5/16 inch driver tool and press the new outer bearing race into the motor carrier housing [Figure 3022-18].

Use a 3-7/8 inch driver tool and press the outer bearing race from the housing.

Press the bearing race in until it is fully seated in the carrier housing.

Check all parts for wear and damage. Replace the bearing race when new bearings are to be installed.

30-22-7


Figure 30-22-20

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly and Assembly (Cont’d) Figure 30-22-19

1 1

2

P-4371

P-4366

Put the motor carrier housing (Item 1) [Figure 30-22-20] over the sprocket shaft as shown.

Use the fabricated press tool (Item 1) and 3.0 inch driver tool, install the new inner bearing (Item 2) [Figure 30-2219] on the sprocket shaft as shown. Remove the press and drive tools from the sprocket shaft.

Put the outer bearing over the end of the sprocket shaft and press the bearing on with the press tool and driver tool [Figure 30-22-20]. Remove the press and driver tools from the sprocket shaft.

30-22-8


Figure 30-22-23


1 1

P-39814

Put the snap ring (Item 1) [Figure 30-22-21] over the end of the sprocket shaft.

P-4375

NOTE: Use the snap ring pliers to spread the snap ring so it will fit over the sprocket shaft.

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-2223] and install the shaft seal.

Using the press and driver tools, press the snap ring (Item 1) [Figure 30-22-21] over the sprocket.

Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-22-23].

Press the snap ring on until it snaps into the groove on the shaft.

Figure 30-22-24

Figure 30-22-22

1

P-39821

Check the end play of the motor carrier as follows:

P-4376

Put a new shaft seal (Item 1) [Figure 30-22-22] on the sprocket shaft.

Use a rubber mallet [Figure 30-22-24], tap down on the cluster shaft.

30-22-9



1

N-15087

Install a dial indicator as shown in Photo [Figure 30-2225]. Use a pry bar (Item 1) [Figure 30-22-25] to lift the carrier shaft and read the end play on the dial indicator. The carrier shaft must turn freely with end play not to exceed 0.007 inch (0,17 mm).

30-22-10


Figure 30-30-2

CHARGE PRESSURE Sender Removal And Installation (Non SJC Machines)

2

WARNING 1


P-28590

Figure 30-30-1

Disconnect the wires (Item 1) [Figure 30-30-2] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-2] from the fitting.

1

Installation: Tighten the sender to 7.4-8.1 ft.-lb. (10-11 N•m) torque. 2

Testing (Non SJC Machines) Lift and block the loader. (See Procedure on Page 10-101.) P-48580

Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 30-30-1].

Open the rear door. Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 30-30-1]. Installation: Tighten the mounting bolts and nuts to 15 ft.-lb. (20 N•m) torque.

Disconnect the wires (Item 1) [Figure 30-30-2] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-2] from the fitting. Installation: Tighten the sender to 7.4-8.1 ft.-lb. (10-11 N•m) torque. Install a tee fitting into the charge pressure sender fitting. Install a hose with a pressure gauge of at least 500 PSI on one end of the tee fitting and the charge pressure sender into the other end. Reconnect the wires to the charge pressure sender. Start the engine. The gauge must read as follows: 220-270 PSI (15,1-18,6 bar) with approximately 140°F (60°C) fluid @ High Idle.

30-30-1


Figure 30-30-4

CHARGE PRESSURE (CONT'D) Adjusting (Non SJC Machines)


Figure 30-30-3

Remove the plug, spring and poppet [Figure 30-30-4]. Check the poppet and spring for wear or damage. 1

Figure 30-30-5

N-19567

1

If the charge pressure is not correct loosen the charge relief valve plug (Item 1) [Figure 30-30-3]. Assemble: Always use a new O-ring. Tighten the plug to 30-50 ft.-lb. (41-68 N•m) torque.

N-19568

There are several different thickness of the shims (Item 1) [Figure 30-30-5] and are used to adjust the charge pressure. NOTE: 0.010 inch (0,254 mm) is 8 PSI (55.16 kPa) increase in pressure. The charge pressure should be set at 220-270 PSI (15,118,6 bar).

30-30-2


CHARGE PRESSURE (CONT'D)

Testing (SJC Machines)

Sender Removal And Installation (SJC Machines)

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 Lift Arm Support Device on Page 10-20-1.)


Figure 30-30-6

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the wires (Item 1) [Figure 30-30-6] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-6] from the fitting. Installation: Tighten the sender to 7.4-8.1 ft.-lb. (10-11 N•m) torque.

1

Install a tee fitting into the charge pressure sender fitting.

2

Install a hose with a pressure gauge of at least 500 PSI on one end of the tee fitting and the charge pressure sender into the other end. Reconnect the wires to the charge pressure sender. Start the engine. P-64580

The gauge must read as follows: Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.)

360 PSI (24,8 bar) with approximately 140°F (60°C) fluid @ High Idle.

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the wires (Item 1) [Figure 30-30-6] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-6] from the fitting. Installation: Tighten the sender to 7.4-8.1 ft.-lb. (10-11 N•m) torque.

30-30-3


Figure 30-30-8

CHARGE PRESSURE (CONT'D) Adjusting (SJC Machines)


1

I-2003-0888 P-64435

Figure 30-30-7

Check the poppet and spring for wear or damage. There are several different thickness of shims (Item 1) [Figure 30-30-8] used to adjust the charge pressure. NOTE: 1.0 mm shim (Item 1) [Figure 30-30-8] = 43.5 PSI (3 bar) in pressure change. Adding shims increses charge pressure. Removing shims decreases charge pressure.

1

The charge pressure should be set at 360 PSI (24,8 bar).

P-64431

If the charge pressure is not correct remove the charge relief valve (Item 1) [Figure 30-30-7]. NOTE: The pump has been removed for photo clarity. The charge pressure relief valve is located on the engine side of the hydrostatic pump when installed in the loader. Assemble: Always use a new O-ring. Tighten the plug to 30-50 ft.-lb. (41-68 N•m) torque.

30-30-4


Figure 30-40-2

HYDROSTATIC PUMP Replenishing/High Pressure Relief Valve

1

Figure 30-40-1 2

1

3

N-19566

Remove the high pressure relief valve (Items 1) [Figure 30-40-2] from the pump.

N-19565

There are four replenishing/high pressure relief valves (Item 1) [Figure 30-40-1] in the hydrostatic pump assembly. Two are located at the top of the pumps and two at the bottom of the pumps. (See Replenishing Valve Function on Page 30-10-2.), for valve function. NOTE: The two top valves are for the reverse drive loop and the two bottom valves are for the forward drive loop.

Assemble: Tighten the plug to 30-50 ft.-lb. (41-68 N•m) torque. Check for damage and replace as needed. Check the O-rings (Items 2 & 3) [Figure 30-40-2] for damage and replace as needed. If the high pressure relief valve must be replaced, it must be replaced as a complete unit. The pressure setting for a new high pressure relief valve is 5000 PSI (34475 kPa).

30-40-1


Figure 30-40-4

HYDROSTATIC PUMP (CONT’D) Removal And Installation

1


2

I-2003-0888

Remove the engine/hydrostatic pump assembly from the loader. (See Removal And Installation on Page 70-80-1.) Remove the control handle linkage from the hydrostatic pump. (See Control Lever Removal And Installation on Page 50-110-1.) Remove the hydraulic pump from the hydrostatic pump. (See Removal And Installation on Page 20-60-5.) Figure 30-40-3

P-34567

Loosen the drive belt tensioner (Item 1) [Figure 30-40-4] and remove the drive belt. Remove the hydrostatic pump drive pulley mounting nut (Item 2) [Figure 30-40-4] and washer. Installation: Tighten the pump pulley mounting nut to 175-200 ft.-lb. (237-271 N•m) torque. Figure 30-40-5

1 P-34568 P-4235

Remove the hydrostatic pump mounting bolt (Item 1) [Figure 30-40-3] and washer(s).

Install a puller on the hydrostatic pump drive pulley and remove the pulley from the pump shaft [Figure 30-40-5].

Installation: Tighten the mounting bolt to 65-70 ft.-lb. (88-95 N•m) torque.

30-40-2


HYDROSTATIC PUMP (CONT’D)

WARNING

Removal And Installation (Cont’d) Figure 30-40-6

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

1

W-2103-1285

Reverse the removal procedure to install the hydrostatic pump assembly.

2 P-48650

Installation: Install the key in the hydrostatic pump shaft (Item 1) [Figure 30-40-6] before installing the pump drive pulley. Figure 30-40-7

1

P-28850

Hold the nut (Item 1) [Figure 30-40-7] on the two hydrostatic pump mounting bolts (Item 2) [Figure 30-406]. Remove the two hydrostatic pump mounting bolts from the pump and drive belt housing. Installation: Tighten the pump mounting bolts to 65-70 ft.-lb. (88-95 N•m) torque.

30-40-3


HYDROSTATIC PUMP (CONT'D) Parts Identification (Right Half)

5 8

7

4 3

6

2

1

9 13

10

11

14 15

12

17 19 16

21 20

23 27

25 22

24

29

18

26 28 38

30

33 36 34

32 31

37

35 46

49 40 42

45 39

41

47 48

44 49

43 D-2427

30-40-4


HYDROSTATIC PUMP (CONT'D) Parts Identification (Right Half) (Cont'd) Ref.

Description

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.

Bolt End Cap Plug O-ring Plug O-ring O-ring Relief Valve Bolt Gasket Bearing Plug O-ring O-ring Relief Valve Pin Valve Plate Retainer Washer Spring Washer Block Retainer Pin Washer

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.

Retainer Retainer Piston Assembly Plate Swashplate Pin Housing Plug Bearing Seal O-ring Cover Boltg Shaft Snap Ring Bearing Snap Ring Snap Ring Plug O-ring Bearing O-ring Plate Bolt

30-40-5


HYDROSTATIC PUMP (CONT'D) Parts Identification (Left Half) 4 17

6 16

8

11

14 13

3

1

2

5

10

7

12 9

15 22 18

19

23

21 20

24 26 28 25

30 32 34 38

27 31

29

36 33 35 37

47

39

46 45 44 43

48 49

40

42

50

51

41 58

52 53 53 52 54

55

30-40-6

56

57 59 D-2428


HYDROSTATIC PUMP (CONT'D) Parts Identification (Left Half) (Cont'd) Ref.

Description

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.

Snap Ring Washer Seal Snap Ring Snap Ring Bearing Snap Ring Key Shaft Housing Plug O-ring Bearing Seal O-ring Cover Bolt Pin O-ring Plug Bearing O-ring Plate Bolt Swash Plate Wear Plate Piston Assembly Piston Retainer Retainer Washer

31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59.

Pin Retainer Block Washer Spring Washer Washer Valve Plate Pin Gasket Bearing Plug Poppet Spring Shim O-ring Plug Relief Valve O-ring O-ring Plug Pin O-ring Coupler O-ring Bolt O-ring O-ring Relief Valve

30-40-7


HYDROSTATIC PUMP (CONT'D)

Pump Separation

Hydraulic Pump Removal And Installation

Figure 30-40-10

Figure 30-40-8 1 1

2

1

1

1 N-21967

Remove the pump mounting bolts (Item 1) [Figure 3040-8] (both sides).

N-19569

Remove the four mounting bolts (Item 1) [Figure 30-4010]. Figure 30-40-11

Installation: Tighten the mounting bolts to 25-27 ft.-lb. (34-37 N•m) torque. Remove the hydraulic pump (Item 2) [Figure 30-40-8] from the hydrostatic pumps. Figure 30-40-9

2

1

N-19570

Separate the two hydrostatic pumps [Figure 30-40-11].

N-21969

Remove the O-ring (Item 1) [Figure 30-40-9] and coupler (Item 2) [Figure 30-40-9] with the hydraulic pump.

30-40-8


Figure 30-40-14

HYDROSTATIC PUMP (CONT'D) Pump Separation (Cont’d) Figure 30-40-12

1

3

2 1

N-19551

2

3 Remove the pump housing end cap (Item 1) [Figure 3040-14].

N-19571

Remove the gasket (Item 2) [Figure 30-40-14].

Remove the pump coupler (Item 1) [Figure 30-40-12].

Figure 30-40-15

Remove the large O-ring (Item 2) [Figure 30-40-12]. Remove the two small O-rings (Item 3) [Figure 30-4012].

1

Disassembly Figure 30-40-13 1

1

N-17193

Remove the valve plate (Item 1) [Figure 30-40-15]. Check the valve plate for wear. (Both Sides.)

N-19550

Remove the four bolts (Item 1) [Figure 30-40-13] from the pump housing end cap.

30-40-9


Figure 30-40-18

HYDROSTATIC PUMP (CONT'D) Disassembly (Cont'd)

1

Figure 30-40-16

1

2

2

N-17198

Remove the slipper guide and pistons (Item 1) [Figure 30-40-18] from the cylinder block.

N-17194

Check the valve plate locating pin (Item 1) [Figure 30-4016] for wear and replace if needed. Check the needle bearing (Item 2) [Figure 30-40-16] for wear and replace if needed.

Check all the pistons (Item 2) [Figure 30-40-18] for wear and replace the rotating group as needed. Figure 30-40-19 1

Figure 30-40-17

1

N-17199

Remove the ball guide retainer (Item 1) [Figure 30-4019] from the cylinder block.

N-17197

Remove the rotating group (Item 1) [Figure 30-40-17] from the pump.

30-40-10


Figure 30-40-22

HYDROSTATIC PUMP (CONT'D) Disassembly (Cont'd) Figure 30-40-20

1 3

3

3

3

2

1

2

3

N-17481

Remove the driveshaft key (Item 1) the snap ring (Item 2) and the support washer (Item 3) from the drive shaft end of the pump [Figure 30-40-22].

N-17200

Check the ball guide retainer (Item 1) and washer (Item 2) for wear and replace as needed [Figure 30-40-20].

Figure 30-40-23

Remove the four pins (Item 3) [Figure 30-40-20] from the cylinder block.

1

Check the cylinder block for wear and replace as needed. Check pins (Item 3) [Figure 30-40-20] to see if they are all the same length. Figure 30-40-21

N-17239

Use a seal puller and remove the seal (Item 1) [Figure 30-40-23] from the pump housing. 1

N-17201

Remove the thrust plate (Item 1) [Figure 30-40-21] from the pump housing.

30-40-11


Figure 30-40-26

HYDROSTATIC PUMP (CONT'D) Disassembly (Cont'd)

1

Figure 30-40-24

1 N-17242

Check the pump shaft (Item 1) [Figure 30-40-26] for wear and replace if needed.

N-17240

Remove the snap ring (Item 1) [Figure 30-40-24] from the pump housing and remove the driveshaft and bearing from the housing.

Figure 30-40-27

Figure 30-40-25

1

1

N-17243

1 Remove the four mount bolts (Item 1) [Figure 30-40-27] from the lower trunnion cover. Remove the cover. N-17241

Remove the snap ring (Item 1) [Figure 30-40-25] from the driveshaft and remove the bearing. Check the bearing for wear and replace if worn.

30-40-12


Figure 30-40-30


2

2 1

1

1

N-17246

Remove the four mount bolts (Item 1) from the pump housing and remove the linkage bracket (Item 2) [Figure 30-40-30].

N-17244

Remove the O-ring (Item 1) and bearing race (Item 2) from the pump housing [Figure 30-40-28].

Figure 30-40-31

Figure 30-40-29

1 1 2 N-17247

Remove the upper trunnion cover (Item 1) [Figure 30-4031].

N-17245

Check the bearing race (Item 1) and O-ring (Item 2) for wear and replace as needed [Figure 30-40-29].

30-40-13


Figure 30-40-34


1 2 1

N-17249

Inspect the bearing race (Item 1) and O-ring (Item 2) [Figure 30-40-34] and replace as needed.

N-17250

Inspect the seal (Item 1) [Figure 30-40-32] in the upper trunnion cover and replace if needed.

Figure 30-40-35

Figure 30-40-33

1

1

N-17251

2

Slide the swashplate from side to side and remove the tapered roller bearing (Item 1) [Figure 30-40-35] from the swashplate shaft.

N-17248

Remove the O-ring (Item 1) [Figure 30-40-33] and bearing race (Item 2) [Figure 30-40-33] from the pump housing.

30-40-14


Figure 30-40-38

HYDROSTATIC PUMP (CONT'D) Assembly Figure 30-40-36 1

N-17252

Install the swashplate and bearing into the pump housing [Figure 30-40-38].

N-17252

Tilt the swashplate (Item 1) [Figure 30-40-36] and remove the swashplate and lower bearing from the pump housing.

Figure 30-40-39

Figure 30-40-37 1

1

2 3 N-17249

Install the tapered bearing (Item 1) [Figure 30-40-39] on the swashplate shaft. N-17253

Install the lower bearing (Item 1) [Figure 30-40-37] on the swashplate.

30-40-15


Figure 30-40-42

HYDROSTATIC PUMP (CONT'D) Assembly (Cont'd) Figure 30-40-40

1

2

N-17246

1 Install the linkage bracket (Item 1) [Figure 30-40-42] and the four mounting bolts and tighten to 18-22 ft.-lb. (24-30 N•m) torque.

N-17248

Install the bearing race (Item 1) and O-ring (Item 2) as shown in [Figure 30-40-40]. Figure 30-40-41

1

N-17247

Install the upper trunnion seal (Item 1) [Figure 30-40-41] and cover.

30-40-16


Figure 30-40-45


1

2 N-17243

Align the marks on the lower trunnion cover and pump housing as shown in [Figure 30-40-45].

N-17245

Install the four mounting bolts and tighten to 18-22 ft.-lb. (24-30 N•m) torque.

Figure 30-40-44

Figure 30-40-46

1

N-17244

N-17242

Install the bearing race (Item 1) and O-ring (Item 2) at the lower trunnion as shown in [Figure 30-40-44].

Install the snap ring (Item 1) [Figure 30-40-46] on the pump shaft.

30-40-17


Figure 30-40-49

HYDROSTATIC PUMP (CONT'D) Assembly (Cont'd)

1

1

Figure 30-40-47

1

1

2

1

3

N-17200

Install the four slipper pins (Item 1) [Figure 30-40-49] into the cylinder block.

N-17241

Install the bearing and snap ring (Item 1) [Figure 30-4047] on the pump shaft.

Apply a small amount of grease to the washer (Item 2) and install into the ball guide retainer (Item 3) [Figure 3040-49].

Figure 30-40-48

Figure 30-40-50 1

1

N-17240

N-17199

Install the pump shaft into the pump housing [Figure 3040-48].

Install the ball guide retainer and washer (Item 1) [Figure 30-40-50] onto the slipper holddown pins.

Install the snap ring (Item 1) [Figure 30-40-48].

30-40-18


Figure 30-40-53


1

2

Figure 30-40-51

N-17194

Replace the needle bearing (Item 1) and valve plate locating pin (Item 2) in the charge pump [Figure 30-4053].

N-17198

Assemble the piston assemblies into the slipper guide. Lubricate the pistons and cylinder block bores and insert the piston assemblies into the cylinder bores [Figure 3040-51].

Figure 30-40-54

Figure 30-40-52 2

1

N-17196

The bearing cage (Item 1) [Figure 30-40-54] will protrude from 0.08-0.10 inch (2,0-2,5 mm) from the surface of the charge pump.

N-17197

Lay the pump housing on its side and install the cylinder block, piston assembly into the housing.

The valve plate locating spring pin (Item 2) [Figure 3040-54] will protrude from 1.65-0.185 inch (4,19-4,70 mm) from the surface of the charge pump.

Place the pump on a work surface with the end cap opening up [Figure 30-40-52].

30-40-19


Figure 30-40-57


1

1

Figure 30-40-55

1

N-19550

Install the valve plate and end cap on the pump housing. Tighten the bolts (Item 1) [Figure 30-40-57] to 35-45 ft.lb. (47-61 N•m) torque.

N-17193

Coat the backside of the valve plate with petroleum jelly to hold it in position and install the valve plate onto the charge pump, bronze face up [Figure 30-40-55].

Figure 30-40-58

The notch (Item 1) [Figure 30-40-55] on the valve plate must engage the locating pin. Figure 30-40-56

1 3

2 1 N-19571

1

Install the two small O-rings (Item 1) [Figure 30-40-58]. Install the large new O-ring (Item 2) [Figure 30-40-58]. Install the pump coupler (Item 3) [Figure 30-40-58].

N-19551

Coat a new end cap gasket (Item 1) [Figure 30-40-56] with petroleum jelly and install onto the end cap.

30-40-20



N-19570

Install the two pumps together [Figure 30-40-59]. Figure 30-40-60

1

1

N-19569

Tighten the four bolts (Item 1) [Figure 30-40-60] to 35-45 ft.-lb. (47-61 N•m) torque.

30-40-21


30-40-22


HYDROSTATIC PUMP (SJC) Description The SJC hydrostatic pump is a fully proportional dual piston pump in one pump casing. The endcaps are removable to gain access to the rotating assemblies. The hydraulic controllers are fed charge pressure from an external charge pump. 12 volt electrical solenoids shift a spool in the hydraulic controller that directs flow to a servo piston.

The servo piston strokes the swash plate in the rotating group. The rotating group generates flow to the A or B ports on the hydrostatic pump. The flow from the A and B ports is sent to the hydrostatic drive motors where forward or reverse drive motor rotation is obtained. There are swash plate angle sensors on the bottom of the pump that monitor swash plate movement. Ports are labeled on the hydrostatic pump casting.

Figure 30-41-1

P-64943

A,B

Service Line Ports (High Pressure Outlet Ports to Drive Motors)

T1

Case Drain Port

MA

Operating Pressure of “A” Port

MB

Operating Pressure of “B” Port

R

Air Bleed Port

X1,X2 Control Pressure Gauge Port G

Charge Pressure Inlet Port

MG

Gauge Port For Charge Pressure

30-41-1


Figure 30-41-3

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Removal And Installation The loader’s right hand side hydraulic controller can be removed with the hydrostatic pump still in the loader. The loader’s left hand side hydraulic controller can only be removed when the hydrostatic pump is separated from the engine/hydrostatic pump cast mount.

1

Controller solenoids can be bled of trapped air in the controller. This should be performed when hydraulic controllers are replaced, removed or uncommanded oscillations in the controls are present. Raise the lift arms and install and approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Place the loader on jack stands. ((See Procedure on Page 10-10-1.)

P-64460

Disconnect all of the electrical harness connectors (Item 1) [Figure 30-41-3] from the loader harness. Removal:



Raise the operator cab. ((See Raising The Operator Cab on Page 10-30-1.)

Figure 30-41-4

Figure 30-41-2 1

1

P-64426 P-64425

Locate the two hydraulic controllers (Item 1) [Figure 3041-2] on the hydrostatic pumps.

Remove the four mount bolts (Item 1) [Figure 30-41-4] from the hydraulic controller.

30-41-2


Figure 30-41-7

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Removal And Installation (Cont'd)

1

Figure 30-41-5

1

2 1

2

P-64427

3

Alternately tighten bolts (Item 1) [Figure 30-41-7] to 7.7 ft.-lb. (10,4 N•m) torque. Ensure bolts are tight to specifications.

P-64427

Remove the controller (Item 1) [Figure 30-41-5] from the pump. Remove the controller gaskets (Item 2) [Figure 30-41-5] from the pump.

NOTE: When a hydraulic controller is replaced, the hydrostatic pumps must be calibrated. (See Hydraulic Controller Neutral Adjustment on Page 30-41-28.) Figure 30-41-8

Installation: Figure 30-41-6 1

1

P-64978

P-64444

Be sure the feedback lever (Item 3) [Figure 30-41-5] is in the center of the servo piston groove (Item 1) [Figure 3041-6]. Use a small amount of grease on a new gasket and install the gasket on the hydraulic controller (Item 1) [Figure 30-41-5].

With the engine running and the loader on jack stands: Bleed the trapped air in the controller by loosening the small set screw (Item 1) [Figure 30-41-8] a maximum of 2 turns. Leave the screw loose until oil comes dripping out of the set screw. Tighten set screw to 18 in.-lb. (2 N•m) torque. Repeat the bleeding procedure for all of the solenoids.

Be sure the pump surface is clean.

30-41-3


Figure 30-41-10

HYDROSTATIC PUMP (SJC) (CONT'D) Removal And Installation Remove the hydrostatic pump/engine assembly from the loader. ((See Removal And Installation on Page 70-801.)

IMPORTANT

1


Figure 30-41-9

P-64345

Loosen the washer and nut (Item 1) [Figure 30-41-10] on the hydrostatic pump drive shaft. Installation: Tighten the nut to 175-200 ft.-lb. (237-271 N•m) torque Figure 30-41-11

1

2

1

P-64344

Loosen the tensioner mount bolt (Item 1) [Figure 30-419]. Remove the drive belt (Item 2) [Figure 30-41-9]. Installation: (See Drive Belt Replacement on Page 3050-3.)

P-64346

Use a puller (Item 1) [Figure 30-41-11] to loosen the pulley from the pump drive shaft. NOTE: DO NOT strike puller or pump shaft with a hammer. Internal pump damage may result. Remove the nut and washer from the pump drive shaft. Remove the pump pulley from the pump drive shaft.

30-41-4


Figure 30-41-14

HYDROSTATIC PUMP (SJC) (CONT'D) Removal And Installation (Cont’d) Figure 30-41-12

2

1

1

1

P-64343

Remove the mounting bolt (Item 1) [Figure 30-41-14] at the hydraulic pump mounting bracket.

P-64348

Remove the hydrostatic pump from the mounting bracket and drive belt housing.

Figure 30-41-13

NOTE: The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts. Figure 30-41-15

1

1

P-64337

1

P-64338

Remove the two mounting bolts (Item 1) [Figure 30-4112] and nuts (Item 1) [Figure 30-41-13]. P-64458

Installation: Tighten the mounting bolts and nuts to 6570 ft.-lb. (88-95 N•m) torque. Make sure the key (Item 2) [Figure 30-41-12] installed.

is

Remove the air bleed plugs (Item 1) [Figure 30-41-15]. 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 N•m) torque.

30-41-5


HYDROSTATIC PUMP (SJC) (CONT'D) Parts Identification

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

8

7

3

4

5

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

6

10 11 12

24 25

20

1

21 23 22

26

9 13 14 15

2

16 17

19

18

26

18

27

32

29

19

31

6

2

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

30-41-6


Figure 30-41-18

HYDROSTATIC PUMP (SJC) (CONT'D) High Pressure Relief and By-Pass Valve Figure 30-41-16

1 2 1 1

P-64437

Check the valve seat surface (Item 1) [Figure 30-41-18] for scratches and replace as needed.

P-64431

There are four system check relief valves (Item 1) [Figure 30-41-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.

Remove the relief valve cap (Item 1) [Figure 30-41-16]. Assembly: Tighten cap to 111-125 ft.-lb. (150-170 N•m) torque.

Do not disassemble the relief valve assembly. If replacement is required, replace as an assembly . Factory setting on the relief valve is 5250 PSI (362 bar).

Figure 30-41-17

4

2

Inspect the spring (Item 2) [Figure 30-41-18] for breakage.

3

1

P-64436

Check the valve cap O-ring (Item 1) and back-up ring (Item 2) [Figure 30-41-17], replace as needed. Remove relief valve assembly (Item 3) [Figure 30-41-17] from the valve cap. Check the conical spring (Item 4) [Figure 30-41-17] to ensure it is not broken or flattened.

30-41-7


Figure 30-41-21

HYDROSTATIC PUMP (SJC) (CONT'D) Charge Relief Valve

3

Figure 30-41-19

1

1

2

5

4

P-64435

Inspect the poppet (Item 1) and the mating seat (Item 2) [Figure 30-41-21] for damage or foreign material. Ensure the poppet moves freely in it’s bore.

P-64431

The charge relief valve (Item 1) [Figure 30-41-19] is located on the back of the hydrostatic pump. Remove the charge relief valve. Assembly: Tighten charge relief valve to 52 ft.-lb. (70 N•m) torque.

Inspect the sealing ring (Item 3) [Figure 30-41-21] and the mating seat in the pump housing for damage or foreign material. Inspect the spring (Item 4) and the charge relief valve shims (Item 5) [Figure 30-41-21]. NOTE: 1.0 mm shim (Item 5) [Figure 30-41-21] = 43.5 PSI (3 bar) in pressure change. Adding shims increases charge pressure. Removing shims decreases charge pressure.

Figure 30-41-20

1

P-64435

Check and replace the O-ring (Item 1) [Figure 30-41-20].

30-41-8


Figure 30-41-24

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly Remove the hydrostatic pump/engine assembly from the loader. ((See Removal And Installation on Page 70-801.)

2

Figure 30-41-22

1

1

1 P-64439

Remove the bolts (Item 1) mounting the steel covers (Item 2) [Figure 30-41-24]. Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque. Figure 30-41-25

P-64458

Remove the hydraulic controllers (Item 1) [Figure 30-4122]. (See Hydraulic Controller Removal And Installation on Page 30-41-2.)

1

Figure 30-41-23

2

2 1

1

1

P-64440

Remove the mounting bolts and washers for the swashplate angle sensor (Item 1) [Figure 30-41-25]. Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque. P-64438

Swashplate angle sensors (Item 1) are mounted on the bottom of the hydrostatic pump. They are protected by steel covers (Item 2) [Figure 30-41-23]. Note the connectors facing each other. Note the steel covers facing direction.

30-41-9


Figure 30-41-28

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd) Figure 30-41-26 1

2

P-64442

Both swashplate angle sensors and associated hardware removed from the hydrostatic pump. [Figure 30-41-28]

P-64441

Assembly: Note the slotted portion (Item 1) of the positioning pin tightly fits the machined section on the swashplate angle sensor shaft (Item 2) [Figure 30-4126] Note the machined section of the swashplate angle sensor shaft faces the center of the hydrostatic pump. Figure 30-41-27

1

P-64453

NOTE: Improperly installing the swashplate angle sensor, with the shaft facing toward the outside of the hydrostatic pump, will make it hard to install the sensor mounting bolts and also destroy the seal (Item 1) [Figure 30-4127].

30-41-10


Figure 30-41-31

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd) Right End Housing Figure 30-41-29 3

1

2 P-64464

Pull the end housings from the case housing [Figure 3041-31].

1 P-64445

Left End Housing Figure 30-41-30 3

1

2

1 P-64447

Remove the four mount bolts (Item 1) securing the end housing (Item 2) to the main case housing (Item 3) [Figure 30-41-29] and [Figure 30-41-30] Assembly: Alternately, tighten mount bolts to 96 ft.-lb. (130 N•m) torque.

30-41-11


Figure 30-41-34

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd) Figure 30-41-32

1 1

2

2

P-64463

Assembly: Ensure dowel pin (Item 1) is aligned with hole in case housing (Item 2) [Figure 30-41-34] before tightening screws.

P-64465

Replace O-ring (Item 1) [Figure 30-41-32]. Figure 30-41-33

1

P-64466

Ensure servo follower (Item 2) [Figure 30-41-32] is swung out for proper engagement with the notch in the servo piston (Item 1) [Figure 30-41-33].

30-41-12


HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd) Figure 30-41-35 RIGHT SIDE

1

2 P-64454

Figure 30-41-36 LEFT SIDE

1

2

P-64501

Remove valve plate (Item 1) [Figure 30-41-35] and [Figure 30-41-36] from the case housing. Inspect valve plate for scratches or scoring. Replace a valve plate if the scratches are deep enough to catch with a fingernail. NOTE: Pay attention to the notches (Item 2) [Figure 30-41-35] and [Figure 30-41-36] in the valve plate for assembly reasons. There are different valve plates for the left and right side. The valve plates are NOT interchangeable.

30-41-13


HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-41-39

Disassembly and Assembly (Cont'd)

RIGHT SIDE

Figure 30-41-37

1 2

RIGHT SIDE

1

P-64456

2 Figure 30-41-40 P-64455

LEFT SIDE Figure 30-41-38

1 2

LEFT SIDE

P-64503

1 2 P-64502

Assembly: Align the timing pin (Item 1) [Figure 30-4137] and [Figure 30-41-38] in the case housing with the notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40] that does not go through the valve plate. Align the shoulder of the roller bearing (Item 2) [Figure 30-41-37] and [Figure 30-41-38] with the beveled edge on the valve plate (Item 2) [Figure 30-41-39] and [Figure 30-41-40]. NOTE: Valve plate should sit FLUSH with the case housing when properly installed.

30-41-14


Figure 30-41-43


1

P-64469

Remove the piston assembly (Item 1) [Figure 30-41-43]. B25012

Figure 30-41-44

Right Side Rotating Group [Figure 30-41-41]. Figure 30-41-42

1

P-64475

B25011

Remove the pistons (Item 1) [Figure 30-41-44] from the rotating block.

Left Side Rotating Group [Figure 30-41-42].

30-41-15


Figure 30-41-47

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd)

1

Figure 30-41-45

1

P-64471

Remove the spherical washer (Item 1) [Figure 30-4147].

P-64476

Inspect the pistons, look for scoring and scratches. Ensure the holes (Item 1) [Figure 30-41-45] in the slippers, are not plugged.

Figure 30-41-48 1

Figure 30-41-46

1

1

P-64472

Inspect the pins (Item 1) [Figure 30-41-48]. They should be all the same length. Do not remove. P-64477

Inspect the mating surface of the spherical washer for scoring or scratches (Item 1) [Figure 30-41-46].

30-41-16


Figure 30-41-51

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly and Assembly (Cont'd)

3

Figure 30-41-49 1 1

2

P-64479

Inspect mating surface for the slippers on the swashplate (Item 1) [Figure 30-41-51].

P-64474

Inspect the sperical washer for scoring and wear (Item 1) [Figure 30-41-49].

Remove the swashplate from the endcap housing (Item 2) [Figure 30-41-51]. Remove the slide ring (Item 3) [Figure 30-41-51], ensure it pivots freely.

Figure 30-41-50

Figure 30-41-52 1 2 1

3

2

P-64478

Inspect the back surface of the rotating block (Item 1) [Figure 30-41-50] where the valve plate seals. Ensure there is no scratches or scoring. Visually ensure spring (Item 2) and c-clip (Item 3) [Figure 30-41-50] are not bent or damaged.

P-64480

Assembly: Carefully align bearing pin eyelets (Item 1) into holes in endcap housing (Item 2) [Figure 30-41-52].

30-41-17


Figure 30-41-55


2


1

Figure 30-41-53

1

2

1

P-64483

Remove the shell bearing races (Item 1) [Figure 30-4155].

P-64481

Assembly: Ensure bearing pins are in the holes of the swashplate (Item 1) [Figure 30-41-53].

Assembly: Note shell bearing races have an edge (Item 2) [Figure 30-41-55] on them. The edges face towards the outside of the endcap housing

Figure 30-41-54

Inspect bearing surfaces for scratches or scoring.

2

1

P-64482

Remove the shell bearing (Item 1) [Figure 30-41-54]. Inspect individual roller bearings and machined surfaces (Item 2) [Figure 30-41-54] on swashplate.

30-41-18


Figure 30-41-58


LEFT SIDE

Disassembly and Assembly (Cont'd) Figure 30-41-56 1 2

1

P-64486

Figure 30-41-59 P-64484

RIGHT SIDE

Remove the snap ring (Item 1) from the positioning pin (Item 2) [Figure 30-41-56].

1

Figure 30-41-57

2

1

P-64523

Remove the snap ring (Item 1) [Figure 30-41-58] and [Figure 30-41-59] from the end housing. Figure 30-41-60 P-64485

Pull the positioning pin from the end housing. Replace O-ring (Item 1) [Figure 30-41-57]. Inspect wear surfaces (Item 2) [Figure 30-41-57] for scratches or scoring. Ensure positioning pin can rotate smoothly in the end housing without excessive play. 1

P-64524

The pump seal (Item 1) [Figure 30-41-60] is removed by inserting a screw into the seal and prying out. 30-41-19


Figure 30-41-62


2 1

P-64488

The drive shaft can be tapped out of the end housing with a rubber mallet. Inspect wear surfaces for scratches, and inspect splines for excessive wear. Inspect bearing (Item 1); if bearing needs replacement, remove snap ring (Item 2) [Figure 30-41-61] and remove bearing.

B25013

Servo Piston Assembly [Figure 30-41-62]. Figure 30-41-63

The Servo Piston Assembly [Figure 30-41-62] cannot be removed unless the hydraulic controller and rotating group is removed first. 1

1

P-64489

Remove servo piston mounting bolts (Item 1) [Figure 3041-63]. Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.

30-41-20


Figure 30-41-66


P-64492

Slide the servo piston assembly out of the bore. [Figure 30-41-66].

P-64490

Measure and record servo piston depth at the adjustment screw [Figure 30-41-64]. Figure 30-41-65

1

P-64491

Use a rubber mallet to rotate servo piston cover (Item 1) [Figure 30-41-65].

30-41-21


Figure 30-41-69


1 2 1 2

P-64493

Remove the bushings (Item 1), seals and O-rings (Item 2) [Figure 30-41-69] from the pump housing.

P-64467

Figure 30-41-70

Figure 30-41-68

1 1 2 3 P-64494 P-64466

Assembly: Align the servo piston so the guide slot (Item 1) [Figure 30-41-68] is parallel to the driveshaft centerline. Measure with a straight-edge [Figure 30-4167].

Each servo has a pair of bushings (Item 1), O-rings (Item 2) and square-cut seals (Item 3) [Figure 30-41-70].

30-41-22


Figure 30-41-73


1 P-64497

1 Remove snap ring (Item 1) [Figure 30-41-73] from the servo piston.

P-64495

Remove the lock nut (Item 1) [Figure 30-41-71] from the servo piston.

Figure 30-41-74 1 2

Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. Figure 30-41-72

1

P-64498

Remove the piston stop adjustment mechanism (Item 1) [Figure 30-41-74] from the servo piston. Inspect mechanism for broken parts.

P-64496

Remove the servo cover (Item 1) [Figure 30-41-72] from the servo piston.

Replace O-ring (Item 2) [Figure 30-41-74]

30-41-23


Figure 30-41-77


1 2

1

1

3 P-64499

Remove the four control pressure plugs (Item 1) [Figure 30-41-77] at the top of the case housing to gain access to the four orifices (Item 1) [Figure 30-41-78].

P-64461

Remove the plug (Item 1) from the top center of the case housing. Replace O-ring (Item 2) [Figure 30-41-75].

Replace O-rings on plugs. Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.

Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque.

Figure 30-41-78

Remove internal screen (Item 3) [Figure 30-41-75]. Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m) torque.

1

Figure 30-41-76

P-64500

Ensure the four orifices (Item 1) [Figure 30-41-78] in case housing are clean and not plugged. P-64462

Ensure screen is clean [Figure 30-41-76].

30-41-24



Mechanical Neutral Adjustment


The pump mechanical neutral adjustment sets the position of the servo piston and pump swashplate relative to the hydraulic controller. This procedure should be followed if the hydrostatic pump has been disassembled for servicing the servo piston and the setting has been disrupted.

Figure 30-41-79

Place the loader on jackstands. (See Procedure on Page 10-10-1.) 2 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.

P-64502

W-2017-0286

Bearings (Item 1) [Figure 30-41-79] in case housing are replaced by using a press and bearing driver. Inspect center coupler (Item 2) [Figure 30-41-79].

Raise the lift arms, and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool. (See Procedure on Page 10-60-1.) Disconnect the swashplate angle sensors in the electrical harness. This prevents unwanted swashplate movement error codes from occurring during adjustments. Disconnecting the sensors does not have to be done directly at the sensor, follow the harness back to find an accessible connector to disconnect. Disconnect the speed sensors located on the top of the motor carriers. This prevents uncommanded wheel movement error codes from occurring during adjustments.

WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290

30-41-25


Figure 30-41-82

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment (Cont’d) Figure 30-41-80 1 1

1

P-64438

Remove the plugs (Item 1) [Figure 30-41-82] from the MA ports on the bottom of the pump, and install 7500 PSI pressure gauges.

P-64973

Connect a hydraulic hose (Item 1) [Figure 30-41-80] between port X1 and port X2 on each side of the hydrostatic pump, to equalize the pressures on both ends of the servo pistons.

Figure 30-41-83

Figure 30-41-81

1 1

1

1 P-64977

P-64425

Remove the plugs (Item 1) [Figure 30-41-81] from the MB ports on the front side of the pump, and install 7500 PSI (241 bar) pressure gauges.

Remove drive hoses from the A and B ports (Item 1) [Figure 30-41-83]. Plug the ports with metal caps. The caps must be able to handle at least 7500 PSI. Plugging the A and B ports eliminates leakage at the drive motors from causing errors in the pump mechanical neutral setting.

30-41-26


Figure 30-41-86

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment (Cont’d) Figure 30-41-84

1

1 P-64457

P-64457

Loosen the pump neutral adjustment lock nut (Item 1) [Figure 30-41-84].

Turn the adjustment screw (Item 1) [Figure 30-41-86] counterclockwise, until the other gauge registers an increase in system pressure. Mark the position of the adjustment screw. Figure 30-41-87

Start the loader using the remote start tool and run at an idle.

WARNING Stay clear of the loader wheels. They will turn whenever the pump is not centered. W-2276-1297

1

Figure 30-41-85 P-64457

Turn the adjustment screw (Item 1) [Figure 30-41-87] clockwise, to a position halfway between the recorded positions. The pressure gauges should read equal pressures.

1 P-64457

Turn the adjustment screw (Item 1) [Figure 30-41-85] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw. 30-41-27



Hydraulic Controller Neutral Adjustment

Mechanical Neutral Adjustment (Cont’d)

The hydraulic controller neutral adjustment, aligns the pump swash plate and the control spool so that a zero angle control setting provides a zero degree swash plate setting. This adjustment should be performed whenever any part of the control or swash plate mechanisms are adjusted or removed or after the pump mechanical neutral setting is adjusted. Ensure the pump mechanical neutral setting is correct before performing hydraulic controller neutral adjustments.

Figure 30-41-88

NOTE: Procedure is shown for the left side hydraulic controller. Procedure is the same for the right side hydraulic controller, except you disconnect the electrical connectors for the right side hydraulic controller and connect pressure gauges in the X1 and X2 ports on the right side of the pump.

2

1 P-64457

While holding the adjustment screw (Item 1) in position, tighten the lock nut (Item 2) [Figure 30-41-88] to 22 ft.-lb. (30 N•m) torque.

Place the loader on jack stands. (See Procedure on Page 10-10-1.)

WARNING

Shut loader OFF. Remove the hydraulic hose from the X1 and X2 ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. Remove the pressure gauges from the MA and MB ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. NOTE: The Hydraulic Controller Neutral Adjustment must be performed whenever the Mechanical Neutral Adjustment is done. (See Hydraulic Controller Neutral Adjustment on Page 30-4128.)


Raise the lift arms, and install an approved lift arm support device. ((See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool. (See Procedure on Page 10-60-1.)

WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290

30-41-28


Figure 30-41-91

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment (Cont’d) Figure 30-41-89

2 1

P-64975

1

Install 500 PSI pressure gauges in the X1 and X2 ports pertaining to the side of the hydrostatic pump you are adjusting.

P-64460

Disconnect the hydraulic controller connectors (Item 1) [Figure 30-41-89] from the loader wiring harness for the hydraulic controller you are adjusting.

Figure 30-41-92

Figure 30-41-90

1

1

2 P-64459

Loosen the locking screw (Item 1) [Figure 30-41-92]. P-64458

Remove the X1 plug (Item 1) and X2 plug (Item 2) [Figure 30-41-90] pertaining to the side of the hydrostatic pump you are adjusting.

Start the loader using the remote start tool and run at an idle.

WARNING Stay clear of the loader wheels. They will turn whenever the pump is not centered. W-2276-1297

30-41-29


Figure 30-41-95

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment (Cont’d) Figure 30-41-93

1

1 P-64459

P-64459

Turn the adjustment screw (Item 1) [Figure 30-41-93] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw.

Turn the adjustment screw (Item 1) [Figure 30-41-95] clockwise, to a position halfway between the recorded positions. The pressure gauges should read equal pressures. Figure 30-41-96 2

Figure 30-41-94

1

1

P-64459

While holding the adjustment screw (Item 1) in position, tighten the locking screw (Item 2) [Figure 30-41-96] to 4.5 ft.-lb. (6,1 N•m) torque.

P-64459

Turn the adjustment screw (Item 1) [Figure 30-41-94] counterclockwise, until the other gauge registers an increase in system pressure. Mark the position of the adjustment screw.

Shut loader OFF. Remove the pressure gauges from the X1 and X2 ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. Connect the hydraulic controller wire connectors to the loader wiring harness. Perform a controller calibration procedure. (See Calibration Procedure (ACS) on Page 60-160-11.)

30-41-30


DRIVE BELT

Adjusting

Shield Removal And Installation

To adjust the drive belt between the flywheel and the hydrostatic pump pulley, use the following procedure:

Figure 30-50-1

Stop the engine. Open the rear door. Disconnect the negative (-) battery cable. Remove the belt shield. (See Shield Removal And Installation, Page 30-50-1.) The pulley tensioner is located between the flywheel and pump pulley.

1

Figure 30-50-3

1

P-48001

2

Remove the three drive belt shield mounting clips (Item 1) [Figure 30-50-1] . Figure 30-50-2

1

P-48478

Loosen the bolt (Item 1) [Figure 30-50-3] on the spring loaded drive idler. NOTE: The pointer (Item 2) [Figure 30-50-3] will be at the 1 o'clock position when the idler is not under spring tension. P-48000

Remove the belt shield (Item 1) [Figure 30-50-2].

30-50-1


Figure 30-50-5

DRIVE BELT (CONT’D) Adjusting (Cont’d) Figure 30-50-4

1

1

P-48480

Raise the idler assembly slightly so that the pulley is operating on spring tension and not against the stop.

P-48479

Using the Belt Tensioner Bar (MEL1405) or a pry bar push the idler assembly against the belt, the pointer (Item 1) [Figure 30-50-4] will be at the 3 o'clock position when the idler stop is bottomed out. Do not pry directly on the pulley, pry on the tensioner bracket the pulley is mounted on. Note:

If the pointer does not move when prying on the tensioner mounting bracket, manually move the arrow towards the 3 o’clock position with a screwdriver while putting tension on the bracket to help get it started.

Tighten the mounting bolt (Item 1) [Figure 30-50-5] to 25-28 ft.-lb. (34-38 N•m) torque. NOTE: Do not set the idler against the travel stop in the 3 o'clock position. Run the engine for a few minutes. Stop the engine and recheck the pointer position. Readjust if necessary. After the idler has been in service, readjust when the pointer reaches the 1 o'clock position. Install the belt shield using the fasteners. Reconnect the negative (-) battery cable. Close the rear door.

30-50-2


Figure 30-50-7

DRIVE BELT (CONT’D) Drive Belt Replacement

1

Figure 30-50-6

2

P-48478

Remove the fan drive belt (Item 1) [Figure 30-50-7]. P-48000

Remove the air conditioner belt if so equipped.

Stop the engine. Open the rear door. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the negative (-) cable from the battery. The battery may be removed for additional working clearance. (See Removal And Installation on Page 60-20-1.)

The belt tensioner is located between the flywheel and pump pulley. Loosen and remove the bolt (Item 2) [Figure 30-50-7] from the belt tensioner. Remove the belt tensioner assembly. Figure 30-50-8

Remove the belt shield [Figure 30-50-6]. (See Shield Removal And Installation, Page 30-50-1.)

P-48481

Remove the drive belt from the pump pulley and flywheel. Remove the drive belt from the loader [Figure 30-50-8]. Install the new drive belt. Install the belt tensioner assembly. Install the fan drive belt. Adjust the drive belt. (See Adjusting, Page 30-50-1.) Reinstall belt shield and connect the negative (-) cable to the battery.

30-50-3


Figure 30-50-10

DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation Figure 30-50-9

1

P-48478

Loosen and remove the tensioner pulley mounting bolt (Item 1) [Figure 30-50-10].

P-48000

Installation: Tighten the bolt to 25-28 ft.-lb. (34-38 N•m) torque.

Stop the engine. Open rear door. Remove the negative (-) cable from the battery. the battery may be removed for additional working clearance. (See Removal And Installation on Page 60-20-1.) Remove the belt shield [Figure 30-50-9]. (See Shield Removal And Installation, Page 30-50-1.)

Remove the belt tensioner pulley from the housing. Reverse the removal procedure to install the drive belt tensioner.

30-50-4


DRIVE BELT (CONT’D) Tensioner Pulley Parts Identification

1. Cover 2. Bolt 3. Washer 4. Pins 5. Washer 6. Spring 7. Snap Ring 8. Snap Ring 9. Bearing 10. Dust Shield 11. Pulley 12. Bushing 13. Hub 14. Washer 15. Seal 16. Arrow Indicator Plate 17. Locating Pin 18. Spring 19. Shaft 20. Bracket

1

2

11

3 12

4 5

13

6

14

5 NOTE: Drive idler parts are not available individually. Consult parts catalog for available 7 sub-assemblies.

15

8

16 17

9

18

10

19

20

E-2296

30-50-5


Figure 30-50-13

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly Figure 30-50-11

3 1 1

4 2

P-8861

Remove the two pins (Item 1) from the hub assembly (Item 2) [Figure 30-50-13] only if they have been damaged.

P-8858

Remove the grease cover (Item 1) [Figure 30-50-11].

Remove the bracket assembly (Item 3) by tapping on the shaft (Item 4) [Figure 30-50-13] with a plastic hammer.

Figure 30-50-12

Figure 30-50-14 5 2

2

3

1 1

4 P-8859 P-8862

Remove the bolt (Item 1), the flat washer (Item 2), the retainer washer (Item 3), the spring washer (Item 4) and the second retainer washer (Item 3) from the pulley assembly (Item 5) [Figure 30-50-12].

Remove the spring (Item 1) from the bracket (Item 2) [Figure 30-50-14].

30-50-6


Figure 30-50-17

DRIVE BELT (CONT’D) Tensioner Pulley Assembly Figure 30-50-15

1

1

P-8873

2

Turn the pulley assembly over and install the two pins (Item 1) [Figure 30-50-17] into the hub.

P-8871

Install the spring (Item 1) on the pulley (Item 2) [Figure 30-50-15] as shown.

Figure 30-50-18

Figure 30-50-16

1 3

2 P-8874

Install a punch as shown and turn clockwise while applying down pressure on the pulley.

P-8872

Install the shaft from the bracket assembly (Item 1) into the pulley assembly (Item 2) and align the spring (Item 3) [Figure 30-50-16] over the alignment pin on the bracket.

Turn until the pulley snaps down into place; this procedure winds the spring and retains the end of the spring in proper location [Figure 30-50-18].

30-50-7


Figure 30-50-21

DRIVE BELT (CONT’D) Tensioner Pulley Assembly (Cont'd) Figure 30-50-19

2 2 1

1

P-8877

Press the grease cap (Item 1) onto the pulley assembly (Item 2) [Figure 30-50-21]. Press on the outer formed edge of the grease cap.

P-8875

Install the first retainer washer (Item 1) and spring washer (Item 2) [Figure 30-50-19] over the roll pins. Figure 30-50-20

NOTE: When pressing the grease cap onto the pulley assembly, do not press down on the arrow indicator plate. Support the hub assembly so that it contacts only the hub and not the arrow indicator plate.

3

1

2

P-8876

Install the second retainer washer (Item 1), the washer (Item 2) and the bolt (Item 3) [Figure 30-50-20]. Tighten the bolt to 28-32 ft.-lb. (38-45 N•m) torque. Fill the grease cap 1/4 full (approximately 1/2-3/4 oz.) of grease.

30-50-8


Figure 30-60-2

OIL COOLER Removal and Installation

WARNING When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-19346

Remove the rear grill from the loader. (See Removal And Installation on Page 50-60-1.) Figure 30-60-3 Figure 30-60-1

1 2

P-45242 N-19345

Install tool MEL 1558 (Item 1) to outside of rubber sleeve (Item 2) [Figure 30-60-1].

Slide the rubber sleeve in toward the radiator. The connector will release [Figure 30-60-2] & [Figure 30-603].

30-60-1


OIL COOLER (CONT’D) Removal and Installation (Cont’d) Figure 30-60-4

1 1

2

P-45101

Disconnect the inlet and outlet hoses (Item 1) [Figure 3060-4] from the oil cooler (Item 2) [Figure 30-60-4]. NOTE: When installing the cooler hoses, the fittings should make a clicking sound when pushed together. Lift up the oil cooler and remove the cooler from the loader. Reverse the removal procedure to install the oil cooler.

30-60-2


DRIVE SYSTEM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . 40-10-2 CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Cover Removal And Installation. . . . . . . . . . . . . . . Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Removal And Installation . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Cover Removal And Installation . . . . . . . . . . . . . . . . Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40-30-1 40-30-3 40-30-1 40-30-2 40-30-2 40-30-4 40-30-1

DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . Axle Sprocket And Bearings Removal And Installation . . . Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . .

40-20-1 40-20-1 40-20-3 40-20-8

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE SPECIFIED.


DRIVE SYSTEM

SYSTEM & ANALYSIS ENGINE SERVICE

SPECIFICATIONS

40-01


40-02


Figure 40-10-2

BRAKE Disk Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)


Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)

1 N-19105

Inspect the traction lock guides (Item 1) [Figure 40-10-2] and the brake disc for damage or wear and replace as necessary. (See Inspecting on Page 60-110-3.)

Disconnect and remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel from the loader. (See Removal and Installation on Page 50-100-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Figure 40-10-1

1

1 N-19081

The parking brake discs (Item 1) [Figure 40-10-1] are located beneath the center chaincase cover.

40-10-1


BRAKE (CONT’D)

Switch Operated Parking Brake

Disk Removal And Installation (Cont’d)

Figure 40-10-5

Figure 40-10-3

1

2

1 P-21944 N-19082

The parking brake switch in the front panel (Item 1) [Figure 40-10-5] replaced the pedal parking brake. (See INSTRUMENT PANEL on Page 60-50-1.)

Figure 40-10-4

1

N-19083

A snap ring pliers with 90° tips are necessary for removing the parking brake disc. Remove the snap ring (Item 1) [Figure 40-10-3] from the end of the sprocket on the hydrostatic motor carrier. Slide the disc (Item 2) [Figure 40-10-3] off the sprocket (Item 1) [Figure 40-10-4] and remove the disc through the front chaincase cover. Reverse the removal procedure to install the disc in the loader.

40-10-2


Axle Seal Removal And Installation

Installation: Support the flange of the axle hub and install the two studs with a hammer. A hydraulic press can also be used to install the studs.

Figure 40-20-1

Figure 40-20-2

DRIVE COMPONENTS

2

2

1

1

2 P-4157

P-4159

The tools listed are needed for the following procedure:

Install the puller tool (Item 1) [Figure 40-20-2] on the axle hub.

Axle Hub Puller Tool MEL1399 - Seal Driver Tool MEL1242 - Power Ram (may be used if desired)

A driver tool (Item 2) [Figure 40-20-2] can be used for centering the threaded rod of the puller.

To loosen the axle hub mounting bolt (Item 1) [Figure 40-20-1], use the following procedure: Before lifting and blocking the loader, loosen the hub mounting bolt (Item 1) [Figure 40-20-1]. NOTE: If the axle and bearings are being replaced, also loosen the sprocket mounting bolt inside the chaincase before lifting and blocking the loader. (See Axle Sprocket And Bearings Removal And Installation on Page 40-20- 3.) Lift and block the loader. (See Procedure on Page 10-101.) Remove the front tire/wheel assembly.

WARNING NEVER STAND IN-LINE OF THE HUB WHEN REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle end and can come off the axle with great force and cause serious injury. W-2186-0395

Use a wrench with the puller and remove the axle hub from the axle tube. A spacer and a power ram can be used between the axle and the tool if available, instead of the wrench, threaded rod and driver tool.

Installation: Tighten the wheel mounting nuts to 105-115 ft.-lb. (142-156 N•m) torque. Remove the hub mounting bolt (Item 1) [Figure 40-20-1] and washer from the axle. Installation: Tighten the hub mounting bolt to 725-800 ft.-lb. (983-1085 N•m) torque. Remove two of the wheel mounting studs (Item 2) [Figure 40-20-1]. Use a wheel mounting nut on each stud and remove the two studs with a hammer. 40-20-1


Figure 40-20-5

DRIVE COMPONENTS (CONT’D) Axle Seal Removal And Installation (Cont’d) Figure 40-20-3

P-4160

1

Installation: MEL1399 seal driver tool is necessary for the following procedure:

P-4161

Clean the seal area and inspect the shaft for wear.

Remove the key (Item 1) [Figure 40-20-3] from the axle.

NOTE: If the shaft is damaged or worn, an axle repair sleeve kit is available from Bobcat Parts.

Figure 40-20-4

Place the new axle seal over the axle and into the axle tube. Install MEL1399 seal driver tool over the axle and put against the axle seal [Figure 40-20-5]. Hit the seal driver tool with a hammer until the tool is flush with the edge of the axle tube [Figure 40-20-5]. Reverse removal procedure to install the axle hub and wheel assembly.

1

P-4181

Drill a small hole in the axle seal. Install a slide hammer (Item 1) [Figure 40-20-4] with a screw tip end in the axle seal. Remove the axle seal.

40-20-2


Remove the eight front cover mounting bolts (Item 1) and the front cover (Item 2) from the chaincase [Figure 4020-6].

DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation

Figure 40-20-7

The tools listed are needed for the following procedure: MEL1242 - Power Ram MEL1202B - Axle Bearing Service Set NOTE: The procedure shown is for removing the front axle, bearings and sprocket. This procedure can also be used for the rear axle, bearings and sprocket. (See Rear Cover Removal And Installation on Page 40-30-4.) Use jackstands to support the rear of the loader. (The loader wheels should remain on the ground.)

1 P-4147


Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.)

Loosen the axle sprocket mounting bolt (Item 1) [Figure 40-20-7]. Lift and block the loader. (See Procedure on Page 10-101.) Remove the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.) Remove the axle hub. (See Axle Seal Removal And Installation on Page 40-20-1.) Remove the sprocket mounting bolt (Item 1) [Figure 4020-7]. Installation: Tighten the sprocket mounting bolt to 300330 ft.-lb. (407-447 N•m) torque.

Figure 40-20-6

2 1

P-34255

40-20-3


Installation: Pack both axle bearings with grease before installing them.

DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d)

Figure 40-20-10

Figure 40-20-8

1

P-4170

1 P-4158

Install the MEL1242 power ram (Item 1) [Figure 40-20-8] between the two sprockets. Put a spacer between the power ram and axle. Push the axle out to the end of the power ram stroke. Add another spacer and push the axle again. Repeat this procedure until the axle is free from the sprocket and inner bearing.

A bearing puller (Item 1) [Figure 40-20-10] is needed for the following procedure: Put the axle/outer bearing assembly in the bearing puller as shown and put in the hydraulic press [Figure 40-2010]. Figure 40-20-11

Figure 40-20-9

1

2

P-4171

P-4162

Remove the drive chain from the sprocket (Item 1) [Figure 40-20-9] and remove the sprocket from the chaincase. Remove the inner bearing (Item 2) [Figure 40-20-9] and remove the axle from the axle tube. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.)

Be sure the bearing puller makes good contact with the inner race of the bearing and press the bearing off the mounting surface of the axle. Be sure to hold onto the axle during removal as it will slide freely along the axle shaft after removal from the bearing mounting surface and until the bearing contacts the spline on the shaft. Press the splined end of the axle free from the bearing [Figure 40-20-11].

40-20-4


Figure 40-20-13

DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d) Figure 40-20-12

3

4

1 P-4175

2

When the bearing reaches the bearing mounting surface, continue the installation until the bearing is fully seated [Figure 40-20-13].

P-4169

Installation: A piece of round tubing (Item 1) [Figure 4020-12] is needed to install the bearing on the axle shaft. The tubing needs to measure approximately 0.500 inch (12,7 mm) to 1.0 inch (25,4 mm) in length. The inside diameter of the tubing should not be under 2.100 inches (53,3 mm) and the outside diameter should not be over 2.400 inches (60 mm), A bearing puller (Item 2) [Figure 40-20-12] is also needed to install the bearing on the axle. Put the tubing (Item 1) [Figure 40-20-12] on the bearing puller (Item 2) [Figure 40-20-12]. Put the bearing (Item 3) [Figure 40-20-12] on the tube as shown. Put the spline end of the axle shaft (Item 4) [Figure 4020-12] in the bearing and press the bearing onto the axle. Be sure to hold onto the axle during installation, as it will slide freely along the axle shaft after the spline end has passed through the bearing and until it reaches the bearing mounting surface on the axle.

40-20-5


After the bearing cup tool is inside the axle tube, pull the tool against the bearing cup and tighten the nut (Item 2) [Figure 40-20-15] on the tool.


Figure 40-20-16

Figure 40-20-14

P-4180 P-4172

Use the tools provided in the MEL1202B Axle Bearing Service Set for bearing cup removal and installation. A slide hammer is also necessary for this procedure.

Use the slide hammer and remove the bearing cup from the axle tube [Figure 40-20-16].

Use the long rod and bearing cup tool to remove the inner bearing cup [Figure 40-20-14]. Hit the long rod with a hammer to remove the bearing cup from the axle tube [Figure 40-20-14]. Figure 40-20-15

2 1 P-4179

To remove the outer bearing cup, place the bearing cup tool (Item 1) [Figure 40-20-15] on the slide hammer. Leave the bearing cup tool loose until the tool is installed inside the tube [Figure 40-20-15].

40-20-6


Put the installation tool (Item 1) [Figure 40-20-18] in the axle tube with the threaded rod through the hole in the tool.


Secure the tool to the threaded rod with a nut [Figure 4020-18].

Figure 40-20-17

1

Hold the inside nut (Item 3) [Figure 40-20-17] with a wrench and tighten the outside nut as shown in photo [Figure 40-20-18].

2

Tighten the nut until the bearing cup is seated. Figure 40-20-19 3

P-4174

Figure 40-20-18 1 P-4173

To install the outer bearing cup, use the short rod and the bearing cup tool used for removing the bearing cups. Put the bearing cup tool on the short rod. 2

Put the bearing cup in the axle tube and put the tool into the tube over the bearing cup [Figure 40-20-19]. P-4164

Use the bearing cup installation tools (Item 1) [Figure 4020-17] and (Item 1) [Figure 40-20-18] and the long threaded rod (Item 2) [Figure 40-20-18] from the service set to install the inner and outer bearing cups.

Hit the short rod with a hammer until the bearing cup is seated inside the axle tube.

Put the inner bearing cup in the axle tube (Item 2) [Figure 40-20-17]. Put the installation tool (Item 1) [Figure 40-20-17] in the axle tube. Install the long threaded rod (Item 2) [Figure 40-20-18] into the axle tube and through the installation tool (Item 1) [Figure 40-20-17]. Secure the tool to the threaded rod with a nut (Item 3) [Figure 40-20-17].

40-20-7


Figure 40-20-20

DRIVE COMPONENTS (CONT’D) Chain Removal And Installation

2

WARNING 1


Raise the loader lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)

P-4152

Remove the parking brake disc (Item 1) [Figure 40-2020]. (See Disk Removal And Installation on Page 40-101.) Remove the six carrier mounting bolts (Item 2) [Figure 40-20-20] from inside the chaincase. Installation: Tighten the motor carrier mounting bolts to 125-140 ft.-lb. (170-190 N•m) torque. Figure 40-20-21

Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel. (See Removal and Installation on Page 50-100-1.) Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.)

1

Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the front (or rear) chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) Remove the front (or rear) axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-20-3.)

P-4167

Tip the end of the sprocket on the motor carrier toward the rear of the loader and remove the rear drive chain from the sprocket. NOTE: It may be necessary to tie the front drive chain up as shown in photo [Figure 40-20-21], so the carrier/motor assembly can be moved enough to free the rear drive chain (Item 1) [Figure 4020-21] from the sprocket. Remove the front drive chain from the chaincase.

40-20-8


DRIVE COMPONENTS (CONT’D) Chain Removal And Installation (Cont’d) Figure 40-20-22

B-13504

The tool listed is needed for the following procedure: MEL1037 - Chain Link Tool Installation: If a new chain is installed, a connector link must be used to connect the chain together. Use MEL1037 Chain Link Tool and #80 chain adapter. Secure the tool and place the connector link in the tool as shown [Figure 40-20-22]. Turn the threaded rod of the tool and press the connector link together on the chain [Figure 40-20-22]. Tighten the threaded rod of the chain link tool to 130 ft.-lb. (176 N•m) torque.

WARNING DO NOT exceed the recommended torque of 130 ft.lb. (176 N•m). The tool may fail under too much torque. Put cloth around the tool to protect yourself from flying debris. W-2233-0296

40-20-9


40-20-10


CHAINCASE

Removing The Oil

Checking And Adding Oil

Figure 40-30-2

Figure 40-30-1

1 1

P-64141 P-34453

The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/ hydrostatic system. (See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.)

Remove the chaincase cover (Item 1) [Figure 40-302](See Front Cover Removal And Installation on Page 40-30-2.) Use a vacuum pump to extract the fluid from the chain case.

To check the chaincase oil level, use the following procedure: Drive the loader on a level surface. Stop the engine. Remove the plug (Item 1) [Figure 40-30-1] from the front of the chaincase housing. If oil can be reached with the tip of the your finger through the hole the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

40-30-1


CHAINCASE (CONT’D)

Figure 40-30-3

General Information 3

Early chaincase designs were assembled with gaskets and polyurethane sealant between the chaincase covers and chaincase housing. This was due to a weld that ran down the middle of the top of the chaincase.The gasket helps seal around the welded area. The polyurethane sealant should be used with the gasket to ensure a good seal.

1 2 3

Later chaincase designs do not use a gasket because the weld was moved to the top edge of the chaincase. This creates a “flat top”, on the chaincase, for the cover to seal against. Polyurethane sealant is all that is needed to seal the covers. Note:

Both the later “flat top” and early chaincase designs should use polyurethane sealer on the screw threads, to ensure a good seal.

3

3

P-34255

Remove the front chaincase cover mounting screws (Item 1) [Figure 40-30-3]. Remove the front chaincase cover (Item 2) [Figure 4030-3] from the loader.

Front Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)

Note:

On later “flat top” chaincases there are machined recesses (Item 3) [Figure 40-30-3] on the bottom side of the cover to help pry the covers off.

Installation: Install a new gasket (if equipped). When installing a cover on “flat top” chaincases, apply polyurethane sealer to mating surfaces. Polyurethane sealant should be applied to the screw threads and gasket (if equipped) to stop oil leakage. Tighten the mounting screws to 15-20 ft.-lb. (20-27 N•m) torque.


40-30-2


CHAINCASE COVERS (CONT’D)

WARNING

Center Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)


Figure 40-30-5 2 3

3 1

1 Remove the control panel. (See Removal and Installation on Page 50-100-1.) 1

Figure 40-30-4

3

3

4 P-34446

3

2

Remove the chaincase cover mounting screws (Item 1) [Figure 40-30-5].

1

Remove the center chaincase cover (Item 2) [Figure 4030-5] from the loader. Note: P-34257

Disconnect the lift control cross bar (Item 1) [Figure 4030-4] from the lift pedal linkage. Disconnect the lift control cross bar (Item 2) [Figure 4030-4] from the lift spool on the main control valve.



Disconnect the electrical connector (Item 3) [Figure 4030-4] from the traction lock solenoid. Remove the crossbar mounting bolt (Item 4) [Figure 4030-4]. Remove the crossbar and wire harness from the center chaincase cover.

40-30-3


Figure 40-30-6

CHAINCASE COVERS (CONT’D) Rear Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

3

3 1

Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)

2 3 3 P-34259

Remove the rear chaincase cover mounting screws (Item 1) [Figure 40-30-6]. Remove the rear chaincase cover (Item 2) [Figure 4030-6].


Disconnect the front steering linkage bars from the rear linkage bars. (See Removal and Installation on Page 50100-1.)

Note:



Move the linkage bars to allow adequate space to remove the rear chaincase cover.

40-30-4


MAIN FRAME BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1


CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS). . . 50-111-1 Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1 Control Handle Disassembly and Assembly . . . . . . . . . . . . . . . . 50-111-5 Control Handle Removal and Installation. . . . . . . . . . . . . . . . . . . 50-111-4 Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7 Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-111-6 Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . 50-111-2 CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 Control Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . 50-110-1 CONTROL HANDLE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1 Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2 Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1 Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . . . . . . 50-112-3 CONTROL PANEL (ADJUSTABLE PINTLES) . . . . . . . . . . . . . . . . . 50-101-1 Linkage Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-17 Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-13 Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-101-7 Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 50-101-11 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2 Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-101-6 Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5 Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5

DRIVE SYSTEM

MAIN FRAME


SPECIFICATIONS

CONTROL PANEL (NON-ADJUSTABLE PINTLES) . . . . . . . . . . . . 50-100-1 Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8 Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12 Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1 Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4 Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4 Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4 CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1 CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 Crossbar Linkage Removal and Installation . . . . . . . . . . . . . . . . . 50-90-2 Lift Foot Pedal Linkage Removal and Installation . . . . . . . . . . . . . 50-90-3 Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 Tilt Foot Pedal Linkage Removal and Installation . . . . . . . . . . . . . 50-90-3 Continued On Next

50-01


MAIN FRAME (CONT’D) CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . Foot Pedal Linkage Disassembly And Assembly. . . . . . . . Foot Pedal Removal And Installation. . . . . . . . . . . . . . . . . Foot Sensor Removal And Installation. . . . . . . . . . . . . . . .

50-91-1 50-91-3 50-91-2 50-91-1

FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Fill Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

50-80-1 50-80-2 50-80-2 50-80-1

LIFT ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar Removal And Installation. . . . . . . . . . . . . . .

50-50-1 50-50-5 50-50-1 50-50-6

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

50-20-1 50-20-4 50-20-1 50-20-4

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1 OPERATOR SEAT (SUSPENSION). . . . . . . . . . . . . . . . . . . . Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 3-Point Seat Belt Removal And Installation . . . . . . . . . . . .

50-31-1 50-31-4 50-31-2 50-31-1 50-31-4 50-31-2 50-31-5

POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1 Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . 50-41-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting The Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . Striker Removal and Installation . . . . . . . . . . . . . . . . . . . .

50-70-1 50-70-2 50-70-3 50-70-1 50-70-2 50-70-2

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Spring Disassembly And Assembly . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

50-10-1 50-10-2 50-10-4 50-10-1

50-02


Figure 50-10-3

SEAT BAR Removal And Installation Figure 50-10-1

1

P10564

P10563

Loosen the nut (both sides) at the front corners of the operator cab [Figure 50-10-3].

N-19225

Remove the nuts and plates (both sides) [Figure 50-103].

Raise the seat bar (Item 1) [Figure 50-10-1]. Figure 50-10-2

Installation: Tighten the nuts to 40-50 ft.-lb. (54-68 N•m) torque. Figure 50-10-4

1

N-18463

Disconnect the seat bar sensor (Item 1) [Figure 50-10-2] from the cab harness. Lower the seat bar.

P-31858

Lift on the grab handle and bottom of the operator cab slowly until the cab is all the way up and the latching mechanism engages [Figure 50-10-4].

50-10-1


SEAT BAR (CONT’D)

Assembling Components


Figure 50-10-7

Figure 50-10-5

4

6

5

7

3 1

2 10

9

8

1

N-19383 N-18572

Figure 50-10-8

Remove the seat bar mounting nuts (Item 1) [Figure 5010-5] (both sides).

4 5

Installation: Tighten the nuts to 28 ft.-lb. (38 N•m) torque.

9

3

6

2

Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

10 1

Figure 50-10-6

8

7

N-19219

1

Assemble the parts as shown for the left side of the seat bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].

N-19224

Remove the seat bar (Item 1) [Figure 50-10-6] from the operator cab. Reverse the above procedure to install the seat bar into the operator cab.

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) Installation: Tighten the mounting bolt (Item 2) [Figure 50-10-7] & [Figure 50-10-8] to 50-70 in.-lb. (5,6-7,9 N•m) torque.

50-10-2


SEAT BAR (CONT’D) Assembling Components (Cont’d) Figure 50-10-9 5 4

6

3 7

2

1 N-19340

Figure 50-10-10 4 3

5 6

2 7 1

N-19220

Assemble the parts as shown for the right side of the seat bar pivot assembly [Figure 50-10-9] & [Figure 50-1010]. 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 50-10-9] & [Figure 50-10-10] to 50-70 in.-lb. (5,6-7,9 N•m) torque.

50-10-3


SEAT BAR (CONT’D)

Figure 50-10-12 1

Compression Spring Disassembly And Assembly Figure 50-10-11 7

6

5 4

6 N-19222

3 2 1 N-19384

Turn the bolt (Item 1) [Figure 50-10-12] & [Figure 50-1011] 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. Disassemble and assemble the seat bar compression spring and parts as shown in Fig. [Figure 50-10-11]. Bolt (Item 1) Bushing (Item 2) Spring (Item 3) Clevis (Item 4) Retaining Pin (Item 5) Pin (Item 6) Bushing (Item 7)

50-10-4


Figure 50-20-2

OPERATOR CAB Gas Cylinder Removal And Installation

WARNING

1

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W-2113-0288

Figure 50-20-1 P1528

P1518

Remove the cab nut and holddown plate (Item 1) [Figure 50-20-2] (both sides).

1

Installation: Tighten the nut to 40-50 ft.-lb. (54-68 N•m) torque. Figure 50-20-3 1 N-19165

Remove the operator cab stop (Item 1) (both sides) [Figure 50-20-1]. Start the engine.

WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598 P-31965

Raise the lift arms. (See Installing Lift Arm Support Device on Page 10-20-1.) Install an approved lift arm support device. Stop the engine.

Install a strap (Item 1) [Figure 50-20-3] to the cab handles to prevent the cab from falling forward. Raise the operator cab (See Raising The Operator Cab on Page 10-30-1), to release the tension on the gas cylinder.

50-20-1


Figure 50-20-5

OPERATOR CAB (CONT’D)

SINGLE GAS CYLINDER

Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-4

1

2

1 P-48262A

Figure 50-20-6 DUAL GAS CYLINDER

P-31966

Install a strap (Item 1) [Figure 50-20-4] from the operator cab to the loader main frame to prevent the cab from tipping forward when the gas cylinder(s) are removed. 1

2 P-43354A

Loosen the front bolt (Item 1) and remove the rear bolt (Item 2) [Figure 50-20-5] and [Figure 50-20-6] from the gas cylinder mounting bracket.

50-20-2


Figure 50-20-8

OPERATOR CAB (CONT’D) Gas Cylinder Removal And Installation (Cont'd)

SINGLE GAS CYLINDER

Figure 50-20-7 1

2 1 N-20618

Figure 50-20-9 DUAL GAS CYLINDER

N-19184

Rotate the mounting bracket forward to relieve any remaining tension on the gas cylinder(s) [Figure 50-207].

1

Remove the front bolt (Item 1) [Figure 50-20-7] from the gas cylinder mounting bracket.

2

Installation: Tighten the bolts to 100-130 in.-lb. (11,314,7 N•m) torque. P-39601

Remove the retaining pin(s) (Item 1) [Figure 50-20-8] and [Figure 50-20-9] from the top pivot pin(s). Remove the gas cylinder(s) (Item 2) [Figure 50-20-8] and [Figure 50-20-9] from the operator cab. Reverse the above procedure to install the gas cylinders onto the operator cab.

50-20-3




Gas Cylinder Disassembly

Figure 50-20-12

Figure 50-20-10

1

2

P1008

Remove the clevis (Item 1) [Figure 50-20-10] and washer (Item 2) [Figure 50-20-10] from the end of the gas cylinder. Remove the gas cylinder from the outer housing. Assembly: Install a replacement cylinder inside the cylinder housing. P-31965

Figure 50-20-11 Remove the operator cab gas cylinder(s). (See Gas Cylinder Removal And Installation on page 50-20- 1.)

WARNING AVOID INJURY OR DEATH Attach a chain hoist to the grab handles of the operator cab before removing the operator cab gas cylinders. If the operator cab is tilted forward without the gas cylinders operational, the cab will fall and could cause injury or death. W-2245-0796

P1006

Apply a small amount of LOCTITE on the threads of the cylinder rod [Figure 50-20-11].

Use the hoist connected to the operator cab grab handles to lower or (raise) the operator cab when the gas cylinders are disconnected [Figure 50-20-12].

Reinstall the washer and clevis on the cylinder rod.

50-20-4


Figure 50-20-15

OPERATOR CAB (CONT’D) Removal And Installation (Cont’d) Figure 50-20-13

1

1

N-19231

Install lift eye (Item 1) [Figure 50-20-15] (both sides) to the cab.

P-34227

Remove bolt (Item 1) [Figure 50-20-13] from the cab ground.

Figure 50-20-16

Remove any tie-straps connected to the harness [Figure 50-20-13].

1

Figure 50-20-14

1 P-31966 N-19185

Remove the mounting bolt (Item 1) [Figure 50-20-14] (both sides) to the cab access hole covers.

Remove the strap (Item 1) [Figure 50-20-16] preventing the cab from tipping forward. Lower the cab. Start the engine. Remove the lift arm support device. (See Removing Lift Arm Support Device on Page 10-20-2.) Stop the engine.

50-20-5



Figure 50-20-18


1

1

2

N-19202

N-19165

Remove the rear mounting bolt (Item 1) [Figure 50-2018] (both sides) and nut from the operator cab. Installation: Tighten the bolt and nut to 25-35 ft.-lb. (3447 N•m) torque. Figure 50-20-19

1 P-31967

Connect the slings (Items 1 & 2) [Figure 50-20-17] to a chain hoist.

P-34038

Lift the operator cab up and forward. Disconnect the cab harness connector (Item 1) [Figure 50-20-19]. Remove the operator cab from the loader. Reverse the above procedure to install the operator cab.

50-20-6


OPERATOR SEAT

Seat Belt Removal And Installation


Figure 50-30-3

Figure 50-30-1

1

1

2

1

N-20729 N-20729

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the four seat mounting nuts (Item 1) [Figure 5030-1] and washers from the operator seat mounting studs.

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Item 1 & 2) [Figure 50-30-3] and peel back or cut insulation to gain access to the head. Figure 50-30-4

Installation: Tighten the mounting nuts to 20 ft.-lb. (27 N•m) torque. NOTE: Ensure the washers are installed. Figure 50-30-2 1

2 N-20655

Remove the two nuts (Item 1 & 2) [Figure 50-30-4].

P10564

Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54 ft.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 5030-4] to 34 ft.-lb. (46 N•m) torque.

P10563

Lower the cab and install one of the mounting washers and a nut [Figure 50-30-2].

Repeat for other half of seat belt and guide

NOTE: With the seat removed the cab will raise. Reverse the removal procedure to install the operator seat. 50-30-1


50-30-2


Figure 50-31-3

OPERATOR SEAT (SUSPENSION) Removal And Installation Figure 50-31-1

1 1

1

2 N-20974

NOTE: Assure seat tethers are securely fastened to seatbelt studs (Item 1) and seat rail studs (Item 2) [Figure 50-31-3].

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 N•m) torque. Figure 50-31-2 1

N-20973

NOTE: Verify the front two seat rail studs have washers attached (Item 1) [Figure 50-31-4].

P10564

P10563

Lower the cab and install one of the mounting washers and a nut [Figure 50-31-2]. NOTE: With the seat removed, the cab will raise. Reverse the removal procedure to install the operator seat.

50-31-1


OPERATOR SEAT (SUSPENSION) (CONT’D)

Cushion Removal And Installation

Slide Rail Removal And Installation

Figure 50-31-6

Figure 50-31-5 1 1

1

2

2 1

1 N-18579 N-18587

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-31-1.)

(See

Removal

Press the two buttons (Item 1) [Figure 50-31-6] & [Figure 50-31-7] and lift the seat cushion.

And

Remove the two slide rail mounting bolts (Item 1) [Figure 50-31-5]. Remove the slide rail (Item 2) [Figure 50-31-5] from the bottom of the seat frame. Reverse the removal procedure to install the operator seat slide rail.

50-31-2


Figure 50-31-9

OPERATOR SEAT (SUSPENSION) (CONT’D) Cushion Removal And Installation (Cont’d) Figure 50-31-7 2 1

1

N-18580

Inspect the seat ride adjustment [Figure 50-31-9]. N-18582

Reverse the removal procedure to install the operator seat back.

Figure 50-31-8

1

N-18581

Remove the cushion (Item 2) [Figure 50-31-7] from the seat frame (Item 1) [Figure 50-31-8].

50-31-3


OPERATOR SEAT (SUSPENSION) (CONT’D)

Shock Removal And Installation

Back Removal And Installation

Figure 50-31-12

Figure 50-31-10

1 1

2

1

P-43118 N-18583

Pull the seat back adjustment lever (Item 1) [Figure 5031-10] and tilt the seat back all the way forward. Figure 50-31-11

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-31-1.)

(See

Removal

And

Remove the seat shock mounting bolts (Item 1) [Figure 50-31-12] (Both ends.) Remove the seat shock (Item 2) [Figure 50-31-12]. Reverse the removal procedure to install the operator seat shock. 1

1

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


Figure 50-31-14

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-31-1.)

(See

Removal

2

And 1

Figure 50-31-13

3

2

P16284

Remove the mounting nut (Item 1) [Figure 50-31-14] Remove the seat belt retractor (Item 2) [Figure 50-3114]

1 3

Installation: Be sure tether strap (Item 3) [Figure 50-3114] is on the seat belt stud behind the seat belt retractor. P16285

Remove the mounting nut (Item 1) [Figure 50-31-13] Remove the end release buckle (Item 2) [Figure 50-3113] Installation: Be sure tether strap (Item 3) [Figure 50-3113] is on the seat belt stud behind the end release buckle.

50-31-5


OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation (Cont’d) Figure 50-31-15

1

OUTSIDE OF CAB P16131

Remove the mounting bolt (Item 1) [Figure 50-31-15] Figure 50-31-16

1

2 P16126

INSIDE OF CAB P16128

Remove the shoulder harness retractor (Item 1) [Figure 50-31-16] Installation: Line up the bolt (Item 1) [Figure 50-31-15] with the mounting bracket (Item 2) [Figure 50-31-16] on the inside of the cab.

50-31-6


Figure 50-40-3

BOB-TACH Removal And Installation Figure 50-40-1

1

1 P-48132

N-18544

Tilt the Bob-Tach forward, so it is parallel to the floor. Put blocks (approximately 3 inches) under each side of the Bob-Tach [Figure 50-40-1].

Remove the grease zerk (Item 1) (both sides) [Figure 50-40-3] out of the Bob-Tach frame. This allows grease to escape when driving the pivot pins into the Bob-Tach frame. Figure 50-40-4

Lower the Bob-Tach onto the blocks. Remove the retainer bolt (Item 1) [Figure 50-40-1] and nut from the tilt cylinder rod end pin (both sides). Installation: Tighten the retainer bolt and nut to 25-30 ft.lb. (34-38 N•m) torque. Figure 50-40-2 1

N-18547

1 2

Strike the head of the bolt (Item 1) [Figure 50-40-4] to push the pivot pin into the Bob-Tach frame. Remove the bolt. Use a long punch to push the pivot pin all the way into the Bob-Tach.

N-18545

Remove the pivot pin (Item 1) [Figure 50-40-2] from the tilt cylinder rod end (both sides).

Remove the Bob-Tach from the lift arms. Remove the Bob-Tach pivot pin (both sides).

Remove the tilt cylinder rod end from the Bob-Tach (both sides). Loosen the bolt (Item 2) [Figure 50-40-2] at the BobTach pivot pin. Installation: Tighten the bolt to 175-190 ft.-lb. (240-260 N•m) torque. 50-40-1


Figure 50-40-7

BOB-TACH (CONT’D) Bob-Tach Lever And Wedge Figure 50-40-5

1

N-18560

1 Remove the Wedge (Item 1) [Figure 50-40-7]. N-18558

Always replace bent or broken wedges.

Use the following procedure to remove and install the Bob-Tach lever (Item 1) [Figure 50-40-5], spring and wedge.

Figure 50-40-8

Figure 50-40-6

4 1

3 2 1 N-18561

Remove the lever mounting nut (Item 1), washer (Item 2), spring (Item 3) and lever (Item 4) [Figure 50-40-8].

N-18559

Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-40-6] from the Bob-Tach Wedge and spring clevis.


50-40-2


BOB-TACH (CONT’D) Bob-Tach Lever And Wedge (Cont’d) Figure 50-40-9

2

3

4

1

N-20625

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), or clevis (Item 4) [Figure 50-40-9] are damaged, put the assembly in a vise. Remove the bolt and replace the damaged parts as needed. Figure 50-40-10

1

N-18563

Use a punch and hammer to drive the roll pin (Item 1) [Figure 50-40-10] flush with the face of the Bob-Tach. Reverse the removal procedure to install the Bob-Tach lever and wedge [Figure 50-40-10].

50-40-3


50-40-4


Figure 50-41-2

POWER BOB-TACH Removal And Installation Figure 50-41-1

1

3

2

2

P-48185

1

Remove the pivot pin (Item 1) [Figure 50-41-2] from the tilt cylinder rod end (both sides).

P-48131

Tilt the Bob-Tach forward, so it is parallel to the floor. Put blocks (approximately 3 inches) under each side of the Bob-Tach [Figure 50-41-1]. Lower the Bob-Tach onto the blocks. Remove the hoses [Figure 50-41-1].

to

the

cylinder

fittings

NOTE: The hose with the 45° end (Item 1) [Figure 50-41-1] is connected to the base end fitting on the cylinder.

Remove the tilt cylinder rod end from the Bob-Tach (both sides). Loosen the bolt (Item 2) [Figure 50-41-2] at the BobTach pivot pin. Installation: Tighten the bolt to 175-190 ft.-lb. (240-260 N•m) torque. Figure 50-41-3

Remove the hose clamp on the hoses and use the bolt (Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to secure the clamp. 1

Remove the retainer bolt (Item 3) [Figure 50-41-1] and nut from the tilt cylinder rod end pin (both sides). Installation: Tighten the retainer bolt and nut to 25-28 ft.lb. (34-38 N•m) torque.

P-48132

Remove the grease zerk (Item 1) (both sides) [Figure 50-41-3] out of the Bob-Tach frame. This allows the grease to escape when driving the pivot pins in to the Bob-Tach frame.

50-41-1


Figure 50-41-6

POWER BOB-TACH (CONT’D) Removal And Installation (Cont’d) Figure 50-41-4

1

1

N-18559

Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-41-6] from the Bob-Tach Wedge and spring clevis.

N-18547

Strike the head of the bolt (Item 1) [Figure 50-41-4] to push the pivot pin into the Bob-Tach frame.

Figure 50-41-7

Remove the bolt. Use a long punch to push the pivot pins all the way into the Bob-Tach frame. 1

Remove the Bob-Tach from the lift arms. Remove the Bob-Tach pivot pin (both sides). Power Bob-Tach Lever And Wedge Figure 50-41-5

N-18560

Remove the Wedge (Item 1) [Figure 50-41-7]. Always replace bent or broken wedges.

1

P-48135

Use the following procedure to remove and install the Bob-Tach lever (Item 1) [Figure 50-41-5], spring and wedge.

50-41-2


Figure 50-41-9

POWER BOB-TACH (CONT’D) Power Bob-Tach Lever And Wedge (Cont’d) Figure 50-41-8

4

1 1 2

3

2 N-20625

5

3 4

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), or clevis (Item 4) [Figure 50-41-9] are damaged, put the assembly in a vise.

P-48135

Remove the washers and bolts (Item 1) [Figure 50-418].

Remove the bolt and replace the damaged parts as needed.

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Figure 50-41-10

Remove the cylinder off the lever pivots. Position the rod end to the left with the grease fitting holes to the top [Figure 50-41-8]. Remove the lever mounting nut (Item 2), washer (Item 3), spring (Item 4) and lever (Item 5) [Figure 50-41-8].

1


N-18563

Use a punch and hammer to drive the roll pin (Item 1) [Figure 50-41-10] flush with the face of the Bob-Tach. Reverse the removal procedure to install the Power BobTach lever and wedge [Figure 50-41-10].

50-41-3


50-41-4


Figure 50-50-3

LIFT ARM Removal And Installation Figure 50-50-1

1 N-18850

Mark the tubelines for correct installation (both sides). Pull the tubelines down, disconnect the hoses (Item 1) [Figure 50-50-3] (both sides).

P-31849

Roll the Bob-Tach fully forward. Stop the engine.

Install plugs into the hose and tubeline ends.

Remove the Bob-Tach frame from the lift arms. (See Removal And Installation on Page 50-40-1.)

Figure 50-50-4

Install jackstands under the rear of the loader [Figure 5050-1]. Figure 50-50-2

1 1 P-31832

1

Remove the front auxiliary mount mounting bolts (Item 1) [Figure 50-50-4]. Remove the front auxiliary tubelines from the lift arms.

N-18805

Remove the tubeline clamps (Item 1) [Figure 50-50-2] under the lift arms (both sides).

50-50-1


Figure 50-50-7

LIFT ARM (CONT’D) Removal And Installation (Cont’d) Figure 50-50-5

1 1 1

P-34136

Remove the tilt cylinder mounting bolt base end (Item 1) [Figure 50-50-7].

N-18792

Remove the three front step mounting bolts (Item 1) [Figure 50-50-5].

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the tilt cylinders and tilt tubelines from the loader.

Figure 50-50-6

Figure 50-50-8

1

N-18793

N-18851

Remove the tilt port block mounting bolt (Item 1) [Figure 50-50-6] under the step.

Connect a chain to the front of the lift arm and around the axle [Figure 50-50-8].

50-50-2


Figure 50-50-11

LIFT ARM (CONT’D) Removal And Installation (Cont’d) Figure 50-50-9

1

1

2

P-31973

Use a slide hammer remove the lift cylinder rod end pivot pin (Item 1) [Figure 50-50-11] (both sides).

N-18806

Remove the retainer bolt (Item 1) [Figure 50-50-9] and nut from the lift arm pin (both sides).

Strap the lift cylinders to rear of the uprights.

Installation: Tighten the bolt and nut to 18-20 ft.-lb. (2427 N•m) torque. Use a drift pin and hammer remove the lift arm pivot pin (Item 2) [Figure 50-50-9] (both sides). Figure 50-50-10

1

P-31972

Remove the retainer bolt (Item 1) [Figure 50-50-10] and nut from the lift cylinder rod end pivot pin (both sides). Installation: Tighten the bolt and nut to 18-20 ft.-lb. (2427 N•m) torque.

50-50-3


LIFT ARM (CONT’D)

Figure 50-50-13


1 1

P-31970

2

P-31971

Connect a nylon lift strap, chain and chain hoist to the lift arms (Item 1) [Figure 50-50-12] & [Figure 50-50-13]. Remove the retainer bolt (Item 2) [Figure 50-50-12] from the stabilizer pivot pin. Installation: Tighten to 18-20 ft.-lb. (24-27 N•m) torque. Use a slide hammer, remove the stabilizer pivot pin (Item 2) [Figure 50-50-12] (both sides). Remove the chain from the front axle. Remove the lift arms from the loader. Reverse the removal procedure to install the lift arm.

50-50-4


LIFT ARM (CONT’D)

Figure 50-50-15

Link Removal And Installation Figure 50-50-14 1

1

2

P-31974

Connect a chain and chain hoist on the lift arm link [Figure 50-50-15].

N-18806

Lower the lift arms. Stop the engine.

Remove the retainer bolt (Item 1) [Figure 50-50-15] and nut from the lift arm link pivot pin.

Remove the retainer bolt (Item 1) [Figure 50-50-14] and nut from the lift arm pivot pin.

Installation: Tighten to 18-20 ft.-lb. (24-27 N•m) torque. Figure 50-50-16

Installation: Tighten to 18-20 ft.-lb. (24-27 N•m) torque. Use a drift pin and hammer, remove the lift arm pivot pin (Item 2) [Figure 50-50-14] (both sides).

WARNING Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.

1

P-31975

W-2019-1285

Open the rear door. Raise the radiator cover part way to gain access to the pivot pin. Use a drift pin and hammer, remove the lift arm pivot pin (Item 1) [Figure 50-50-16] (both sides). Lower the rear grill. Close the rear door. Raise the lift arm link with the chain hoist and remove it from the loader frame. Reverse the removal procedure to install the lift arm link on the loader. 50-50-5


Remove the stabilizer link pivot pin (Item 2) [Figure 5050-18].

LIFT ARM (CONT’D) Stabilizer Bar Removal And Installation

Figure 50-50-19

Figure 50-50-17

1 2

P-31969 N-18851

Lower the lift arms.

Remove the retainer bolt (Item 1) [Figure 50-50-19] from the stabilizer link pivot pin.


Installation: Tighten to 18-20 ft.-lb. ( 24-27 N•m) torque.

Connect a chain to the front of the lift arm and around the axle [Figure 50-50-17].

Figure 50-50-20

NOTE: The Bob-Tach and front wheel are removed in photo [Figure 50-50-17] for clarity purpose only. The Bob-Tach and front wheel do not need to be removed to remove the stabilizer link.

2

1

Figure 50-50-18

P-31968

1

Use a slide hammer (Item 1), remove the stabilizer link pivot pin (Item 2) [Figure 50-50-20].

2

Remove the stabilizer link (Item 2) [Figure 50-50-20] from the lift arm. Reverse the above procedure to install the stabilizer link.

N-18813

Remove the retainer bolt (Item 1) [Figure 50-50-18] from the stabilizer link pivot pin. Installation: tighten to 18-20 ft.-lb. ( 24-27 N•m) torque.

50-50-6


Figure 50-60-3

REAR GRILL Removal And Installation Figure 50-60-1

2

1 1

P-48130

Installation: Line up the tab (Item 1) on the grill with the slot (Item 2) [Figure 50-60-3] on the loader mainframe. Insert the tab fully and then push down.

P-48251

Open the rear door.

Reverse the removal procedure to install the grill.

Figure 50-60-2

1

P-48252

Lift up on the rear grill (Item 1) [Figure 50-60-1] and [Figure 50-60-2]. Lift the grill away from the loader.

50-60-1


50-60-2


Connect a chain hoist (Item 2) [Figure 50-70-2] to the lifting chain.

REAR DOOR Removal And Installation

Figure 50-70-3

Figure 50-70-1

1 2

2

3 1

P-34606 P-48519

Disconnect the light harness connector (Item 1) [Figure 50-70-1] from the engine harness. Remove both rear lights (Item 2) [Figure 50-70-1] from the door. (See Rear Removal And Installation on Page 60-60-2.)

Remove the top and bottom door hinge mounting bolts (Item 1) [Figure 50-70-3] and nuts. NOTE: Install the door stop (Item 2) and the door stop retainer (Item 3) in the top hinge as shown [Figure 50-70-3]. Installation: Tighten the mounting bolts and nuts to 2528 ft.-lb. (34-38 N•m) torque.

Figure 50-70-2

Lift the door away from the loader frame and put the door flat on the floor. 2

1

P-34588

Secure the chain hooks (Item 1) [Figure 50-70-2] to the door as shown.

50-70-1


Adjusting The Striker

REAR DOOR (CONT’D) Striker Removal and Installation

WARNING

Figure 50-70-4

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

1

W-2012-0497

Figure 50-70-6

1

1 P-31126

Remove the two striker mount bolts (Item 1) [Figure 5070-4].

1

Remove the striker assembly from the loader. Striker Disassembly and Assembly

P-31126

Figure 50-70-5 Loosen the striker assembly mount bolts (Item 1) [Figure 50-70-6].

2

2 3

Align the striker assembly in the center of the mounting holes. NOTE: Tighten the striker assembly, top mount bolt only, until it will hold the striker assembly in the center of the mounting slots.

4

1

Close the rear door. (This will align the striker assembly to the correct position.) Open the door. P-31320

Tighten both striker mount bolts (Item 1) [Figure 50-706].

Remove the lock nut (Item 1) [Figure 50-70-5]. Remove the rollers (Item 2) and the spacer (Item 3) from the bolt (Item 4) [Figure 50-70-5].

Close the rear door.

Check the parts for wear and replace as needed.

50-70-2


Figure 50-70-9

REAR DOOR (CONT’D) Latch Removal and Installation Figure 50-70-7

1

2

P-31128

1

Remove the door handle (Item 1) [Figure 50-70-9] from the rear door.

P-31125

Disconnect the spring (Item 1) [Figure 50-70-7] from the rear door. Remove the bolt and nut (Item 2) [Figure 50-70-7] from the latch. Figure 50-70-8

3

2

1 P-31127

Remove the spring (Item 1) [Figure 50-70-8] from the door handle. Remove the spring (Item 2) [Figure 50-70-8] from the door latch. Remove the door latch (Item 3) [Figure 50-70-8] from the door handle.

50-70-3


50-70-4


Figure 50-80-3

FUEL TANK Removal And Installation

2

Figure 50-80-1

1

1 P-28143

Open the rear door of the loader. P1616

Remove the cover (Item 1) [Figure 50-80-1] which is installed over the fuel drain near the rear of the chaincase.

Remove the engine/hydrostatic pump assembly from the loader. (See Removal And Installation on Page 70-80-1.) Remove the two mounting bolts (Item 1) [Figure 50-803] from the battery holder.

Installation: Tighten the cover mounting bolts to 190-240 in.-lb. (21,5-27 N•m) torque.

Installation: Tighten the battery holder mounting bolts to 190-240 in.-lb. (21,5-27 N•m) torque.

Figure 50-80-2

Remove the battery holder (Item 2) [Figure 50-80-3] from the loader. Figure 50-80-4

1 1

1

P1619

Drain the fuel from the tank through the fuel drain (Item 1) [Figure 50-80-2].

P-28144

Remove the mounting bolts (Item 1) [Figure 50-80-4] from the fuel tank retainer bracket. Installation: Tighten the mounting bolts to 190-240 in.-lb. (21,5-27 N•m) torque.

50-80-1


Installation: tighten the fuel level sender to 50-60 in.-lb. (5,7-6,8 N•m) torque.

FUEL TANK (CONT’D) Removal And Installation (Cont’d)

Fuel Fill Screen

Figure 50-80-5

Figure 50-80-7

2 1

P13876 P13874

Disconnect fuel sender. Disconnect fuel venthose.

Remove the clamp (Item 1) [Figure 50-80-7] and remove the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.

Disconnect fuel fillhose.

Figure 50-80-8

Lift the fuel tank up and remove the tank from the loader [Figure 50-80-5]. Fuel Level Sender

1

Figure 50-80-6

1

P13875

Remove the fuel fill screen (Item 1) [Figure 50-80-8] from the tank. Check the screen for damage and replace if necessary. P13870

Loosen the fuel level sender (Item 1) [Figure 50-80-6] with a wrench. Turn the fuel level sender out and remove it from the fuel tank. Check the fuel level sender for damage and replace if necessary.

50-80-2


FUEL TANK (CONT’D) Fuel Fill Screen (Cont’d) Figure 50-80-9

1

P13873

Remove the fitting (Item 1) [Figure 50-80-9] and grommet from the tank. Figure 50-80-10

1 P13872

Remove the fuel supply screen (Item 1) [Figure 50-8010] from the hose. Check the screen for damage and replace if necessary.

50-80-3


50-80-4


Figure 50-90-2

CONTROL PEDALS Removal And Installation Figure 50-90-1

1

1

P-34375

Remove the two mounting bolts (Item 1) [Figure 50-902] from the pedal mounting bracket.

P-26008

Remove the bolt (Item 1) [Figure 50-90-1] and nut from the pedal linkage.

Remove the pedal assembly from the loader. Remove the pedal assembly from the loader.

Installation: Tighten the bolt and nut to 21-25 ft.-lb. (2834 N•m) torque.

Pedal Adjustment

Check the rubber bushing in the pedal for wear and replace as needed.

After installing the pedal, adjust the pedal so that there is clearance under the rear of the pedal. The valve spool must travel full stroke without the pedal hitting the floor panel.

50-90-1


Figure 50-90-4

CONTROL PEDALS (CONT’D) Crossbar Linkage Removal and Installation

1

WARNING

P-34260


Remove the hairpin clip and cross-pin (Item 1) [Figure 50-90-4] from the control valve lift spool. Disconnect the crossbar from the control valve. Figure 50-90-5

Raise the lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.) Figure 50-90-3 2

1

1

P-34376

Remove the crossbar from the pivot [Figure 50-90-5]. Installation: Check the nylon bushing (Item 1) [Figure 50-90-5] for wear and replace as needed.

P-34257

Remove the bolt and nut (Item 1) [Figure 50-90-3] to disconnect the lift pedal linkage from the crossbar. Remove the crossbar pivot bolt (Item 2) [Figure 50-903].

50-90-2


CONTROL PEDALS (CONT’D)

Tilt Foot Pedal Linkage Removal and Installation

Lift Foot Pedal Linkage Removal and Installation

Figure 50-90-8

Figure 50-90-6

1

1

P-34258 P-34257

Remove the bolt and nut (Item 1) [Figure 50-90-6] to disconnect the lift foot pedal linkage from the crossbar linkage.

Remove the hairpin clip and cross-pin (Item 1) [Figure 50-90-8] from the control valve tilt spool. Figure 50-90-9

Figure 50-90-7

1

1

P-26008

Remove the bolt and nut (Item 1) [Figure 50-90-9] to disconnect the lift foot pedal.

P-24759

Remove the bolt and nut (Item 1) [Figure 50-90-7] to disconnect the lift foot pedal.



50-90-3


50-90-4


Figure 50-91-3

CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Figure 50-91-1

2

1 P-21936

P-21927

Remove the two bolts (Item 1) [Figure 50-91-3] from the foot sensor shield.

1 P-21938

Pull the pin (Item 1) [Figure 50-91-1] holding the foot pedal linkage to the sensor.

Installation: Tighten the bolts to 80-90 in.-lb. (9,0-10,2 N•m) torque.

Disconnect the two connectors (Item 2) [Figure 50-91-1] from the sensor and lock solenoid. Figure 50-91-2

1

P-21935

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.

50-91-1


CONTROL PEDALS (ACS) (CONT'D)

Foot Pedal Removal And Installation

Foot Sensor Removal And Installation (Cont’d)

Figure 50-91-5

Figure 50-91-4

1

2

1 P-21940 P-21924

Remove the pin (Item 1) [Figure 50-91-5] holding the linkage to the sensor.

Remove foot lock solenoid (Item 1) [Figure 50-91-4]. Installation: Apply a drop of oil to the solenoid threads and tighten the solenoid to 35-40 ft.-lb. (47-54 N•m) lubed torque.

Figure 50-91-6

1

Remove the two bolts (Item 2) [Figure 50-91-4] from the bracket and sensor assembly.

P-21935A

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the sensor assembly. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure (ACS) on Page 60-16011.)

P-21934

Tip the foot pedal up and remove the two nuts (Item 1) [Figure 50-91-6]. Remove the foot pedal assembly.

50-91-2


CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Linkage Disassembly And Assembly Figure 50-91-7

2 1 P-21931

Remove the bolt (Item 1) holding the linkage (Item 2) to the side of the foot pedal [Figure 50-91-7]. Figure 50-91-8

2

3 1 P-21932

Remove the spacer (Item 1), linkage (Item 2), and nut (Item 3) from the foot pedal [Figure 50-91-8].

50-91-3


50-91-4


Disconnect the control harness connectors (Item 4) [Figure 50-100-1] from right control levers.

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Removal and Installation


WARNING

Figure 50-100-2


1

W-2059-0598

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)

P-48277

Disconnect the control harness connectors (Item 1) [Figure 50-100-2] from left control levers.

Figure 50-100-1

2 1

3

4 P-48462

Loosen the jam nut (Item 1) from the by-pass control knob (Item 2) [Figure 50-100-1]. Remove the control knob (Item 2), jam nut (Item 1) and rubber washer (Item 3) [Figure 50-100-1].

50-100-1


Figure 50-100-4

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Removal And Installation (Cont’d)

2 1

3

1

Figure 50-100-3

1

2

2

1

P-26323

Remove the fuse/relay mounting bolts (Item 1) [Figure 50-100-4]. P-48235

Remove the fuse/relay shield (Item 2) [Figure 50-100-4]. Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-100-3] which are connected to the steering shaft on the control panel.

Remove the fuse/relay cover (Item 3) [Figure 50-100-4]. Figure 50-100-5

Remove the four steering linkage mounting bolts (Item 2) [Figure 50-100-3]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 2528 ft.-lb. (34-38 N•m) torque.

P-26325

Remove the fuse/relay block [Figure 50-100-5].

50-100-2


CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D)

Figure 50-100-8

Removal And Installation (Cont’d) Figure 50-100-6 1

1

1

1

1

1 P-26327

P-34363

Remove the control panel mounting bolts (Item 1) [Figure 50-100-6], [Figure 50-100-7] & [Figure 50-1008] from both sides of the control panel. Installation: Tighten the control panel mounting bolts to 15-20 ft.-lb. (20-27 N•m) torque.

Figure 50-100-7

Remove the control panel from the loader. Reverse the removal procedure to install the control panel.

1

P-26329

50-100-3


Figure 50-100-10

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Shock Removal And Installation Figure 50-100-9

1 3

3 2

1

P-4146

Remove Control Handle Lever (Item 1) [Figure 50-10010]. (See Control Lever Removal And Installation on Page 50-110-1.)

2 P-34365

Remove the mounting nut (Item 1) [Figure 50-100-9] from the end of the shock connected to the steering linkage. Remove the mounting nut (Item 2) [Figure 50-100-9] from the other end of the shock connected to the bracket on the control panel. Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Remove the steering shaft pivot bolt (Item 2) [Figure 50100-10] from both sides of the control panel. Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the steering shaft from the control panel. Shaft Disassembly And Assembly Figure 50-100-11

Shaft Removal And Installation NOTE: The steering shaft can be removed without removing the control panel from the loader. Photo [Figure 50-100-10] shows the control panel removed for clarity purpose only.

1 1

Remove the steering linkage mounting bolts (Item 3) [Figure 50-100-9]. Remove the steering shock mounting nuts (Item 2) [Figure 50-100-9].

1

P-4154

Disassemble the right and left steering shafts from the cross shaft assembly [Figure 50-100-11]. Assembly: Install new nylon bushings (Item 1) [Figure 50-100-11] as needed when assembling the steering shaft. Be sure to apply grease on the cross shaft before installing the right and left steering shaft.

50-100-4


Linkage Removal And Installation


Figure 50-100-13

Shaft Disassembly And Assembly (Cont’d) Figure 50-100-12 1

2

1

P-3729

1 Remove the nut (Item 1) from the end of the centering spring shoulder bolt (Item 2) [Figure 50-100-13].

P-26331

To remove the steering shaft mounting bracket (Item 3) [Figure 50-100-10], remove the three mounting bolts (Item 1) [Figure 50-100-12] from the front of the control panel.

Remove the shoulder bolt/spring assembly.

Remove the steering shaft mounting bracket from each side of the control panel.

Figure 50-100-14

Installation: Tighten the centering spring shoulder bolt and a NEW lock nut to 25-28 ft.-lb. (34-38 N•m) torque.

Installation: Tighten the mounting bolts to 15-20 ft.-lb. (20-27 N•m) torque. 1

2

3

2

P-3736

Slide the plate (Item 1) to the right and remove it from the two guide pins (Item 2) [Figure 50-100-14]. NOTE: The two guide bushings (Item 3) will be loose and can fall out of the plate (Item 1) as soon as it is removed from the guide pins (Item 2) [Figure 50-100-14].

50-100-5


Figure 50-100-16

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d)

1

Figure 50-100-15

1

2

5 6

2

4

1

N-15312

2

3

2

Check the wear on the centering blocks (Item 1) [Figure 50-100-16]. N-15310

The centering plate/centering spring assembly consists of the following parts; ITEM

DESCRIPTION

1

Shoulder Bolt

2

Bushings

3

Spring

4

Lock Nut

5

Centering Plate

6

Guide Bushings

If the centering blocks need replacement, remove the bolts (Item 2) [Figure 50-100-16]. Remove the centering blocks. Installation: Tighten the centering block bolts to 25-28 ft.-lb. (34-38 N•m) torque. Figure 50-100-17

1

1

2

2

P-3733

If the surface of any of the four pintle cams (Item 1) are worn, loosen the bolt (Item 2) [Figure 50-100-17] and rotate the cams 1/4 turn. Tighten the bolts to 45-50 ft.-lb. (62-68 N•m) torque. When replacing the old style pintle levers, wear cams and cam bolts, install the latest style parts.

50-100-6


Figure 50-100-20

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d) Figure 50-100-18

1 3 2

1

1 1 P-34365

Remove the nuts (Item 1) [Figure 50-100-20] from both shock absorber ball joint ends. P-3733

Remove the shock absorbers. Remove the nut (Item 1) [Figure 50-100-18] from the torsion bushing/linkage bar. The bolt is threaded into the linkage bar, remove the bolt from underneath the pintle lever. Installation: Tighten the bolt to 11-13 ft.-lb. (21-25 N•m) torque, then tighten the nut to 21-25 ft.-lb. (28-33 N•m) torque. Figure 50-100-19

Installation: Tighten the nuts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the nuts (Item 2) from the linkage bar mounting bolt. The bolts (Item 3) are threaded into the linkage bars, remove the bolts (Item 3) [Figure 50-100-20]. The torsion bushings can now be removed from the steering bell cranks. Installation: Tighten the bolts to 11-13 ft.-lb. (21-25 N•m) torque, then tighten the nuts to 21-25 ft.-lb. (28-33 N•m) torque.

2

The linkage and the centering plate must be readjusted for neutral after the components have been reassembled. (See Page 50-100-12 for the neutral adjustment procedure.) 1

P-3734

Remove the linkage bar (Item 1) and remove the torsion bushing (Item 2) [Figure 50-100-19].

50-100-7



Figure 50-100-21

Linkage Adjustment 2

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.

2 1 3

W-2059-0598

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

P-34365

Lift and block the loader. (See Procedure on Page 10-101.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)


Connect the remote start Procedure on Page 10-60-1.)

tool

(MEL1429).

(See

Pre-load tension in the torsion bushings must be removed before adjusting the steering linkage. Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bar (Item 3). The bolt (Item 2) [Figure 50-100-21] must be loosened enough to allow the torsion bushing to turn freely between the steering bellcrank and the linkage bar. Figure 50-100-22

1

2

3 3 P-3726

Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bar (Item 3). The bolt (Item 2) [Figure 50-100-22] must be loosened enough to allow the torsion bushing to turn freely between the pintle arm and the linkage bar. 50-100-8


Figure 50-100-25

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Adjustment (Cont’d) Figure 50-100-23

2

1 1

3 P-3723

Move the right side steering lever forward and install a 15/16 inch (24 mm) thick spacer (Item 1) between the center plate (Item 2) and the mounting plate (Item 3) [Figure 50-100-25].

P-37574

Remove access plug from the top of the control valve. Turn the control lever drift adjustment bolts (Item 1) [Figure 50-100-23] (one on each control lever) out until it is flush with the bottom of the nut. Figure 50-100-24

This will allow the pintle arms to move freely while adjusting the steering linkage for full forward travel speed. Remove the 3/8 inch (10 mm) thick spacer (Item 1) [Figure 50-100-25]. Figure 50-100-26

4 2 1 3 3

1

2

4 P-3724 P-3730

Move the right side steering lever to the rear and install a 3/8 inch (10 mm) thick spacer (Item 1) between the pintle arm cam (Item 2) and the centering block (Item 3) [Figure 50-100-24].

Before adjusting the linkage, check that the pintle arm mounting bolt (Item 1) is tight, 25-28 ft.-lb. (34-38 N•m) torque and that there is no play between the pintle arm (Item 2) and the square pump shaft (Item 3). Also check that the cam mounting bolts (Item 4) [Figure 50-100-26] are tight, 45-50 ft.-lb. (62-68 N•m) torque.

50-100-9


Figure 50-100-28

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Adjustment (Cont’d) Figure 50-100-27

P-3728

1

P-3727

Loosen the two bolts and nuts (Item 1) [Figure 50-10027] on each steering linkage bar.

Move the left control lever to the full forward position, then pull forward on the left rear linkage bar until the pintle arm is rotated to the front as far as possible [Figure 50-100-28]. Use a locking plier and clamp the two linkage bars together. Installation: Tighten the nuts and bolts to 25-28 ft.-lb. (34-38 N•m) torque. Check the lever movement to make sure that the pintle arm and the control lever are both at full stroke at the same time. This will allow for maximum forward speed. Repeat the procedure for the right side linkage. After both sides of the linkage have been adjusted, the feel of both levers at full stroke should be the same. Readjust the linkage if necessary. Figure 50-100-29

1 P-3723

Remove the spacer (Item 1) [Figure 50-100-29]. Disconnect the remote start tool.

50-100-10


CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT'D) Linkage Adjustment (Cont'd) Figure 50-100-30

1

P-37574

Push the control lever to full stroke and turn drift adjustment bolt (Item 1) [Figure 50-100-30] in until it touches the U-bolt holding the control lever. Repeat steps on the other control lever. Drive the loader forward and check for drift. The traditional benchmark for drift is less than 10 ft. of “drift” in 100 ft. of travel distance. If the drift is excessive to the left, turn the right adjustment bolt (Item 1) [Figure 50-100-30] in. If the drift is excessive to the right, turn the left adjustment bolt in. NOTE: When using the drift adjustment bolts, only adjust one bolt for each test drive. In addition only move each bolt a maximum of one turn for each test drive. This will help prevent over correction and excess reduction in travel speed. Drift adjustment is for forward travel only. Adjust the drift to an acceptable level. Re-install the plug in the drift bolt access hole after adjustment.

50-100-11


Figure 50-100-32

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment The following tool listed will be needed to do the following procedure:

1

2

2

1

MEL1563 - Remote Start Tool Kit Connect the remote start tool to the engine harness. (See Procedure on Page 10-60-1.)

WARNING

P-3731


Figure 50-100-31

Loosen the four bolts (Item 1) [Figure 50-100-32] holding the two centering blocks. Move the right hand centering block to the right as far as possible. NOTE: Bolt holes (Item 2) [Figure 50-100-32] are slotted for pintle arm centering adjustment. Figure 50-100-33

1

2 4

3 P-3726 P-3725

Loosen the nut (Item 1) a couple of turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bars (Items 3 & 4) [Figure 50-100-31].

Adjust the left centering block first [Figure 50-100-33].

The bolt (Item 2) [Figure 50-100-31] must be loose enough to allow the torsion bushing to turn freely between the pintle arm and the linkage bar.

50-100-12


Figure 50-100-35

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-100-34

1

P-3732

Adjust the right centering block [Figure 50-100-35]. Move the right control lever until the tires do not turn (neutral position).

P16121

Start the engine and run at high RPM. Move the traction lock override switch (Item 1) [Figure 50-100-34] to the OFF position so the traction function is unlocked. The wheels are now able to turn. Move the left control lever until the tires do not turn (neutral position). Move the left centering block to the left until it contacts both pintle cams and the control lever is still in the neutral position [Figure 50-100-33]. Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. NOTE: If the centering blocks are worn, they can be removed and rotated 180 degrees and reinstalled. If the cams are worn, they can be loosened and rotated 90 degrees and reinstalled.

Move the right centering block to the left until it contacts both pintle cams and the control lever is still in the neutral position [Figure 50-100-35]. Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Test both levers by moving them backward and forward and letting them return to neutral by the return spring force. If the levers do not return to neutral and the tires do not come to a complete stop, repeat the adjustment procedure again. Stop the engine.

50-100-13


Figure 50-100-37

CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-100-36

1 1 2

P-34365

2 Tighten the two bolts to 11-13 ft.-lb. (15-17 N•m) torque, then tighten the two nuts to 21-25 ft.-lb. (28-33 N•m) torque at the steering cross shaft (Items 1 & 2) [Figure 50-100-37].

P-3726

Tighten the two bolts (Item 1) to 11-13 ft.-lb. (15-17 N•m) torque, then tighten the two nuts (Item 2) [Figure 50-10036] to 21-25 ft.-lb. (28-33 N•m) torque.

50-100-14


CONTROL PANEL (ADJUSTABLE PINTLES) Description Figure 50-100-1

P-54658

The steering system [Figure 50-101-1] consists of independent steering levers the operator uses to provide steering input to the loader. The steering levers are attached to pivoting bellcranks that pivot on a steering shaft and plastic bushings. The bellcranks have grease fittings.

Pintle arms are of a two-piece design that allow easy adjustment of the neutral or “creep”. Earlier designs use a “spring return” adjustment, later designs use a “thread return” adjustment. The steering system returns the levers to their starting position by means of the centering spring and the returning force of the torsion bushings.

The forward travel is adjusted by drift adjustment bolts. The bellcranks are attached to steering linkage bars with rubber torsion bushings pressed into the bellcranks. Bellcranks mount to the control panel. Steering linkage bars are a two-piece design. Steering linkage bars are adjustable in length for “full travel adjustment”. Steering linkage bars attach to the pintle arms where a rubber torsion bushing is pressed into the pintle arms.

NOTE: Torsion bushings need to be replaced if torn or rotating in the housing. Loosen torsion bushing bolts slightly before adjustments are made. Do not fully tighten torsion bushing bolts again until all steering adjustments have been made first. Sequence of steering adjustments: 1. Set neutral of pintle arms, “creep” 2. Set full travel at steering linkage bars 3. Set drift at drift adjustment bolts

50-101-1


CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)

Figure 50-101-2

Removal and Installation 2

1

3

4

P-48462


Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Loosen the jam nut (Item 1) from the by-pass control knob (Item 2) [Figure 50-101-2].


Remove the control knob (Item 2), jam nut (Item 1) and rubber washer (Item 3) [Figure 50-101-2]. Figure 50-101-3

W-2017-0286

4

P-48277

Disconnect the control harness connectors (Item 4) [Figure 50-101-2] & [Figure 50-101-3] from the control levers.

50-101-2


Figure 50-101-5

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D) Removal and Installation (Cont'd)

2

Figure 50-101-4

1

2

2

1 3

P-26323

1

1 Remove the fuse/relay mounting bolts (Item 1) [Figure 50-101-5]. P-54609

Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-101-4] which are connected to the steering shaft on the control panel.

Remove the fuse/relay cover (Item 2) and fuse/relay block retaining bracket (Item 3) [Figure 50-101-5]. Figure 50-101-6

Remove the four steering linkage mounting bolts (Item 2) [Figure 50-101-4]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 3540 ft.-lb. (47,5-54,2 N•m) torque.

P-26325

Remove the fuse/relay block [Figure 50-101-6].

50-101-3


CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)

Figure 50-101-9 1

Removal and Installation (Cont'd) Figure 50-101-7 11 P-26329

1

P-26328

P-26329

1

P-26326

Remove the control panel mounting bolts (Item 1) [Figure 50-101-7], [Figure 50-101-8] & [Figure 50-1019] from both sides of the control panel. Installation: Tighten the control panel mounting bolts to 15-20 ft.-lb. (20-27 N•m) torque.

Figure 50-101-8

Remove the control panel from the loader. Reverse the removal procedure to install the control panel. 1

1 P-26327

50-101-4


Shaft Removal And Installation

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)

NOTE: The steering shaft can be removed without removing the control panel from the loader. Photo [Figure 50-101-11] shows the control panel removed for clarity purpose only.

Shock Removal And Installation Figure 50-101-10

Remove the steering linkage mounting bolts (Item 3) [Figure 50-101-10]. Remove the steering shock mounting nuts (Item 2) [Figure 50-101-10].

1 3

Figure 50-101-11

2 P-48275

Remove the mounting nut (Item 1) [Figure 50-101-10] from the end of the shock connected to the steering linkage.

3

Remove the mounting nut (Item 2) [Figure 50-101-10] from the other end of the shock connected to the bracket on the control panel. Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque.

1

2 P-48278

Remove Control Handle Lever (Item 1) [Figure 50-10111]. (See Control Lever Removal And Installation on Page 50-110-1.) Remove the steering shaft pivot bolt (Item 2) [Figure 50101-11] from both sides of the control panel. Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the steering shaft from the control panel.

50-101-5


Figure 50-101-13

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Shaft Disassembly And Assembly

1

Figure 50-101-12

1

2 2 1 1

P-26331

2 To remove the steering shaft mounting bracket (Item 3) [Figure 50-101-11], remove the three mounting bolts (Item 1) [Figure 50-101-13] from the front of the control panel.

P-4154

Disassemble the right and left steering bellcranks (Item 1) from the cross shaft assembly [Figure 50-10112].

Remove the steering shaft mounting bracket. Installation: Tighten the mounting bolts to 15-20 ft.-lb. (20-27 N•m) torque.

Assembly: Install new nylon bushings (Item 2) [Figure 50-101-12] as needed when assembling the steering shaft. Be sure to apply grease on the cross shaft before installing the right and left bellcranks. NOTE: The bellcranks should pivot freely on the cross shaft when assembled correctly.

50-101-6


Figure 50-101-14

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation

WARNING

2


2

1

1

W-2059-0598 P-54609


Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.)

Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-101-14] which are connected to the steering shaft on the control panel. Remove the four steering linkage mounting bolts (Item 2) [Figure 50-101-14]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 3540 ft.-lb. (47,5-54,2 N•m) torque. NOTE: After removal and installation of the linkage, the linkage neutral adjustment procedure must be performed. See Page 50-101-13 for Linkage Neutral Adjustment procedure.

50-101-7


Figure 50-101-17

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d)

7

Figure 50-101-15

3

1

6

4

8

1

5

2

2 P-48630

The centering plate/centering spring assembly consists of the following parts:

2

P-48631

ITEM

DESCRIPTION

Remove the nut (Item 1) from the end of the centering spring shoulder bolt (Item 2) [Figure 50-101-15].

1

Bolt

2

Bushings

Remove the bolt/spring assembly.

3

Washer

4

Bushing Spacer

5

Spring

6

Lock Nut

7

Centering Plate

8

Guide Bushings

Installation: Tighten the centering spring bolt and a NEW lock nut to 25-28 ft.-lb. (34-38 N•m) torque. Figure 50-101-16

1

P-48632

Slide the centering plate (Item 1) [Figure 50-101-16] to the right to remove it from the hydrostatic pumps. NOTE: Directions are shown and stated as if you were sitting in the operators seat.

50-101-8


Figure 50-101-19


SPRING RETURN STYLE

Linkage Removal And Installation (Cont’d) Figure 50-101-18

2

1 3

6

3

2 5 1 4

2

1 1

P-48627

2

If the surface of any of the four solid pintle cams (Item 1) are worn, loosen the bolt (Item 2) and rotate the cams 1/4 turn [Figure 50-101-19].

P-48629

Check the wear on the centering blocks (Item 1) [Figure 50-101-18]. If the centering blocks need replacement, remove the bolts (Item 2) [Figure 50-101-18]. Remove the centering blocks. Installation: Tighten the centering block bolts to 35-40 ft.-lb. (47,5-54,2 N•m) torque. NOTE: The washers go between the bolts and the centering plate.

Remove the bolts and washers (Item 3) [Figure 50-10119] from the pintle. Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2 N•m) torque. Loosen the creep adjustment bolt (Item 4) [Figure 50101-19]. Remove the pintle arm (Item 5) from the pintle base. (Item 6) [Figure 50-101-19]. Figure 50-101-20

NOTE: If the centering blocks are worn, they can be removed and rotated 180 degrees and reinstalled. If the solid cams are worn, they can be loosened and rotated 90 degrees and reinstalled.

SPRING RETURN STYLE 1

4

3

2 P-48625

NOTE: When installing the pintle arm (Item 1) onto the pintle base (Item 2) align the rear of pintle arm (engine side) (Item 3) into the spring (Item 4) [Figure 50-101-20]. (Spring Return Style Only)

50-101-9


Figure 50-101-23


SPRING RETURN STYLE

Linkage Removal And Installation (Cont’d)

1

Figure 50-101-21 THREAD RETURN STYLE

3

1

2

2

P-48621

3 Remove and inspect the spring (Item 1) [Figure 50-10123]. Spring return style only. P-54617

Figure 50-101-24 Remove the bolts and washers (Item 1) [Figure 50-10121] from the pintle.

THREAD RETURN STYLE

Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2 N•m) torque.

3

Remove the pintle arm (Item 2) from the pintle base (Item 3) [Figure 50-101-21]. Figure 50-101-22 1

2 P-54615

2

Loosen the bolt (Item 2) and remove the pintle base (Item 3) [Figure 50-101-23] and [Figure 50-101-24].

4

3 2 1 P-48624

Remove the bolt and nut (Item 1) [Figure 50-101-22]. Inspect the washers (Item 2), pintle arm (Item 3) and the steering control link (Item 4) for damage and replace as needed [Figure 50-101-22]. NOTE: The washers (Item 2) [Figure 50-101-22] are hardened, and should only be replaced through Bobcat Parts. 50-101-10


Pintle Arm Disassembly and Assembly


Figure 50-101-26

Linkage Removal And Installation (Cont’d)

2

Figure 50-101-25

2

2

1

3 P-54625

1 P-48659

NOTE: When installing the pintle base (Item 1) onto the pump shaft, the cutouts on the pump shaft will not line up with the bolt (Item 3) [Figure 50-101-25]. Installation: Install the pintle base (Item 1) onto the pump shaft (Item 2) [Figure 50-101-25]. The top of the pintle base should be level with the top of the pump shaft. Tighten the bolt to 35-40 ft.-lb. (47,5-54,2 N•m) torque.

Remove the bolt (Item 1) from the pintle solid cams (Item 2)_[Figure 50-101-26] and inspect the pintle solid cams for damage or excessive wear. Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2 N•m) torque. Figure 50-101-27 2 3

NOTE: After installing the linkage onto the hydrostatic pumps the linkage neutral adjustment procedure must be performed. See Page 50-101-13 for Linkage Neutral Adjustment procedure.

2 3

1 P-54624

NOTE: The pintle roller cams (Item 2) [Figure 50-10127] are used on ACS loaders only. 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 50-101-27]. Inspect the torsion bushing (Item 3) [Figure 50-101-27] for damage and replace as needed. Installation: Tighten the nuts to 35-40 ft.-lb. (47,5-54,2 N•m) torque.

50-101-11


Figure 50-101-29

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Pintle Arm Disassembly and Assembly (Cont’d) Figure 50-101-28

1

1

4

2

3

2 P-48619

3 Using a bushing driver (Item 1) remove the torsion bushing (Item 2) by pressing the bushing through the pintle arm into an oversized socket (Item 3) to catch the torsion bushing [Figure 50-101-29].

P-54626

Remove the base pintle (Item 1) [Figure 50-101-28] from the pump shaft. Remove the retaining bolt (Item 2), adjusting screw (Item 3) and neoprene dampener (Item 4) [Figure 50-101-28] from the base pintle. Inspect parts for wear and damage, replace as needed [Figure 50-101-28].

Installation: Install the torsion bushing (Item 2) [Figure 50-101-29] into the pintle arm using the same procedure as the removal. NOTE: When the torsion bushing is installed, the amount of bushing on each side of the pintle arm should be the same.

NOTE: Anti-sieze should be used on the adjusting screw to prevent corrosion and allow free movement while adjusting.

50-101-12



Figure 50-101-31

Linkage Neutral Adjustment 1

The following tool listed will be needed to do the following procedure: MEL1563 - Remote Start Tool Kit Connect the remote start tool to the engine harness. (See Procedure on Page 10-60-1.) Lift and block the loader. (See Procedure on Page 10-101.)

P-48448

Figure 50-101-30

Loosen the bolt/nut (Item 1) [Figure 50-101-31] only until the tension is released from the torsion bushing.

3

Figure 50-101-32 2

1

1

P-48450

2

Tool that may assist in the neutral adjustment [Figure 50-101-30]. To make this tool use a locking grip C-Clamp and grind one edge flat (Item 1) and grind the other edge (Item 2) [Figure 50-101-30] to a small rounded edge. A steering centering block (Item 3) [Figure 50-101-30] is also needed. The centering block can be placed as shown and welded to the C-clamp if desired.

P-54612

Loosen the nut (Item 1) only until the tension is released from the torsion bushing (Item 2) [Figure 50-101-32]. NOTE: The bolt must be loose enough to allow the torsion bushing (Item 2) [Figure 50-101-32] to turn freely between the torsion bushing and the steering linkage bar.


50-101-13


Figure 50-101-35

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-101-33

2

1 1 P16121

Using the remote start tool, turn the key (Item 1) [Figure 50-101-35] to the run position.

2 P-54614

Loosen the two bolts (Item 1) holding the right centering block. Move the right hand centering block (Item 2) [Figure 50-101-33] until both pintle cams contact the centering block. NOTE: The left centering block is not adjustable. By adjusting the right centering block the left centering block will also become aligned properly. Figure 50-101-34

3

Move the traction lock override switch (Item 2) [Figure 50-101-35] so the traction function is unlocked. (The traction lock override switch light will be ON.) On a standard loader the wedge brake will unlock. NOTE: When the engine is started, the wheels/tracks may begin to move. NOTE: In loaders equipped with manual steering and hydraulic brake, the steering levers may have to be moved during engine start-up to reduce the amount of creep. This reduction in creep will allow time for the engine to run and build up hydraulic charge pressure, which will release the hydraulic brake. Using the remote start tool, turn the key (Item 1) [Figure 50-101-35] and start the engine and run at low idle. Tighten bolts (Item 3) [Figure 50-101-34] to 35-40 ft.-lb. (47,5-54,2 N•m).

1 2

NOTE: Check for slack between centering blocks and pintle cams. If there is excessive slack repeat above steps [Figure 50-101-33] & [Figure 50101-34]. P-48451

A modified locking grip C-Clamp and steering block shown in [Figure 50-101-30] may be used to help in aligning the centering blocks. Install the centering block (Item 1) on the inside of the pintle cams and the C-Clamp (Item 2) [Figure 50-10134] around both centering blocks. Lock the C-Clamp in place. 50-101-14


Figure 50-101-37

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Start the neutral adjustment procedure with the left pump first and complete the neutral adjustment for the left pump before adjusting the right pump. Figure 50-101-36

2

1

1

P-54610

Move the engine speed control to high idle. NOTE: The neutral range (dead-band) will vary between the hydrostatic pumps. NOTE: This procedure is shown for neutral adjustment on the left side of the loader. The procedure is the same for the right side neutral adjustment.

P-48632

Loosen the left pump pintle adjustment lock bolts (Item 1). (The right pump pintle adjustment lock bolts are (Item 2) [Figure 50-101-36].) Loosen the bolts enough to allow free movement between the pintle arm and the pintle base. NOTE: If the bolts are too loose or too tight, the neutral adjustment may be affected.

Turn the adjustment screw (Item 1) [Figure 50-101-37] counterclockwise until forward creep is seen. Turn the adjustment screw (Item 1) [Figure 50-101-37] counterclockwise to a point between forward and reverse where there is zero creep. Stroke the left steering lever to forward and allow the lever to return to neutral. Stroke the left steering lever to reverse and allow the lever to return to neutral. Check that there is zero creep when the lever returns from either direction, on the left side. Turn the adjustment screw (if necessary) until zero creep is obtained.

50-101-15


CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-101-38

2

2

1

1

P-48632

Torque the left pump pintle adjustment lock bolts (Item 1) [Figure 50-101-38] to 35-40 ft.-lb. (47,5-54,2 N•m). Repeat the adjustment procedure for the right pump. Torque the right pump pintle adjustment lock bolts (Item 2) [Figure 50-101-38] to 35-40 ft.-lb. (47,5-54,2 N•m). Test both levers by moving them backward and forward and letting them return to neutral by the return spring force. If the levers do not return to neutral and the wheels/ tracks do not come to a complete stop, repeat the adjustment procedure again. Stop the engine. Remove one pintle adjustment bolt (Item 1) [Figure 50101-38] at a time and apply loctite 242 or equivalent thread locker to the bolt and re-install the bolt. Torque the bolt to 35-40 ft.-lb. (47,5-54,2 N•m). Repeat for the three remaining pintle adjustment lock bolts. NOTE: To maintain proper adjustment setting, remove and reinstall only one bolt at a time. New bolts can be installed with pre applied loctite. Remove the loader remote start tool. NOTE: After the neutral adjustment is completed on both pumps, the linkage travel adjustment MUST be completed. (See Page 50-101-17.)

50-101-16


Figure 50-101-39

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Travel Adjustment

2 NOTE: When the linkage travel adjustment procedure is being done as part of the loader neutral adjustment procedure, check the torsion bushings at the pump and at the bell cranks to be sure they are not binding or too loose, which will affect the procedure.

1

2

1

WARNING P-48448



Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) [Figure 50-101-39] must be loosened enough to allow the torsion bushing to turn freely between the steering bellcrank and the linkage bar. Figure 50-101-40 1

WARNING 2



P-54613


Loosen the nut (Item 1) only until the tension is released from the torsion bushing (Item 2) [Figure 50-101-40].

Pre-load tension in the torsion bushings must be removed before adjusting the steering linkage.

The bolt must be loose enough to allow the torsion bushing (Item 2) [Figure 50-101-40] to turn freely between the torsion bushing and the linkage bar.

50-101-17


Figure 50-101-43

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Travel Adjustment (Cont’d)

2

Figure 50-101-41

1

3

1

4 P-51174

Move the right side steering lever forward and install a 15/16 inch (24 mm) thick spacer (Item 1) between the center plate (Item 2) and the mounting plate (Item 3) [Figure 50-101-43].

P-37574

Remove access plug from the top of the control panel. Turn the control lever drift adjustment bolts (Item 1) [Figure 50-101-41] (one on each control lever) out until it is flush with the bottom of the nut. Figure 50-101-42

This will allow the pintle arms to move freely while adjusting the steering linkage for full forward travel speed. Remove the 3/8 inch (10 mm) thick spacer (Item 4) [Figure 50-101-43]. Figure 50-101-44

3

2 2

1

4 1

P-51173

P-51133

Move the right side steering lever to the rear and install a 3/8 inch (10 mm) thick spacer (Item 1) between the pintle arm cam (Item 2) and the centering block (Item 3) [Figure 50-101-42].

Before adjusting the linkage, check that the base pintle arm mounting bolt (Item 1) and both of the upper pintle mount bolts (Item 2) [Figure 50-101-44] and tighten to 35-40 ft.-lb. (48-54 N•m) torque. There should be no play between the pintle arm and the square pump shaft. Also check that the cam mounting nuts or bolts (Item 4) [Figure 50-101-42] are tight, 35-40 ft.-lb. (48-54 N•m) torque .

50-101-18


Figure 50-101-47

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D) Linkage Travel Adjustment (Cont'd) Figure 50-101-45

1

1 1

P-51175

Remove the spacer (Item 1) [Figure 50-101-47]. P-54609

Disconnect the remote start tool. (See Procedure on Page 10-60-1.)

Loosen the two bolts and nuts (Item 1) [Figure 50-10145] on each steering linkage bar.

Figure 50-101-48

Figure 50-101-46

2

1

P-54613

P-51134

Tighten the two bolts (Item 1) and nuts (Item 2) to 35-40 ft.-lb. (47,5-54,2 N•m) [Figure 50-101-48].

Move the left control lever to the full forward position, then pull forward on the left rear linkage bar until the pintle arm is rotated to the front as far as possible [Figure 50-101-46]. Use a locking plier, clamp the two linkage bars together. Installation: Tighten the nuts and bolts to 35-40 ft.-lb. (47,5-54,2 N•m) torque. Check the lever movement to make sure that the pintle arm and the control lever are both at full stroke at the same time. This will allow for maximum forward speed. Repeat the linkage travel adjustment procedure for the right side linkage. 50-101-19


Figure 50-101-50

CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D) Linkage Travel Adjustment (Cont'd)

1

Figure 50-101-49

2

1

P-37574

Push the control lever to full stroke and turn drift adjustment bolt (Item 1) [Figure 50-101-50] in until it touches the U-bolt holding the control lever.

P-48448

Tighten the two bolts and nuts (Items 1 & 2) [Figure 50101-49] to 35-40 ft.-lb. (47,5-54,2 N•m) torque at the steering bell cranks.

Repeat steps on the other control lever. Drive the loader forward and check for drift. The traditional benchmark for drift is less than 10 ft. of “drift” in 100 ft. of travel distance. If the drift is excessive to the left, turn the right adjustment bolt (Item 1) [Figure 50-101-50] in. If the drift is excessive to the right, turn the left adjustment bolt in. NOTE: When using the drift adjustment bolts, only adjust one bolt for each test drive. In addition, only move each bolt a maximum of one turn for each test drive. This will help prevent over-correction and excessive reduction in travel speed. Drift adjustment is for forward travel only. Adjust the drift to an acceptable level. Re-install the plug in the drift bolt access hole after adjustment.

50-101-20


Figure 50-102-1

CONTROL PANEL (SJC) Removal And Installation


1

W-2017-0286

P-64311

Remove the lift arm by-pass control knob and rubber washer (Item 1) [Figure 50-102-1]. Figure 50-102-2

2

1

WARNING

1


4

W-2059-0598

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)

3

3 P-64319

Remove the fuse cover mount screws (Item 1) [Figure 50-102-2]. Installation: Tighten screws to 8-11 ft.-lb. (11-15 N•m) torque. Remove the fuse/relay cover (Item 2) [Figure 50-102-2]. Remove the fuse/relay shield mounting screws (Item 3) [Figure 50-102-2]. Installation: Tighten screws to 15-20 ft.-lb. (20-27 N•m) torque. Remove the fuse/relay shield (Item 4) [Figure 50-102-2]

50-102-1


Figure 50-102-5

CONTROL PANEL (SJC) (CONT’D) Removal And Installation (Cont’d) Figure 50-102-3

1

1

1 1

P-64298

1 Disconnect the left joystick wire harness connector (Item 1) [Figure 50-102-5].

P-64309

Remove the control panel mount screws (Item 1) [Figure 50-102-3] from the both sides of the control panel.

Remove the control panel from the loader.

Installation: Tighten the control panel mounting screws to 15-20 ft.-lb. (20-27 N•m) torque. Figure 50-102-4

1

P-64328

Disconnect the right joystick wire harness connector (Item 1) [Figure 50-102-4].

50-102-2


CONTROL HANDLE

Control Lever Boot

Control Lever Removal And Installation

Figure 50-110-3

Figure 50-110-1

2 1 N-18884

1 P-48462

Disconnect the electrical connectors from the control lever [Figure 50-110-1].

To replace the rubber boot (Item 1) [Figure 50-110-3] on the control panel, remove the control lever (See above procedure). Drill out the four rivets (Item 2) [Figure 50-110-3] located on the flange of the rubber boot and remove the old boot.

Figure 50-110-2

Install the new boot and reinstall the control lever.

1

2

1

N-22658

Remove the nuts from the two U-bolts (Item 1) [Figure 50-110-2] used to mount the control lever. Remove the U-bolts from the control lever mount. Remove the control lever (Item 2) [Figure 50-110-2] by sliding the lever through the rubber boot (Item 1) [Figure 50-110-3] on the front of the control panel. Installation: Tighten the U-bolts so the lever can not be moved either right or left when seated in the operator seat. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab.

50-110-1


50-110-2


Figure 50-111-2

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) Components Identification Figure 50-111-1

1

1 P-21879

Handle Sensor (Item 1) [Figure 50-111-2]. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure (ACS) on Page 60-16011.)

P16572

Control Handle (Item 1) [Figure 50-111-1].

50-111-1


Figure 50-111-5

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) (CONT'D) Handle Sensor Removal And Installation

1

Figure 50-111-3

2 1

P-21836

Disconnect the harness connector (Item 1) [Figure 50111-5] from the handle sensor connector. P-21864

Disconnect the harness connector (Item 2) [Figure 50111-5] from the handle lock solenoid connector.

Loosen the nuts (Item 1) [Figure 50-111-3]. Installation: Tighten the u-bolts so the lever can not be moved either right or left when seated in the operator seat. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab.

Figure 50-111-6

1

Figure 50-111-4

2

P-21861

1 Remove the handle sensor connector (Item 1) [Figure 50-111-6] from the clip. NOTE: Pry out with a small screw driver and push the connector down.

P-21837

Tilt the control handle (Item 1) [Figure 50-111-4] to the center of the loader. Lift the boot cover (Item 2) [Figure 50-111-4].

50-111-2


Figure 50-111-9

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) (CONT'D) Handle Sensor Removal And Installation (Cont'd) Figure 50-111-7

1 P-21880

Remove one of the two mounting screws (Item 1) [Figure 50-111-9] from the handle sensor.

1 P-21860

Remove the handle lock solenoid connector (Item1) [Figure 50-111-7] from the clip.

Installation: Tighten bolt to 32-38 in.-lb. (3,6-4,3 N•m) torque. Figure 50-111-10

NOTE: Pry out with a small screw driver and push the connector down. Figure 50-111-8

3

4

8 1

1

5 4

3

2

4 5 2

3

6 P-21882

Remove the handle sensor (Item 1) [Figure 50-111-10] from the handle assembly.

1 P-21862

Remove one of the two mounting screws (Item 1) [Figure 50-111-8] from the handle sensor. Installation: Tighten screws to 32-38 in.-lb. (3,6-4,3 N•m) torque.

NOTE: The handle sensor (Item 1) [Figure 50-111-10] can only be replaced as a complete assembly. Check the spacer (Item 2) and screws (Item 3), mounting pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut (Item 7), stop strap (Item 8) and replace as needed [Figure 50-111-10].

While removing the mounting pin (Item 2) from the handle sensor, remove the one plastic spacer (Item 3), the spring (Item 4) and washer (Item 5) [Figure 50-1118].

50-111-3


Control Handle Removal and Installation

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Figure 50-111-13

Handle Sensor Removal And Installation (Cont'd) Figure 50-111-11

3 2

1

1

P-21879

Remove the handle sensor (Item 1) [Figure 50-111-13]. (See Handle Sensor Removal And Installation on Page 50-111-2.)

P-21878

Figure 50-111-12

Figure 50-111-14 3

2

1

1 P-21799 P16534

Installation: When installing the handle sensor into the control handle, check the routing of the switch handle wire harness (Item 1) [Figure 50-111-11] & [Figure 50111-12] to assure proper return of the control handle to neutral and minimize harness movement.

Remove the switch handle (Item 1) [Figure 50-111-14]. (See Switch Handle Removal on Page 60-120-7.)

NOTE: Route wires (Item 2) [Figure 50-111-11] & [Figure 50-111-12] as shown away from stop strap (Item 3) [Figure 50-111-11] & [Figure 50111-12] to avoid wire damage. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure (ACS) on Page 60-16011.)

50-111-4


Control Handle Disassembly and Assembly


Figure 50-111-17

Control Handle Removal And Installation (Cont'd) Figure 50-111-15

1 2

1

2 N-17394

Remove the handle sleeve (Item 1) and bushings (Item 2) from the handle [Figure 50-111-17].

N-17384

Remove the rubber handle cover (Item 1) [Figure 50111-15] from the handle.

Check all parts for wear and replace as needed. Figure 50-111-18

Figure 50-111-16

1

2

2 1

N-22796 N-17385

Using a small screwdriver, hold the handle spacer (Item 1) and remove the allen head screws (Item 2) [Figure 50-111-16] from the handle assembly.

Check the mounting bolt (Item 1) [Figure 50-111-18] that connects the handle to the handle sensor for wear, replace as needed.

Installation: Tighten the allen head screws to 35 in.-lb. (4 N•m) torque.

50-111-5


Figure 50-111-20

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) (CONT'D) Control Lever Removal and Installation

1

Figure 50-111-19

1 1 1

1

N-22658

Figure 50-111-21 N-22667

Disconnect the electrical connectors (Item 1) [Figure 50111-19] from the control lever switch handle. Remove the electrical connectors from the control lever switch handle. (See ADVANCED CONTROL SYSTEM (ACS) on Page 60-120-1.)

18.25”

B-16618

Loosen the two u-clamps (Item 1) [Figure 50-111-20] nuts. Installation: Tighten the u-bolts so the lever can not be moved either right or left when seated in the operator seat. Control lever end (Item 2) [Figure 50-111-20] should be flush with bellcrank. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab. The distance between handles should be 18.25 inches [Figure 50-111-21]. Remove the control lever from the cross shaft and control panel.

50-111-6


Control Lever Boot


Figure 50-111-23

Control Lever Removal And Installation (Cont'd) Figure 50-111-22

2

2 1

1 N-22659

P13734

The control lever (Item 1) [Figure 50-111-22] must be replaced as a complete unit. The connector clip (Item 2) [Figure 50-111-22] can be replaced separately from the control lever.

To replace the rubber boot (Item 1) [Figure 50-111-23] on the control panel, remove the control lever. (See Control Lever Removal And Installation on Page 50-1101.) Drill out the four rivets (Item 2) [Figure 50-111-23] located on the flange of the rubber boot and remove the old boot. Install the new boot and reinstall the control lever. (See Control Lever Removal And Installation on Page 50-1101.)

50-111-7


50-111-8


Figure 50-112-3

CONTROL HANDLE (SJC) Joystick Testing (Right & Left)

1

Figure 50-112-1

3 2

P-28312

Disconnect the joystick harness connector (Item 1) from the loader wiring harness (Item 2) [Figure 50-112-3].

P-28301


Install the test harness (Item 3) [Figure 50-112-3] between the two connectors. Turn the remote start key to ON position without starting the loader.

MEL1608-Joystick Test Harness [Figure 50-112-1] MEL1563-Remote Start Tool Multimeter Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

Check the voltage between pin 3 and pin 5 on the joystick test harness (Item 3) [Figure 50-112-3]. The voltage should be between 2.45 and 2.55 volts. Figure 50-112-4

Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.) Figure 50-112-2 1

P-64328

1

Repeat the procedure at the right joystick wiring harness connector (Item 1) [Figure 50-112-4]. (If needed.)

P-64298

At the back side of the control panel, locate the left joystick wire connector (Item 1) [Figure 50-112-2]. 50-112-1


Figure 50-112-7

CONTROL HANDLE (SJC) (CONT'D) Joystick Removal (Right & Left) When replacing joystick assemblys, they are available as a complete assembly with the boot and lever already attached. This procedure is shown so the electrical connections can be checked at the bottom of the joystick, if suspected to be loose or disconnected.

1

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)

P-26222

Figure 50-112-5 Remove the two outside joystick mount screws (Item 1) [Figure 50-112-7]. Figure 50-112-8

1

P-26220A

Roll the joystick rubber boot (Item 1) [Figure 50-112-5] down from the joystick handle.

P-26223A

Figure 50-112-6 Remove the joystick from the rubber boot [Figure 50112-8]. 1

P-26221

Remove the two inside joystick mount bolts (Item 1) [Figure 50-112-6].

50-112-2


CONTROL HANDLE (SJC) (CONT'D)

Lever Assembly Removal (Right & Left)

Joystick Removal (Right & Left) (Cont'd)


Figure 50-112-9


1

Figure 50-112-10

1

P-26224

Disconnect the electrical harness (Item 1) [Figure 50112-9] from the joystick. P-64328

Remove the joystick from the loader.

Disconnect the joystick wiring harness connectors (Item 1) on both the right and left hand joysticks [Figure 50112-10].

50-112-3


CONTROL HANDLE (SJC) (CONT'D) Lever Assembly Removal (Right & Left) (Cont'd) Figure 50-112-11

1

P-64303

Remove the two control lever mounting bolts (Item 1) [Figure 50-112-11]. The mounting bolts are secured with lock-nuts on the back of the control panel. Once removed, they need to be replaced with new. Figure 50-112-12

P-64308

Remove the control lever from the loader [Figure 50112-12].

50-112-4


ELECTRICAL SYSTEM ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . 60-120-1 Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-120-12 ACS Controller Removal And Installation . . . . . . . . . . . . 60-120-5 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-16 Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1 Controller, Connector And Wire Identification . . . . . . . . . 60-120-4 Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-120-20 Foot Lock Solenoid Removal And Installation . . . . . . . . 60-120-19 Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-18 Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-120-18 Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6 Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-120-15 Handle Lock Solenoid Disassembly And Assembly. . . . 60-120-14 Handle Lock Solenoid Removal And Installation . . . . . . 60-120-14 Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-7 Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-120-9 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Regulator Test. . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-30-1 60-30-1 60-30-6 60-30-1 60-30-3 60-30-9 60-30-2 60-30-7 60-30-4 60-30-4 60-30-5 60-30-4 60-30-8 60-30-8 60-30-8 60-30-8

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . .

60-20-1 60-20-1 60-20-2 60-20-3


DRIVE SYSTEM

ELECTRICAL SYSTEM

ENGINE SERVICE

SPECIFICATIONS

Continued On Next Page

60-01

Service Manual

ELECTRICAL SYSTEM (CONT’D) BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 Additional Inspection For Loaders With Advanced Hand Controls (ACS) 60-90-2 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . . . . . 60-90-1 Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . 60-90-1 Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . 60-90-1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4 BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Actuator Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Calibration Procedure (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5 Lift and Tilt Calibration Procedure (SJC) . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . 60-71-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1 DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1 Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-2 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . 60-130-1 Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1 Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1 ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5 Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3 FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1 Continued On Next Page

60-02


ELECTRICAL SYSTEM (CONT’D) INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . . 60-50-10 Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6 Front Accessory Panel Removal And Installation . . . . . . . . . . . . . 60-50-12 Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Option And Field Accessory Panels (If Equipped) . . . . . . . . . . . . . . 60-50-8 Passwords (Deluxe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6 Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . . 60-50-3 Right Panel (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . . 60-50-2 Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . . 60-50-5 Standard & Deluxe Panel Removal And Installation (Left Side) . . 60-50-11 Standard Panel Removal And Installation (Right Side) . . . . . . . . . . 60-50-9 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 Connecting The Service PC To Remote Start Tool . . . . . . . . . . . . 60-150-1 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4 Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1 Description Of The Control System . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2 Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-7 Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-5 Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3 Inspecting The Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1 60-03

Service Manual

60-04


C105

+ -

C112 C107

-

C113

C104

4840 4830 4820 4810

2530

A

G

K

A

G

K

E

H J

DGN

YEL

RGN

WHT

WHT/BLK

B

F C

PUR

D

K D

LGN

WHT/LGN

WHT/RED

3600 120

C489

E

E

L P

9620

D

G 9410 F 9400

S

S

R

D

R

E 9210

G

G

9520

C

C

2240

H

H

1740

B

B

1170

A

A

D 9110

F

F

9420

9710

2710

B

C

G

1080

A

C404

+

-

1040

BATTERY

C426 ACD & REMOTE START CONNECTOR

TO OPTIONS (ATTACHMENT CONTROL)

V-0440 (7-12-05)

A B

K

B

N

K

RNG/DBL

N

4550

DETENT FLOW

RIGHT HANDLE HORN

RNG/WHT

6510

SKI CTRL

TWO SPD

FLOAT

C488

1490

4230

4940

H J

F C

E

D

4930

B

4920

4310

4910

4320

K

4300

4640

9610

E

1030 1310

25A

Printed in U.S.A.

9510

FUSE 12

YEL

P

1050 1300 1060

100A 1010

ACS

25A

F

25A

D

STARTER

9800

TRACTION PULL

SKI CTRL

(ACS)

1730

COMPUTER

FUEL PULL

DBL

1070 FUSE 12 25A

1160

FUSE 4

FUSE 10 ATTCHMNT

GLOW PLUG

WHT

1040

FUSE 8

6410

C492

FUSE / RELAY CENTER

1160

FUSE 9 25A (UNSWITCHED POWER)

J

L

9720

FUSE 5 30A

FUSE 6 30A

M

J

4275

1080

ALT & KITS

15A

YEL/LGN

30

1360 2050 2060

2040 2050 1350

2060

FUSE 4 (COMPUTER)

85

M

7200

4220

25A

85

87

TRACTION 87A LOCK

1110

30

86

1120

85

86

1130

87A 87

4100

30

86

4150

87A 87

4110

8110

8150

85

FUEL PULL

STARTER

1030

FUSE 3 15A

30

86

2030 2040 1060

2010 2020 1320

FUSE 2 15A

85

87A 87

8100

30

86

8210

85

87A 87

8200

30

8510

85

86

8550

30

87A 87

GLOW PLUG

REAR LIGHT

2020 2030 1330

(ATTACHMENT) FUSE 10 25A 1730

86

8500

87A 87

6210

MARKER LIGHT

SWITCHED POWER

1720

6200

6320

1720

6310

2720

A

6000

B

(ACS CONNECTOR) 1055

6300

FUSE 11

REAR LT

C

(ALTERNATOR & KITS) FUSE 11 25A

2000 2010 1050

FUSE 3

B G

1740

8010

25A

FUSE 7

D C

1150

25A

15A

B G

1140

FUSE 9

FR & MK LT

4840

A H

C411 TO OPTIONS (ACCESSORY CONNECTOR)

UNSWITCHED

30A

4830

E

4550 1700

D A

4275

S

C

6300

E

BRN

4235

C

DGN

4730

N

1150

FUEL PULL

4820

SIDE SHIFT

6400

RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES

SWITCH POWER

RGN

TURN SIGNAL

1140

REAR LIGHT

YEL/RED

6500

F D

(HEATER ) FUSE 1 25A

FRONT & MARKER LIGHT

J

LEFT HANDLE

6000

6600

L

MAINFRAME HARNESS 7101181

25A

-

PWM

2730

P M

1700

HEATER

F A

PULL 0.3 ohm

C407

1800

FUSE 2

F

SEE CAB CONNECTOR

TO OPTIONS (BACKUP ALARM SWITCH)

K

FUSE 1

4810

B

HOLD 10.9 ohm

B

30A

1480

B

C409

C410 H E

4100

A C

G

TRACTION

A J

2200

A C

R

FUSE 5

E

J

FUSE 6

H

A B

7100

TO OPTIONS (ACCESSORY CONNECTOR)

4240

C109

4300 4640

J2

C425

C103

4320

43 36 26

2520

1400

C101

C110

4310

9

A


LEFT

4920

4910

4200

6410

6600

2900 4940

8500

6500

4930

8560

6400

8570

E D

8580

6310

G C

40 30 20

9100

9340

HR HR HR HR 8590

6200

SEE FUSE/RELAY CENTER (EUROPEAN LIGHTING)

4500

+

2600

H A

2900 2770 2750 2760

H

C407

Traction Lock

GLOW PLUGS 1.0 ohm each


9200

41 4

4200

F B

RIGHT

8 48 17

7200

6510

9700

9600

9500

9800

1110

1120

1130

8100

4150

8800

B

2100

A

4110

B

8110

8100

8150

8800

B

2800

8800

A

B

C

8210

8200

A

C A

2800

8250

A

FRONT WORKLIGHTS

44 14 24 34 16

33 28 13

22

2910

10

G

38

6736515 8510

8250

46 5 15 44 4

16

20 32 40

30

GROUND

50

12

36 9

LEFT PANEL

19

8550

B

1200 1900

6 39

42

9340

49 3520

1210

48 7200

E

47

2910 2920 2930 2740

9350

24

19 29

ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)

3420

D

46

HEADLIGHTS

45

PROTECTED POWER

HORN

C434

HYD CHARGE PRESS SIGNAL

C435

8110

1910

6320

9110

2100

F H

3500

SYSTEM Tx

8550

COMPUTER POWER

9700

A B

A

6100

1130

9210

8150

K

4350

SYSTEM Rx

40

44

30

B

A

3920

14

3300

2900

39

9800

3900

2750

6100

38

43

3910

25 34

2900

37

9300

36

CLOCK/LATCH

35

42

50

35 45

9340

34

8000

49

9310

33

41

OPEN

OPEN

48

9330

32

1400

HYDRAULIC TEMP

9320

31 31

SPARE OUTPUT 2

47

J

8210 FUEL PULL RELAY

+5V SUPPLY

46 4500

A B

4450 MARKER LT RELAY

ATTACHMENT KEY INPUT

45 3920

DATA

28 1120 GROUND

SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)

OPEN

44 9340

START

29

27 ENG OIL PRESS +8v

6210

B A

8200

26 GLOW PLUG FEEDBACK

4470

40 4940

20 8800 STARTER RELAY

OPEN

6320

0.3 ohm 8250

19 6210 DIVERTER

CAN SELECT

8000

B

R S

18 4460

RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)

3010

4730

STARTER

M

17

39

A

J1

2010 HOLD PULL

1010

25 4730

FUEL RELAY HOLD

4200

38 38

FUEL SHUTOFF 10.9 ohm

BATTERY CABLE

24 9600

16 6510 F&R AUX RELIEF

J1 P01

REAR WKLT RELAY

HIGH FLOW / 900 LOAD

UNSWITCHED BATTERY (3)

25 1800 EXCITATION

23

15

BRAKE SW IN

43 4640

BUZZER C

ALTERNATOR

TRAVEL CONTROL

10 4110

4150

A B

3400

CAN LOW

RH SKI UP

9340

B

J1

14 9500

9 8510

FUEL PULL FEEDBACK

HANDLE POWER

1800

13 1110

TRACTION LOCK HOLD

8 6410

D3

A

A

12

RIGHT BLINKER

E3

G B

A

HYD CHARGE PRESS +8V

OPEN

6110

B

B R P S F E D C M A J H 9200

180 0

CAN HIGH

8250

22

7

GROUND

9200

3210

SEE J2-8


66

30 4930

GLOW PLUG TRACTION LOCK RELAY PULL / 963

LEFT BLINKER

4390

SEATBAR SIGNAL

42 9410

9320

B

SUPPLY 1020

A

3200

B

5

TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS

TWO SPEED SOLENOID OPEN

B

3200

4 4910

SPARE OUTPUT 1

HEADLIGHT SWITCH

41

FLOAT

29 4320

2110

4410

N K G L

RH SKI DOWN

28 3100

A

C408

See C492

9100

SPARE DIGITAL 2

3 3430

TWO SPEED OPEN MAKE-UP

36 4840

PWM SIGNAL

N K G L B R P S F E D C M A J

E G

9100

11

3510

RESERVED (BOOTSTRAP)

35 3910

FUEL SENDER

9410

4500

STARTER FEEDBACK

TWO SPEED SWITCH

37

34 9350

2930

2 2

HYD FILTER SIGNAL

STATUS OUT

33

OPEN

BUZZER

32 4420

LH SKI UP

RIGHT PANEL

SEATBAR GROUND

27

42

D F

4500

KEY/ENTER SWITCH

OPEN

26

4920

9110 9210

2740

OPEN

LH SKI DOWN

4830

4310

9400

1900

OPEN

BUCKET POSITION

4820

J2 P05

3700

11 7 23

1200

25 3900

20

2740

24 1900

RH FRONT DETENT

19

1900

23 9400

3600

PWM -

1200

1

21

A

SEAT BAR +8v

22 4430

9 4300

18

2770

OPEN OPEN

RESERVED (hall)

ENGINE HARNESS 7101311 A B

COMPUTER POWER

21

10

8 3200 AIR FILTER SIGNAL

1930 BRAKE SWITCH

RESERVED (AC INPUT)

2710

t

9200

4340

HYD LOCK SOLENOID

2350

ENGINE COOLANT SENDER 500-3000 ohm

1200

7

9330

49

12

17

STATUS IN

6

9310

37

3520

9210 SPARE DIGITAL 1

16

J

3500

3520

4810 LH AUX LEFT

15

9350

3500

C B

9100 SYSTEM Rx

14

3100

28

ENG SPEED SIGNAL

PWM +8V SUPPLY

3900

A

2900 PROTECTED POWER

13

COOLANT TEMP SIGNAL

B

6120

+8

9350

3

3430

3 4330 SPARE ANALOG 2

REAR ROD

5

L HAND SERIAL IN

-

3900

3430

LH AUX RIGHT

2

4440

FRONT BASE

B

4

SYSTEM Tx

FUEL SENDER 30-270 ohm

2760

C

9110

COMPUTER GROUND

B A

3920

B

B A

AIR FILTER SWITCH

B

3910

C

B

3110

A

3920

C

A B

SEAT BAR

3910

11

FRONT ROD

B

A

A

ENGINE OIL PRESSURE SENDER 0.5-7.5 V

48 8 18

REAR BASE

4360 R HAND SERIAL IN

DIFFERENTIAL SWITCH HARNESS 6728626

2120

B

MAIN FRAME

B

1

15 47 23

2110

2720

3310

HYDRAULIC TEMPERATURE SENDER 500-3000 ohm

A

CAB

SPARE ANALOG 1

31

2730

38

3200

32 12 22 1 41 3 21

2240

2740

10

3700

3010

2000

2600

2110

3420

3410

2200

2300

A

3710

SEE J1 B

3300

3400

3420

B

3510

4410

3400

A

4340

A C B

SEE J2

A B

4360

J2

2390

HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH

SPEED SENSOR

3300

J2 J1

2370

3610

A B

3100

2410

2800

B

3.3 ohm PWM

2

SEE C113

J1

2420

2380

3610

1

3700

11 ohm 12V

B

4330

A C B

A

C405 C406

A

4430

B

4440

A

2490

A

B

2

3600

1 2

SPOOL LOCK

C

1

2340

LOCK VALVE

4420

4490

B

1

A

DATA

2

2340

HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V

FRONT BASE 4340

FRONT AUX RELIEF

18 29 26

2100

2

START

2

9300

2330

9.8 ohm 12V

B

9220

2420

3.3 ohm PWM

9120

B

1

1920

2

1

CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H F

1

2480

4330

2000

4485

4420

A

COMPUTER POWER

4481

REAR AUXILIARY HARNESS 7101973

1220

2480

B

9350

4480

2

2920

1

A

C108

GREEN TIE STRAP

4410 2410 FRONT ROD

A

7.7 ohm PWM

2

BICS HYDRAULIC LOCK

WHITE TIE STRAP

LOCK VALVE

C417A

1 2

2480

1

4455

E

4451

D G

4450

GREEN TIE STRAP

4480

2

2450

GROUND

1

GREEN TIE STRAP

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

2450

RUN/ENTER SWITCH

2

PROTECTED POWER

1

4450

SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY

2330

2

1

CAB 6727178

2

2450

2

7.7 ohm PWM

C419 C106

A

B

YELLOW TIE STRAP

C416A

B

YELLOW TIE STRAP

YELLOW TIE STRAP

2430

2520

2

C418

B

C423

WIRES CONNECT BY LETTER ACROSS CONNECTORS A

A

C

2440

2380

1

C420

4440

2

1

2370

C421

1

4380

1

4370

LIFT SPOOL LOCK (NOT Used With AHC or ACS)

BROWN TIE STRAP

C422

2

9.8 ohm 12V

C424

2400

2430

BLUE TIE STRAP

4450

2440

2460

4460

2450

1

7.5 ohm 12V

4460

4470

2460

A B

C417

GROUNDS

B

C416

2530

4430

2

BUCKET POSITIONING

UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR

2470

A

C414

HIGH FLOW 7.5 ohm 12V

S175 (S/N 525211001 - 525218874) (S/N 525311001 - 525316211) S185 (S/N 525011001 - 525022472) (S/N 525111001 - 525115404) JULY 2005) Here (PRINTED V-0440


1

REAR BASE

C415

Printable Version Click

C413

WIRING SCHEMATIC (Without Options)

2

OPEN

TILT SPOOL LOCK (NOT Used With AHC or ACS)

REAR ROD

1

7.5 ohm 12V


B

1610

4750

2750

B

A

C

B C

A

B

A

C

C105

+ -

C112 C107

-

C113

C104

C101

C110

3600

B C A

C

ACS HARNESS 6733292

C469 A

2760

C

120

A

B

2660

A

4660

B

C450 B C

C

A

1520

C

4760

A

AHC TILT HALL SENSOR

B

C B

1620

A B

C404

RGN

A

A C B

A B

A C B

DETENT FLOW

E

RIGHT HANDLE

SKI CTRL

H

4770

F

4670

G

LGN

J2 BLACK J

HANDLE LOCK TWO SPD

C488

K

YEL

ACS Controller Advanced Control System

K

WHT/LGN

C489

A

G

DGN

C109

K

H J

C103

G

A

2530

1490

4230

4940

E

A

LIFT PEDAL

H J

1500

V-0441 (7-12-05)

E

P

J1

4650

1080

4930

F

+

-

1040

BATTERY

4920

D 9110

C471

ACD & REMOTE START CONNECTOR

4910

2670

4670

B


WHT

1

1740

C470

B

1310

25A

C426

WHT/BLK

1

F

G

ACS

A

FUSE 12

1030

C

1010

E

1060

100A

WHT/RED

BLK

A

2710

9710

9610

9510

25A

F

STARTER

B

DGN

1170

-

A B

B

B

TILT PEDAL

F C

RNG/DBL

RNG/WHT

YEL

4680

1530

B

1050 1300

D

ALT & KITS

TRACTION PULL

9800

FUSE 11

REAR LT

1730

FUSE 3

D

FLOAT

SKI CTRL

2 3

4

F

5

D

E

A B C D

1160

25A

FUSE 7

ATTCHMNT

F C

PUR

DBL

2 3

A

4750

1040

15A

D

WHT

4 5

K

GREY J3

1080

FR & MK LT

30A

FUSE 10

B

K D

YEL/LGN

RED

G H

RED

1740

2280

4690

D

2250

9620

J H

4680

9520

2240

F

4690

9520

H

C

2770

C

H

C B G E 4550

9720

6 7 8

C

2240

G

4310

C

D A

6 7 8

G

9520

9420

R

4770

E 9210

R

S

1 2

S

1630

G 9410 F 9400

4780

9620

4780

9720

D

3

E

4 5

E D

1740

(ACS)

4550

9720 9620

4790

K

C429

4790

1070 FUSE 12 25A

A N

K

2270

FUSE / RELAY CENTER

1160


P N

4550

C492


1170

6410 6510

2260

1360 2050 2060

2040 2050 1350

2060

1030

FUSE 5 30A

FUSE 6 30A

4275

4220

30

6 7 8

87

J L

4260

85

2500

86

85

J L

1190

86

4220

7200 4275

1180

30

2510

87A 87

85

M

M

4270

4280

86

FUSE 4 (COMPUTER)

30

4220

25A

87A 87

TRACTION 87A LOCK

1110

85

1120

86

1130

30

2030 2040 1060

FUSE 3 15A

87A 87

FUEL PULL

STARTER

4100

85

2010 2020 1320

2020 2030 1330

2000 2010 1050 FUSE 2 15A

86

4150

30

4110

87A 87

8110

85

8150

86

GLOW PLUG

REAR LIGHT

8100

30

8210

87A 87

8200

85

8510

86

8550

30

8500

87A 87

6210

MARKER LIGHT

SWITCHED POWER

1720

6200

6320

6310

1055

6000

1720

6300

2720

A

8010

B

4320

K

B G

DGN

1510

A B

C428 (ALTERNATOR & KITS) 1800 FUSE 11 25A

4300

4640

D C

B G

4840

4830

4820

SIDE SHIFT

C

E

C468

25A

FUEL PULL

Printed in U.S.A.

BRN

A B

C467

1 2 3 4 5 6 7 8

A B A B

FUSE 9

SWITCH POWER

25A FUSE 2

25A

LIFT ACTUATOR

M

UNSWITCHED

REAR LIGHT

30A FUSE 6

COMPUTER

RGN

1150


FUSE 4

YEL/RED

H

TILT ACTUATOR

M 1740

1150

FUSE 8

J

1140

1140

FUEL PULL

F A

1700

A


GLOW PLUG

F

S


13 ohm 12V

FOOT PEDAL LOCK

(ATTACHMENT) FUSE 10 25A

15A

A J

4550

4650

4275

E


BLK

6300

C

2650

4235

N

DGN

D

BLK

4730

RED

F

1730


HORN

C472

RED

6400

C466

PWM

TURN SIGNAL

C449

BLK

6500

1700

HEATER

H

C407

K

FUSE 1

+

HANDLE LOCK

LEFT HANDLE

G

TRACTION

4240

C465

PULL 0.3 ohm

B

FUSE 5

4810

B

R


1480

B

C409

C410 HOLD 10.9 ohm

A B

4100

A C

A B

2200

A C

6000


6600

LEFT

4810

2730

L

RIGHT

4820

H E

J

FRONT WORKLIGHTS

4830

A P

2910

4840

E

SEE CAB CONNECTOR


M

G

4300 4640

J2

C425

A B

GROUND

4320

AHC LIFT HALL SENSOR

7100

LEFT PANEL

4310

2520

1400

6600

4920

4910

4200

6410

6500

2900 4940

8500

6400

4930

9100

8560

8590

6310

8570

HR HR HR HR

6200

8580

2600

H A E


9340

Traction Lock


D

H

C407

8100


G C

40 30 20

41 4

4200

F B

9340

8 48 17

7200

6510

9700

9600

9500

9800

1110

1120

1130

4150

2100

4110

8800

8110

A B

8150

A B

2800

8800

8200

8800 8100

C

8210

A

A B

C

8250

8250

1210

44 14 24 34 16

33 28 13

22

E

10

D

38

2900 2770 2750 2760

4500

16

20 32 40

2910 2920 2930 2740

J1 2800

8510

B

9200

36 26

30

HEADLIGHTS

12

36 9

PROTECTED POWER

19

C434

39

42

8550

B A

46 5 15 44 4

6

6736515

A B

1200 1900

9 43

50

C435

49 3520

1910

48 7200

9110

47

A B

9350

24

19 29


3420

F H

46

SYSTEM Tx

45

COMPUTER POWER

HORN

B

A

6100


9210

8110

K

6320

SYSTEM Rx

2100

2900

3500

44

30

2750

A

3920

14

3300

A

6100

8550

9800

50

3900

2900

9700

9300

1130

9310

8150

9330

4350

J

40

A B

39

DATA

38

START

37

CLOCK/LATCH

36

43

49

3910

25 34

9340

35

42

OPEN

OPEN

48

35 45

6110

B


34

8000

HYDRAULIC TEMP

N K G L

9100

33

41

40 4940

9340

32

1400

39

9200

31 31

SPARE OUTPUT 2

38 38

9100


+5V SUPPLY

47

9320



46 4500

9320

28 1120 GROUND


45 3920

BUZZER

29


6210

8200

26 4470

RH SKI UP


GLOW PLUG FEEDBACK

6320

0.3 ohm 8250

19 6210 DIVERTER

OPEN

8000

B

R S

18 4460


CAN SELECT

4730

STARTER

M

17

44 9340

BUZZER C

2010 HOLD PULL

1010

25 4730

FUEL RELAY HOLD

4200

OPEN

FUEL SHUTOFF

10.9 ohm

BATTERY CABLE

24 9600

16 6510 F&R AUX RELIEF

J1 P01

REAR WKLT RELAY


3010

25 1800 EXCITATION

23

15

GROUND

4500

ALTERNATOR

TRAVEL CONTROL

10 4110


A B

3400

CAN LOW

OPEN

43 4640

2930

B

J1

14 9500

9 8510

4150

HANDLE POWER

1800

13 1110

TRACTION LOCK HOLD

8 6410

D3

A

A

12

RIGHT BLINKER

E3

G B

A


BRAKE SW IN

42 9410

RIGHT PANEL

180 0

CAN HIGH

8250

22

7

30 4930

A

C408

See C492 G

RH SKI DOWN

29 4320

B

6120


E

4500

3210

SEE J2-8


66

SEATBAR SIGNAL

41

9410


LEFT BLINKER

4390

HEADLIGHT SWITCH

PWM SIGNAL

28 3100

2110

4410

FLOAT

FUEL SENDER

42

F

2740

B

SUPPLY 1020

A

3200

B

5

SPARE OUTPUT 1

FUEL PULL FEEDBACK


B

3200

4 4910


21

A

3 3430


36 4840

4920

D

9110 9210

1900

SPARE DIGITAL 2


35 3910

4310

9400

1200

STARTER FEEDBACK

TWO SPEED SWITCH

37

34 9350

3700

11 7 23

2740

2 2

HYD FILTER SIGNAL

STATUS OUT

33

OPEN

20

1900

32 4420

LH SKI UP

RH FRONT DETENT

19

1200

SEATBAR GROUND

27

3600

PWM -

2770

KEY/ENTER SWITCH

OPEN

26

1930 BRAKE SWITCH

OPEN

LH SKI DOWN

4830

9330

OPEN

BUCKET POSITION

4820

J2 P05

9310

25 3900

J

24 1900

B

23 9400

DATA

1

11

3510


SEAT BAR +8v

22 4430

START

OPEN OPEN

RESERVED (hall)

2710

t

COMPUTER POWER

21

9 4300

18

9350

RESERVED (AC INPUT)

2350


9200

10

8 3200 AIR FILTER SIGNAL

9300

49

1200

7

CLOCK/LATCH

37

3520

12

17

STATUS IN

6

9350

3500

3520

9210 SPARE DIGITAL 1

16

3900

3500

C B

4810 LH AUX LEFT

15

4340

HYD LOCK SOLENOID

A

9100 SYSTEM Rx

14

3100

28

ENG SPEED SIGNAL

PWM +8V SUPPLY

3920

B

2900 PROTECTED POWER

13

COOLANT TEMP SIGNAL

2760

+8

3910

3

3430

3 4330 SPARE ANALOG 2

REAR ROD

5

L HAND SERIAL IN

-

3900

3430

LH AUX RIGHT

2

4440

FRONT BASE

B

4

SYSTEM Tx


B A

3920

C

B

B A

AIR FILTER SWITCH

B

3910

C

3110

A

A

A


A B

SEAT BAR

C

9110

COMPUTER GROUND

B

MAIN FRAME

B

11

FRONT ROD

REAR BASE

4360 R HAND SERIAL IN

DIFFERENTIAL SWITCH HARNESS 6728626

2120

48 8 18

9220

1

15 47 23

2110

2720

B


A

CAB

SPARE ANALOG 1

31

2730

38

3200

3010

32 12 22 1 41 3 21

2240

2740

10

3700

3420

3410

2000

2600

2110

3400

3420

2200

2300

3310

3710

SEE J1 B

3300

3400

B

3510

4410

A C B

A

4340

J2

SEE J2

A B

A

J2 J1

2390


SPEED SENSOR

3300

3700

11 ohm 12V

B

2370

3610

A B

3100

2410

2800

3.3 ohm PWM

2

SEE C113

J1

2420

2380

B

1

C405 C406

A

4360

B

4330

A

2490

4430

B

3610

2

4440

A C

B

A

1

A C

2

3600

LOCK VALVE

4420

4490

9120

1

SPOOL LOCK


1

2340

2

2340

2100

4340

FRONT AUX RELIEF

18 29 26

2330

9.8 ohm 12V

B

FRONT BASE

LOCK VALVE

A

1920

2

A K

1

2480

H F

4485

2

SYSTEM Tx

4481

REAR AUXILIARY HARNESS 7101973

2

SYSTEM Rx

2480

2330

COMPUTER POWER

4480

2

2420

3.3 ohm PWM

1220

1

B

1

2000

2480

GREEN TIE STRAP

1

9350

4455

4330

2920

4451

4420

C108

1 2

4480 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

4450

GREEN TIE STRAP

C417A

GREEN TIE STRAP

2 1

2450

2450

A

A

GROUND

1

4450


2 1

B

CAB 6727178

2

2450

A

FRONT ROD

C

A

B

YELLOW TIE STRAP

C416A

B

YELLOW TIE STRAP

YELLOW TIE STRAP

4410 2410

C419 C106

B

2

BICS HYDRAULIC LOCK

WHITE TIE STRAP

C418

WIRES CONNECT BY LETTER ACROSS CONNECTORS A

A

9.8 ohm 12V

2430

2520

2

OPEN

2440

2380

2370

C420

4440

2

1

C421

1

4380

1

4370


BROWN TIE STRAP

C422

2

C423

2400

2430

BLUE TIE STRAP

4460

2440

2460

4450

2450

1

7.5 ohm 12V

4460

4470

2460

A B

C414

GROUNDS

B

C424

2530

4430

2

BUCKET POSITIONING


2470

C413


A

C417



C416

S175 (S/N 525211001 - 525218874) (S/N 525311001 - 525316211) S185 (S/N 525011001 - 525022472) (S/N 525111001 - 525115404) (PRINTED JULY 2005) Here V-0441

1

REAR BASE

C415

WIRING SCHEMATIC (With ACS Option)

2

PROTECTED POWER E RUN/ENTER SWITCH D G


REAR ROD

1

7.5 ohm 12V

C110

C105 C108

C416

C424 C417

3600 OPEN

GROUND

OPEN

36

37

38 38

39

9350

3910

4840

C112

FLOAT

HEADLIGHT SWITCH

SEATBAR SIGNAL

BRAKE SW IN

OPEN

HYDRAULIC TEMP

42

43

44

45

46

47

48

C107

B

A

3500

3500

37

C B

3520

3520

49


SPARE OUTPUT 1

LEFT BLINKER

5

66

7

8

9

10

3430

4910

6410

8510

4110

REAR WKLT RELAY

FUEL RELAY HOLD

STARTER FEEDBACK

RESERVED (hall)

11

3510

+ -

-

A B

3210 180 0

3200

1800

B

23

24

25

3010

9600

4730


CAN SELECT

31

32

33

34

4350

8150

1130

9700

HANDLE POWER


41

42

1400

8000

17

18

4200

4460

19


26

27

28

8800 STARTER RELAY

29 4450

8210

OPEN

GROUND

MARKER LT RELAY

FUEL PULL RELAY

35

36

37

38

39

40

8550

3500

2100

6320

8110


HORN

47

48

49

7200

3520

44

SPARE OUTPUT 2

45

46

3420

9800


50

39

42

19

12

36 9

20 32 40

30

38

10

44 14 24 34 16

33 28 13

22

8 48 17

1900

46 5 15 44 4

9200

40 30 20

4930

9100

9340 2900 4940

4920

19 29

4310

9

4300

43 36 26

4640 4840

16

4820

4320

4830

4810

J2

K K

LGN

D B

RGN

YEL

DGN

WHT/LGN

WHT

WHT/RED

120

C489

N

4550

K

K

9720

E

E

9620

D

G 9410 F 9400

S

S

R

R

E 9210

G

G

9520

C

C

2240

H

H

1740

B

B

1170

A

A

D 9110

F

F

D 9420

B

G

1080

A

C404

+

-

1040

BATTERY



V-0717 (7-12-05)

DETENT FLOW

N

SKI CTRL

TWO SPD

C488

2530

G A H

1490

4230

G A H

4940

4930

4920

4910

WHT/BLK

J E F C

D B

J E F C

4310

4320

2710

C

1030 1310

25A

Printed in U.S.A.

9710

1010

FUSE 12 ACS

25A

9610

STARTER

9510

TRACTION PULL

F

FUEL PULL

4300

P

6510

A B

P

RNG/DBL

L

6410

1050 1300 1060

100A

D

GLOW PLUG

COMPUTER

25A

E

ATTCHMNT

9800

FUSE 4

FUSE 10

1730

FUSE 8

(ACS)

1160

ALT & KITS

K

1040

FUSE 11

REAR LT

15A

1070 FUSE 12 25A

J

L

B

FUSE / RELAY CENTER

1160


M

J

4275

C492

FUSE 5 30A

FUSE 6 30A

M

7200

1080

FUSE 3

RIGHT HANDLE HORN

RNG/WHT

30

1360 2050 2060

2040 2050 1350

2060

FUSE 4 (COMPUTER)

85

4220

25A

85

1110

30

86

TRACTION 86 87 87A LOCK

1120

85

1130

87A 87

4100

30

86

4150

87A 87

4110

8100

8110

85

FUEL PULL

STARTER

1030

FUSE 3 15A

30

86

2030 2040 1060

2010 2020 1320

2020 2030 1330

2000 2010 1050 FUSE 2 15A

85

87A 87

8150

30

86

8210

85

GLOW PLUG

REAR LIGHT 87A 87

8200

30

86

8510

85

87A 87

8550

30

86

8500

87A 87


6210

MARKER LIGHT

SWITCHED POWER

1720

6200

6310

6320

1720

6000

2720

A

1055

6300

B

(ACS CONNECTOR) 8010

25A

FUSE 7

YEL

(ALTERNATOR & KITS) FUSE 11 25A

25A

15A

SKI CTRL

1740

FUSE 9

FR & MK LT

FLOAT

1150

UNSWITCHED

30A

DBL

1140


1150

FUEL PULL

PUR

A H


SWITCH POWER

WHT

1700

1140

REAR LIGHT

K D C B

C411

4550

S



4640

4275

E


25A

4840

D A C E

6300

BRN

4235

C

DGN

4730

N

1700

HEATER

4830

SIDE SHIFT

6400

D

1800

FUSE 2

RGN

6500

F

K

FUSE 1

YEL/RED

6600

L

6000

P M

B

30A

YEL/LGN

TURN SIGNAL

G

TRACTION

D C B G

LEFT HANDLE

C407

R

FUSE 5

-

PWM

2730

J

FUSE 6

4820

B

8500

SEE CAB CONNECTOR


8580

A B

7100


4810

A

A


1480

OPEN

2200

C409

C410 E

B

A B

F A J H

4200

8560

6600

G F A J

H E

B

A C

HR HR HR HR 8570

6500

4240

4100

C425

2200

A C

+

2600

6400


4500

2520

1400

C109

1200

24

Brake Valve

8590

C103

A

6732781

6310

E

H

B R P S F E D C M A J H

C407

8100

6200

D

2770 2750 2760

9350

14

8200

G C

N K G L

3920

8250


F B H A

2900

2740

C408

See C492

4910

4200

6410

7200

6510

9700

9600

9500

9800

1110

1120

1130

4150

2100

4110

8110

8150

8800

8800

2800

A B

8210

C

8250

8100

8510

8800

8550

C A B

2800

A B

4200


3900

B

2910 2920 2930

J1 6210

B A

3910

25 34

41 4

6736515

A B

35 45

3300

4500

30


4470

50

20

6210 DIVERTER

GLOW PLUG FEEDBACK

6320

B A

8200

J1 P01

+5V SUPPLY


8000

0.3 ohm 8250

43

16

49


E G

9410

6

4730

M

F&R AUX RELIEF

15

3920

OPEN

OPEN

FUEL SHUTOFF HOLD PULL

B

6510

TRAVEL CONTROL

25

1800 EXCITATION

2010

R S

3400

CAN LOW

22

A

STARTER

BATTERY CABLE

SEE J2-8

J1

10.9 ohm 1010

A

C101

ALTERNATOR

B A

14 9500


E3

A B

A

13 1110

TRACTION LOCK HOLD

D3

G

C110

SUPPLY 1020 B

B

3200

RIGHT BLINKER

12

4150 TWO SPEED SOLENOID OPEN

C113

C104

A B


FUEL PULL FEEDBACK

21

t

CAN HIGH

8250


SPARE DIGITAL 2

ENGINE HARNESS 7101311


4390

9340

4640

40

2110

STATUS OUT

41

9410

RH SKI UP

4940

HYD LOCK SOLENOID

D F

LEFT

4320

LH SKI UP

35

9110 9210 9400

RIGHT

C

B


4

FRONT WORKLIGHTS

3100

SEATBAR GROUND

34

2910

3900

KEY/ENTER SWITCH

33

9340

1900

OPEN

GROUND

9400

BUCKET POSITION

HEADLIGHTS

4430

OPEN

LEFT PANEL

C

TWO SPEED SWITCH

3

1210

A


HYD FILTER SIGNAL

2

G D E

4930

4340

PROTECTED POWER

30

4410 OPEN

1

C434

RH SKI DOWN

29

25


RESERVED (AC INPUT)

C435

PWM SIGNAL

28

SEAT BAR +8v

24

1910

4920

FUEL SENDER

27

COMPUTER POWER

23

9110

3

3430

9210

4310

OPEN

26

9200

STATUS IN

22

SYSTEM Tx

3700

LH SKI DOWN

1200

REAR ROD

21

4830

SYSTEM Rx

4440

FRONT BASE

32 4420

A

A

6100

9110

AIR FILTER SIGNAL

2900

18

4820

A B

6100

17

2900

SPARE DIGITAL 1

16

9340

LH AUX LEFT

15

9340

SYSTEM Rx

14

9200

6

20

PROTECTED POWER

13

9100

6

RH FRONT DETENT

19

SPARE ANALOG 2

12

9200

3440

B

PWM -

REAR BASE

11

11 7 23 42

9100

A

10 3600

4500

A B

9 4300

3100

28

ENG SPEED SIGNAL

PWM +8V SUPPLY

8 3200

R HAND SERIAL IN

31 HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH

COOLANT TEMP SIGNAL

7 9210

J2 P05

6110 2750

4500

B

L HAND SERIAL IN

6 4810

2740

3010

LH AUX RIGHT

5 9100

1900

3420 3410

SYSTEM Tx

4 2900

1900

15 47 23

3400

4

COMPUTER GROUND

3 4330

2740

3 5

FRONT ROD

1200

4

2

9350

5

3410

J

SPARE ANALOG 1

1 4360

3900

3

3420

3310

SPOOL LOCK

1200

3400

H SEE J2-48

9350

A C B

3300

B

A

+8

3920

B

3310

1 2

B

6120

48 8 18

38

3910

C

B

1 2

-

3900

A

C

3300


2760

C

A

A B

10

32 12 22 1 41 3 21

B A

3920

A B



B A

3910

2240

B

3110

AIR FILTER SWITCH

SEAT BAR

B

J2

HARNESS 7112802 HYDRAULIC TEMPERATURE SENDER 500-3000 ohm

2000

3710

A B

A

2390

2370 2200

A

J2 J1

29 26

18

COMPUTER POWER

SEE C110

3100

J1

MAIN FRAME

2770

3200

B

3700

2110

3300

4410

4340

2380

4360

2350

B

4330

2710

2410

B

9.8 ohm 12V

4430

2420

2480

A

9300

SEE C110

SEE C113

3700 4440

2720

A

4470

2120

4450

2730

4460

2740 2100

4480

F H K A

H A

J

4420

2520

CLOCK/LATCH

SPEED SENSOR

CAB

2110

9310

A B

REAR AUX RELIEF

2330

9330

B

C405 C406

2340

9320

11 ohm 12V

B J C

A

3610

1930 BRAKE SWITCH

A B

2600

DATA

3600

2000

A B

2490

START

7.5 ohm 12V

3.3 ohm PWM

FRONT AUX RELIEF 4490 GREEN TIE STRAP

9320

A B

2930

A B

2450

1 2

CAB 6727178

DIVERTER

C419 C106

1 2

2340

4450

9330

FRONT BASE 4340

YELLOW TIE STRAP

9310

3.3 ohm PWM

9300

1 2

9220

1 2

9120

2330

1920

4330

2420

1220

4420

9.8 ohm 12V

9350

A B

A B

2920

A B

FRONT ROD

BUZZER

A B

2410

BUZZER

BICS HYDRAULIC LOCK

4410

WHITE TIE STRAP

RIGHT PANEL

2440

BLUE TIE STRAP

START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E

4440

2

7.7 ohm PWM

2

RUN/ENTER SWITCH

1

1

PROTECTED POWER

2

2

7.7 ohm PWM

D G C

2460

2380

1 2

OPEN

1

7.5 ohm 12V

4460

1

2370

C420

A B

4380

1 2

4370


BROWN TIE STRAP

GROUND

2430

C418

2430

B

C423

2300

3510

A


3610 2400

4430

2

BUCKET POSITIONING


2800

2440

1

C422


C414

A

9.8 ohm 12V

2470

2450

B

2

REAR BASE


GROUNDS

2460

B

C413

2530

A

C415

S175 (S/N 525218875 AND ABOVE) (S/N 525316212 AND ABOVE) S185 (S/N 525022473 AND ABOVE) (S/N 525115405 AND ABOVE) Here (PRINTED JULY 2005) RELAY GROUNDS 2000-2060 V-0717 ARE CONNECTED IN SERIES



REAR ROD

1

7.5 ohm 12V

WIRES CONNECT BY LETTER ACROSS CONNECTORS

C421

WIRING SCHEMATIC (Without Options)


C110

C416

C424

4110

REAR WKLT RELAY

FUEL RELAY HOLD

A

3500

3500

37

C B

3520

3520

49

11

3510

B

23

24

25

3010

9600

4730

CAN SELECT

31

32

33

34

4350

8150

1130

9700

HANDLE POWER


41

42

1400

8000

43

16

J1 P01

17

18

4200

4460

19


26

27

28

8800 STARTER RELAY

29

30

1120

4450

8210

OPEN

GROUND

MARKER LT RELAY

FUEL PULL RELAY

35

36

37

38

39

40

8550

3500

2100

6320

8110


HORN

47

48

49

7200

3520

44

SPARE OUTPUT 2

45

46

3420

9800


50

39

19

12

36 9

20 32 40

30

38

10

44 14 24 34 16

33 28 13

22

8 48 17

40 30 20

4930

4500 9100

9340 2900 4940

4920

19 29

4310

9 43

4300

4320

4640

36 26

4840

16

4820

4830

4810

J2

AHC TILT HALL SENSOR

B C A

B

A B

RGN

C450 B C A B C A

C469 B C A 2750

B C A

ACS HARNESS 6733292

1610

2760

4750

120

A B

C404

K

C488

K

DETENT FLOW

SKI CTRL

C489

2530

LGN

1490

4230

G A H

2660

4760

4660

G A H

B

4940

1520

RIGHT HANDLE

C466

HANDLE LOCK TWO SPD

A C

YEL

B

1620

DGN

V-0718 (7-12-05)

A C B

WHT/LGN

E

4930

H

4920

1080

C471

LIFT PEDAL

+

-

1040

BATTERY

A C

C470

B


G

A

1310

25A

C

ACS

1030


A C B

4910

WHT

2670

4670

F

4770

G

4670

J

4650

2710

9710

9610

9510

1010

FUSE 12

F

STARTER

1060

100A

E

TRACTION PULL

25A

TILT PEDAL

1050 1300

D

ALT & KITS

9800

FUSE 11

REAR LT

ATTCHMNT

1730

FUSE 3

1160

25A

FUSE 7

FUSE 10

WHT/BLK

1

J2 BLACK K

WHT/RED

BLK

ACS Controller Advanced Control System

A B C D

J E F C

A B

B

A

J1

D B

RNG/DBL

RNG/WHT

YEL

B

1500

H

J E F C

SKI CTRL

FLOAT

1740

P

G

2280

D B

K

DBL

PUR

WHT

F

2250

1740

4310

K D C B

A F

2240

B

4320

4300

4640

4840

1170

D 9110

H

4680

B

D

1530

F

2 3 4

H

F E

9520

1 2

2240 1740

9720 9620 9520

3 4 5

4690

D

4750

1040

15A

Printed in U.S.A.

4680

C

R G

1080

FR & MK LT

30A

25A

A

GREY J3

25A

FUEL PULL

COMPUTER

K

4690

C

J H

2770

G

9520

C B G E C

4550

5 6 7 8

E 9210

9420

FUSE 9

SWITCH POWER

25A FUSE 2

FUEL PULL

6 7 8

S

4770 1630

G 9410 F 9400

9720 9620

1 2 3

D

UNSWITCHED

REAR LIGHT

30A FUSE 6

GLOW PLUG

4780

E

R

4780

E D

4 5

(ACS)

4550

9720 9620

S

4790

1070 FUSE 12 25A

K

C429

4790

FUSE / RELAY CENTER


A N

K

6 7 8



1160

P N

4550

2260

1150

1170

6410 6510

C492

1140

4275

2270

1360 2050 2060

2040 2050 1350

2060

1030

FUSE 5 30A

FUSE 6 30A

L

1190

30

J

L

4220

85

J

4275

4260

85

2500

86

4220

7200

1180

30

4270

87A 87

85

M

M

2510

4280

86

FUSE 4 (COMPUTER)

30

4220

25A

87A 87

1110

85


1120

86

1130

30

2030 2040 1060

FUSE 3 15A

87A 87

4100

85

2010 2020 1320

2020 2030 1330

2000 2010 1050 FUSE 2 15A

86

FUEL PULL

STARTER

4150

30

4110

87A 87

8100

85

8110

86

GLOW PLUG

REAR LIGHT

8150

30

8210

87A 87

8200

85

8510

86

8550

30

8500

87A 87

6210

MARKER LIGHT

SWITCHED POWER

1720

6200

6310

6320

1055

6000

1720

6300

2720

A

8010

B

DGN

A B

C428 (ALTERNATOR & KITS) FUSE 11 25A

RED

C468

RED

A B

C467

1 2 3 4 5 6 7 8

A B A B

BLK

1150

DGN

H

LIFT ACTUATOR

M

1740 BLK

1140

RED

A

TILT ACTUATOR

M RED

1700

BLK

S


13 ohm 12V

FOOT PEDAL LOCK


FUSE 4

4830

4550


FUSE 8

YEL/LGN

4275

1700

15A

D C B G

6300

E

C412


1510

4235

C

4650

4730

N

C411

C472

2650

F D

1800


4820

6400

K

HEATER

DGN

6500

6000

6600

L

G

FUSE 1

HORN

2730

P M

B

TRACTION

SIDE SHIFT

C449

R

FUSE 5

YEL/RED

C407

D A C E

J

4810


-

PWM

TURN SIGNAL

BRN

A B

SEE CAB CONNECTOR

+

HANDLE LOCK

LEFT HANDLE AHC LIFT HALL SENSOR

7100


RGN

C465

A


F A J H

6600

G F A J

6500

OPEN

2200

A B

8500

6400

8580

8590

E

B

A B

A B

B

4200

A B

4100

A C

8560

HR HR HR HR

6310

8570

2600 6200

D

E


C425

2200

A C

C409

C410

Brake Valve 6732781

8200

G C

4240

H E

8100

1480

2520

1400

4910

C109

9200

8250


C103

46 5 15 44 4

8800

4200

F B H A

1900

41 4

4200

6410

7200

6510

9700

9600

9500

9800

1110

1120

1130

4150

2100

4110

8110

8150

8800

8210

C A B

8250

C A B

8510

8800 8100

8550

B A

2800

A B

2800

6210

B A


J1 6736515

A B

1200

24

6 42

2770 2750 2760

9350

14

3300

20

6210 DIVERTER

ENG OIL PRESS +8v

4470

+5V SUPPLY



GLOW PLUG FEEDBACK

6320

8200

15


22

8000

0.3 ohm 8250

F&R AUX RELIEF

4730

M

6510

TRAVEL CONTROL

50

FUEL SHUTOFF HOLD PULL

B

3400

CAN LOW

25

1800 EXCITATION

2010

R S

14 9500

4150

A

STARTER

BATTERY CABLE

SEE J2-8

J1

10.9 ohm 1010

A

13 1110

49

A

C113

C104

1800

C101

ALTERNATOR

3200

12 8250

TRACTION LOCK HOLD

E3

A B

B A

RIGHT BLINKER

D3

G B

C110

SUPPLY 1020

A


OPEN

OPEN

C

-

180 0

48

A

-

3210

CAN HIGH

FUEL PULL FEEDBACK


B

3200



SPARE DIGITAL 2


HYDRAULIC TEMP

47

B C

B

STARTER FEEDBACK

21

A B

OPEN

46

A

C407

B

C

B

C107

C

3600

C417

8510

RESERVED (hall)

2710

t

BRAKE SW IN

45

2900

2740

H

3920

A

C112

6410

2350


SEATBAR SIGNAL

44

3900

C

C105 C108

+ 2120

2720

HEADLIGHT SWITCH

43

3910

25 34

LEFT

2730

A


2740

FLOAT

42

35 45

RIGHT

4910

4390

40

2110

STATUS OUT

4500

FRONT WORKLIGHTS

3430

2110

RH SKI UP

4940

41

2910

4840

9340

3910

GROUND

9350

HEADLIGHTS

39

LEFT PANEL

OPEN

38 38

3920

1210

GROUND

37

9340

G D E

OPEN

36

PROTECTED POWER

4320

LH SKI UP

35

4640

C434

3100

SEATBAR GROUND

34

9410

C435

3900

KEY/ENTER SWITCH

33

1910

1900

OPEN

9110

10

9210

9400

BUCKET POSITION

SYSTEM Tx

9

SYSTEM Rx

4430

OPEN

COMPUTER POWER

4930

4340

G

9410

B

2910 2920 2930

6100

8

9300

LEFT BLINKER

7

F H K A

SPARE OUTPUT 1

66

CLOCK/LATCH

30

A



5

A

6100

RH SKI DOWN

29

25

2900


4

9310

TWO SPEED SWITCH

3

9330

PWM SIGNAL

28

SEAT BAR +8v

24

N K G L

9340

HYD FILTER SIGNAL

2

A B

C408

See C492

9200

OPEN

1

6110


E F

9100

4920

FUEL SENDER

27

COMPUTER POWER

23

9340

4310

OPEN

26

9200

STATUS IN

22

9200

3700

LH SKI DOWN

1200

REAR ROD

D

9110 9210 9400

9100

4440

21


RESERVED (AC INPUT)

9320

9110 FRONT BASE

4410

2600

9320

18

AIR FILTER SIGNAL

HYD LOCK SOLENOID

3

3430

DATA B START J C

6

BUZZER

17

4830

BUZZER

SPARE DIGITAL 1

16

4500

LH AUX LEFT

15

32 4420

2930

SYSTEM Rx

14

4820

RIGHT PANEL

PROTECTED POWER

13

J2 P05

B

A

2750

4500

6

20

SPARE ANALOG 2

12

2740

3440

RH FRONT DETENT

19

REAR BASE

11

1900

3010

PWM -

R HAND SERIAL IN

11 7 23 42

1900

3410

10 3600

2740

4

15 47 23

2770

4

3420

1930 BRAKE SWITCH

3410

3400

9 4300

1200

B

3 5

8 3200

9350

5

7 9210

3900

3

3420

6 4810

3100

28

ENG SPEED SIGNAL

PWM +8V SUPPLY

5 9100

3920

3400

COOLANT TEMP SIGNAL

4 2900

3910

A C

9330

J

L HAND SERIAL IN

9310

H SEE J2-48

3310

LH AUX RIGHT

3 4330

1200

3300

2

SYSTEM Tx

9300

1

2

COMPUTER GROUND

B

6120

48 8 18

38

9350

1

3310

FRONT ROD

2760

+8

3900

2

-

3920

SPARE ANALOG 1

1


B A

3910

SPOOL LOCK

2240

2300

B A

AIR FILTER SWITCH

A

3300

B

10

32 12 22 1 41 3 21

31

3610

B

3110

SEAT BAR

C

J2

B

3510

3710

A B

B

A

A B

A

J2 J1

4360

2000

A B

B

J1

2200


SEE C110

3100

29 26

9220

B

MAIN FRAME

CAB

B

SPEED SENSOR

C405 C406

B

9.8 ohm 12V

3200

B

SEE C110

SEE C113

3700

2480

A

2110

A

3300

4480

4410

A C

A B

3700 4340

A C

B

J

4360


A

3610

REAR AUX RELIEF 4330

2410

H A

11 ohm 12V

9120

A B

1920

2490

4430

B

3600

3.3 ohm PWM

2000

A B

4490 GREEN TIE STRAP

1220

7.5 ohm 12V

1 2

FRONT AUX RELIEF


9350

A B

4440

A

1 2

CAB 6727178

2450

YELLOW TIE STRAP

9.8 ohm 12V

FRONT BASE

C419 C106

A B

4450



2800

3.3 ohm PWM

2340

HARNESS 7112802

2370

1 2

4340

2330

2390

1 2

START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E

2330

PROTECTED POWER

4330

2420

A B

2920

4420

OPEN

A B

C418

A B

9.8 ohm 12V

DIVERTER

2520

A B

FRONT ROD

2340

2380

BICS HYDRAULIC LOCK

4410

B A

A B

18

2420

2

2410

2430

2100

2380

WHITE TIE STRAP

C420

2440

C421

4440

2

1

2370

C422

1

4380

1 2

4370


BROWN TIE STRAP

4420

2400

2

4470

2440

2430

BLUE TIE STRAP

4450

2450

2460

4460

2460

1

7.5 ohm 12V

4460

C423

2470

B

A B



GROUNDS

A

C414

2530

4430

2

BUCKET POSITIONING

S175 (S/N 525218875 AND ABOVE) (S/N 525316212 AND ABOVE) S185 (S/N 525022473 AND ABOVE) (S/N 525115405 AND ABOVE) Click Here (PRINTED JULY 2005) V-0718 RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES

1

REAR BASE HIGH FLOW 7.5 ohm 12V

C415

Printable Version

C413

WIRING SCHEMATIC (With ACS Option)

2

RUN/ENTER SWITCH D GROUND G C


REAR ROD

1

7.5 ohm 12V

4310

4310

4320

4320

4300

4300

4640

2530

4840

4910

4830

4230

B K F G

16

4820

1490

A

6

4810 4640

D C B

4840 4830

2200

A C

4100

B

C416

C424 C417

4200

8100

8250

A C

4200

B

OPEN

A B

2200

1480

Brake Valve

4810

A B

4240 2520

6500

13

1 4

LEFT FORWARD DRIVE

CAN LOW DRIVE

R QUAD A DRIVE

R QUAD B DRIVE

D

4235

21

22

23

N

6300

C

4275

E

4550

S

1700

A

1140

H

1150

4270

LEFT REVERSE DRIVE

8

4720

STEER MODE 2

OPEN

15

18

17

2 4

J5

25

19

4530

BRAKE LIGHT OUTPUT

DRIVE GRND

26

27

28

29

3070

4350

4210

2470

2490

2510

L QUAD B DRIVE

SAFETY OUT

BACK-UP ALARM

OPEN

OPEN

OPEN

36

37

38

39

33

34

35

3080

9410

7100

RIGHT RIGHT FORWARD REVERSE DRIVE DRIVE

RIGHT REVERSE GND

TWO UNSWITCHED UNSWITCHED OPEN BATTERY SPEED 2 BATTERY

41

42

43

44

45

46

47

48

2660

4260

4250

2650

4390

1250

1260

SWITCHED BATTERY

49

50

1750

2 5

2 0

3 7

3 8

4 6

3 9

5

3 6

1 9

1 8

1810

1640

2810 4720

3000 3070

1710 1820

4720

2860

4950 1770

3 4 3 4 2 4 4 4 5 3 1 4 1 2 1 1 1 2 6

4260

2 4 3 1 2 4 3 1 1 2 3

2660 4250

85

30

86 85

87A 87 30

86

87A 87

85

30

86 85

85

FUSE / RELAY CENTER

1160


1070 FUSE 12 25A (ACS)

2

2860

1 3 2

4950 1770

1 2

4260

1 2 3

2660

1 2 1

4250

4 5

2650

2680

4270

6 7

4270

2 1

2670

8

8

2670

2

4280

4280

1040

1 2

RIGHT FORWARD DRIVE SOLENOID

1 2

RIGHT REVERSE DRIVE SOLENOID

1 2 1 2

LEFT REVERSE DRIVE SOLENOID

LEFT FORWARD DRIVE SOLENOID

A

TO OPTIONS (BRAKE LIGHT)

C474

6

6 4 2 3 5

9010

6

6

2070

4 2 3 5

4 2 3 5

9210

2080

4275

L

R

9400

1520

1

1

1510

1

1

9110

6 4 2

6 4 2

9010

6 4 2

6 4 2

6410

P

S

9410

N

K

4550

4550

K

M

4220

C441

C437

C404

9720

E

L

4275

P

6410

NOT USED FOR THIS MODEL


TO OPTIONS (BACKUP ALARM)

N

6510

9620

D

G 9410 F 9400

S R

J

7200

B A

B A C

B A

9210

B A

4750 4650

TO OPTIONS (HORN/BLINKER)

2070 1510

3 5 1

3 5 1

4750 4650

4750

2070 1510

G

9520

C

D

2240

H

C

9520

2630 4670

1740

B

B

1740

1610

1 2 3

1170

A

H

2240

D 9110

F

F

9110

4680

4 5

4690

6 7 8

9720 9620

1630

F

A

G

K

J1

ACS Controller

SJC HARNESS 7110406

4770

E

4670

D

4650

B

4750

C

1500

J

2250

H

9740

K

9540

A

9640

D

1760

F

2280

H

4690

J

4780

E

J3 (Gray)

4790

G

2270

C

4680

V-0719 (7-12-05)

2260

B


4780 A

B

D

C

G

F

H

E

J

K

J2 (Black) 4790

3 5 1

4650

E 9210

E

LEFT SWASH PLATE POSITION SENSOR

SIG

G

1180

1080

GRD

J

+

-

1040

BATTERY

PWR

7200

1190

B

ACD & REMOTE START CONNECTOR

1 3 2

RIGHT SWASH PLATE POSITION SENSOR

SIG

4540

G

A

C

F

E

D

1310

PWR

1170

2710

9710

9610

9510

9800

1730

1160

1030

GRD

2

4210

1080

1010

Printed in U.S.A.

C426

1 3

A

1050 1300

C454

1 3

1710

2770

1060

C453

4720

2810

4770

100A

SIG

M

6510

RIGHT SIDE WHEEL SPEED

SIG

4220

C497

FUSE 5 30A

FUSE 6 30A

PWR

4 2 3 5

C492


30

1360 2050 2060

2040 2050 1350

FUSE 3 15A

87A 87

2060

FUSE 2 15A

86

7114735 RED TIE STRAPS

2 4 3 1 2 4 3 1

6 7

4 5

2650

2680

236 0

30

1030

FUSE 8

1 0

235 0

87A 87

120

GLOW PLUG

2

4530

5 0

7100

1 2

4540

2 2

4390

3 2

4350

1 6

1750

9410

6

9530

9400

4

9630

3 5

9730

1

4220

4 8

4550

4 7

4275

2 8

1260

85

1150


2 7

2470

86

FUSE 4 (COMPUTER)

30

25A

87A 87

2030 2040 1060

1140

25A

85

2010 2020 1320

(HEATER ) FUSE 1

86

1110

30


1120

87A 87


STARTER

1130

1720

FUEL PULL

4100

1720

GLOW PLUG

REAR LIGHT

4150

A

MARKER LIGHT

SWITCHED POWER

4110

2720

8100

B

1055

8110

C489

40

3080

4530 8150

25A

SENSER SUPPLY 1 +5V

1640

2680

1250

(ALTERNATOR & KITS) 1800 FUSE 11 25A

8210

COMPUTER

30

GRD

3 1 2 4

3020

7 OPEN

J5 DRIVE

8200


20

3000

3020

OPEN

4540

DRIVE MAIN SENSER GRND GRND

L QUAD A DRIVE

32

9730 RIGHT FORWARD GND

OPEN

16

10

LEFT LEFT JOYSTICK X JOYSTICK Y

4275 TWO SPEED 1

OPEN

9

R

8510

FUSE 4

9630 CAN SHIELD DRIVE

7

4950

31 LEFT REVERSE GND

8550

15A

9530

6

4220

4280

1740

8500

REAR LT

12

11

2670

6210

FUSE 3

OPEN

OPEN

4730

2020 2030 1330

FUSE 7

CAN HIGH DRIVE

6400

6200

15A

5

L

6310

FR & MK LT

4

4550

F

2000 2010 1050

30A

OPEN

3070

SIG

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

3 5 1

HDL SW X LEFT JOYSTICK

Y GRD PWR

HDL SW X RIGHT JOYSTICK

Y GRD PWR

GND SIG

M

LIFT ACTUATOR

M

B

FUEL PULL

3

LEFT FORWARD GND

6320

25A

2

STEERING MODE

2 4

LEFT SIDE WHEEL SPEED

SIG

M

TILT ACTUATOR

C488

FUEL PULL

6600

6000

HEATER

1

2490


REAR LIGHT

TRACTION PULL

SWITCH POWER

P

6300

FUSE 2

OPEN

9400

8010

FUSE 1

OPEN

2730 6000

STARTER

J

SAFETY IN

RIGHT LEFT STEER SWASHPLATE SWASHPLATE OPEN MODE 1 ANGLE ANGLE

3000

PWR

C356

C407

3 1

1530

GRD

3 1 2 4

C355

SEE CAB CONNECTOR


3070

2570

3080

3 1 2 4

C351 C352 C354 C353

A B

7100

2510

3 1 2 4

3020

C459

6600

1530

1540

C460

G C

2570

3000

4 3 1 2 4

2580

C429

6500

3080

3 1 2 4

C428

6400

C404

6310

E

DRIVE CONTROLLER

3020

3 1 2

C449

HR HR HR HR

1540

C454

6736808 2580 1 5 1 3 3 0 9 1 7 1 4 2 9 3 3 3 4 4 0 4 9 2 3 2 4 8

C450

2600 6200

1700

30A


F J H E


K

TRACTION


C453

C101

6732781

G

FUSE 5

G K A

4820

1400

A

FUSE 6

E C D

36 26

8200

D


H J

C350

C113 C109

4920

C360

C107

-

C103

4930

C500

C112 C111

2530

4920

2900

J2

C425

ACS

4940 4930

9100

9340

C409

-

C104

40 30 20

41 4

4200

6410

25A

8 48 17

7200

6510

9700

9600

9500

9800

1110

1120

1130

FUSE 12

33 28 13

22

4150

2100

25A

10

4110

8110

8150

8800

25A

38

44 14 24 34 16

SEE FUSE/RELAY CENTER

4500

8500

ALT & KITS

9200

8800

8580

FUSE 11

1900

46 5 15 44 4

8560

25A

20 32 40

30

8210

8250

8510

2800

8550

8100

C A B

8570

F B H A

1200

24

4910

C A B

8590

ATTCHMNT

50

12

36 9

6210

8800

6320

A B

8000

B A

2800

A B

4730

FUSE 9

49 3520

19

14

9 43


48 7200

A

C407

C410

C110

C105 C108

+

C110

39

42

HORN

47 3420

2770 2750 2760

9350

J1 6736515

HOLD PULL

UNSWITCHED


46

9800


FUSE 10

40 8110

3910

3900

19 29

FUEL SHUTOFF

B A

BATTERY CABLE

39 6320

LEFT

38 2100

RIGHT

37 3500

SPARE OUTPUT 2

45

GROUND

36 8550

FRONT WORKLIGHTS

44


2910



GROUND

25

43

30

1120

LEFT PANEL

42 8000

+5V SUPPLY

ENG OIL PRESS +8v

C434

41 1400

4470

29

C435

34 9700

28

9340

35

33 1130

27


1210

J1

OPEN

32 8150


26

GLOW PLUG FEEDBACK

19 6210 DIVERTER

1910

4730

CAN SELECT

18


G D

9600

FUEL RELAY HOLD

HEADLIGHTS

3010 UNSWITCHED BATTERY (3)

REAR WKLT RELAY


4460

50

3300

2900

2740

H

3920

25 34

OPEN

49

9110

4150 FUEL PULL FEEDBACK

10 4110

17

40

OPEN

48

PROTECTED POWER

25

9 8510

9210

24

J1 P01

8 6410

4200

HYDRAULIC TEMP

COMPUTER POWER

23

16

47

9300

F&R AUX RELIEF

46 4500

SYSTEM Tx

6510

TRAVEL CONTROL

OPEN

45 3920

SEATBAR SIGNAL

9310

15 3400

CAN LOW

BRAKE SW IN

44 9340

HEADLIGHT SWITCH

35 45

RH SKI UP

4940

2110

43

E F H K

14 9500

4840

4640

FLOAT

SYSTEM Rx

13 1110

TRACTION LOCK HOLD

3910

B

2910 2920 2930

6100

1800

RIGHT BLINKER

12

22

HANDLE POWER


9350

42

A

A


A

SEE J2-8

CAN HIGH

7

8250

21

A


66

39


LEFT BLINKER

4390

OPEN

38 38

9410

A B

6100

3200

5

SPARE OUTPUT 1

GROUND

37

2900

A

B

4 4910


SPARE DIGITAL 2

3510

3 3430


OPEN

36

41

9330

37 49


4320

LH SKI UP

35

4410

CLOCK/LATCH A DATA B J

C B

3520

TWO SPEED SWITCH

STATUS OUT

3100

SEATBAR GROUND

34

4830

START

3900

KEY/ENTER SWITCH

33

N K G L

9340

1900

OPEN

32 4420

6110

C408

See C492 G

9410

9340

9400

BUCKET POSITION

9320

4430

OPEN

C

4930

4340

BUZZER

30


E

9200

RH SKI DOWN

29

9200

PWM SIGNAL

28

4820

J2 P05

9100

4920

FUEL SENDER

27

25

9320

3500

0.3 ohm

8200

4310

OPEN

26

9200 SEAT BAR +8v

24

BUZZER

STARTER FEEDBACK


3210

8250

3700

LH SKI DOWN

1200 COMPUTER POWER

D F

9100

3500 3520

1800 EXCITATION

R S

4440

9110 9210 9400

4500

B

STARTER

M

9110

AIR FILTER SIGNAL

2740

C

B

A

10.9 ohm

B

18

23

B

A

2750

4500

A C

2010

1010

17

1900

2

A B

SPARE DIGITAL 1

16

11 7 23 42

2740

B

ALTERNATOR

LH AUX LEFT

15

STATUS IN

2770

1

HYD FILTER SIGNAL

20

SYSTEM Rx

14

22

1930 BRAKE SWITCH

OPEN

RH FRONT DETENT

19

PROTECTED POWER

13

REAR ROD

9330

3430

RESERVED (AC INPUT)

PWM -

SPARE ANALOG 2

12

21

2930

3440

10 3600

FRONT BASE

START

B A

9 4300

REAR BASE

HYD LOCK SOLENOID

3

8 3200

3100

28

ENG SPEED SIGNAL

PWM +8V SUPPLY

7 9210

11

31

3430

COOLANT TEMP SIGNAL

6 4810

R HAND SERIAL IN

3440

6

L HAND SERIAL IN

RIGHT PANEL

3010

LH AUX RIGHT

5 9100

1900

3410

SYSTEM Tx

4 2900

1200

4

15 47 23

COMPUTER GROUND

3 4330

1200

3420

FRONT ROD

B

6120

48 8 18

38

9350

3400

E3

A B

2

2760

+8

3900

3 5

D3

G

SPARE ANALOG 1

1

-

3920

4

A B

SPOOL LOCK


B A

9350

3410

J

31 31

180 0

B A

3900

B

H SEE J2-48

3310

4350

SUPPLY 1020

B

3110

AIR FILTER SWITCH

3920

5

B

3200

3710

SEAT BAR

A

3

3420

3300


B

A B

C

3400

1 2

11

A B

A

3910

A C


t

SEE C110

B

1 2

3310

RESERVED (hall)


J

3910

B A

3200

3300

6 HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH

SEE C110

MAIN FRAME

SEE C113

3700

A B

2110

A B

10

32 12 22 1 41 3 21

4360

B HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH

3300

B

3600

B

4410

A C

4340

A C

4360


SPEED SENSOR

J2 J2

HARNESS 7112800 A B

4330

B

4430

B

9.8 ohm 12V

4440

2480

A

2350

2200 HYDRAULIC TEMPERATURE SENDER 500-3000 ohm

A B

3700

J1

29 26

18

2710

2000 2240

B

3310

4420

A

4470

4450

4460

4480

9310

H

11 ohm 12V

J B

A B

J1

2120

2720

2370

A

3610

3100

2730

2390

3600

REAR AUX RELIEF

2740

2380

A B

2490

A

2100

2410

7.5 ohm 12V

3.3 ohm PWM

FRONT AUX RELIEF 4490 GREEN TIE STRAP

2110

2420

A B

1 2

CAB

2520

2450

DATA

2600

A B

4450 YELLOW TIE STRAP

9300

2330

2300

1 2

2340

C405 C406

3510

FRONT BASE 4340

2000

2800

2340

3.3 ohm PWM

CAB 6727178

2450

3610

1 2

C419 C106

2460

2400

1 2

9220

2330

9120

4330

2420

1920

4420

9.8 ohm 12V

1220

A B

A B

9350

A B

9.8 ohm 12V



A B

FRONT ROD

2920

BUCKET POSITIONING

C418

B A

DIVERTER

GROUNDS

2430

BICS HYDRAULIC LOCK

4410


2470

2440

2

2410

ARE CONNECTED IN SERIES 2530

2380

WHITE TIE STRAP

A K H F

2440

E D G C

4440

2

OPEN

1

1

2370

C420

2

C423

A B

C414

REAR BASE

1

7.5 ohm 12V


4380

1 2

4370

LIFT SPOOL LOCK (Not Use For This Model )

BROWN TIE STRAP

CLOCK/LATCH

2430

SYSTEM Tx

4430

2

SYSTEM Rx

1

COMPUTER POWER

2

RUN/ENTER SWITCH

1

7.5 ohm 12V

BLUE TIE STRAP

GROUND

2460

C421

4460

B

C422

S175 (S/N 525218875 AND ABOVE) (S/N 525316212 AND ABOVE) S185 (S/N 525022473 AND ABOVE) (S/N 525115405 AND ABOVE) Click Here (PRINTED JULY 2005) RELAY GROUNDS 2000-2060 V-0719

A

PROTECTED POWER

TILT SPOOL LOCK (NOT Used For This Model)

REAR ROD

A B

C415

Printable Version


C413

WIRING SCHEMATIC (With SJC Option)

PWR

RED

BLK

GND SIG PWR

RED

BLK

WIRING SCHEMATIC AIR CONDITIONER SWITCH

TO ENGINE OR MAINFRAME

2100

MEDIUM

F

1010 2200

BLOWER SWITCH

3 2 1 4 5 6

RED

BLK POWER RELAY 85

1740

86

87

30

87A

TO OPTIONS (DELUXE ACCESSORY)

2210

A B C

1190

SSL 7-PIN CAN CONNECTOR

C426 D F C E A B G

9800

2740

To Mainframe Harness

TO HORN CONNECTOR

1730

BOOM-MOUNTED ACD CONNECTORS

C703

H OUTPUT

1740

HVAC/ACCESSORY HARNESS - 6725390

K OUTPUT

C704

J3 - 10-PIN GRAY

ACD Input Connector

ID #4 ID #0

OPEN

OPEN

6310

2765 or BRN

2640

6330

G E A D H B

C B A

46 41 40

A B

40 42

C

2745

7310

7210

B C A

C506

B C A

2755

7160

C610

C667

BLK

WIPER HARNESS - 6729739

DOME LIGHT

6730

TO ATTACHMENT

40

B J N P

42

2300

7030

M A WHT BRN BLK DBL RED YEL

S LT TM CENTER GD RT

A OUTPUT B OUTPUT J OUTPUT K OUTPUT

J3 - 10-PIN GRAY

ID #2 ID #3

ACD Input Connector to Engine Compartment

ID #4 ID #0 OPEN

OPEN OPEN OPEN

A B C D E F

RIGHT WORK

C103

C605

C B A A B

A B C D E F

6520

A B C D E F

A B C D E F

6430

6720 6620 2620 OPEN 6320

HARNESS 6731239

C B A

6430 6730 2660

OPEN

2640

OPEN

2630

A B

6330

6830 6630 2630 OPEN 6330

HARNESS 6731239

2630

2610 To Engine Ground

86

87A

85

30

87

86

30

87A

85

87

30

86

87A

85

30

87

86

85

2730

6440

6540

1 2 3

A B

4 WAY FLASHER HARNESS - 6718873 A B

A B

A B

To Starter "B" Terminal Left Marker Fuse 10A

Right Marker Fuse 10A

1010

HARNESS 6726430

C490

ADDITIONAL POWER CONNECTOR 2740

2660

TO OPTIONS (EXTERIOR CAB)

RNG

2 1

87

2650

2670

RNG

1740

87A

2640

RIGHT FLASHER LIGHT

Signal Fuse 10A

ROAD LIGHTS

2 1

TO STROBE/BEACON

C632

C669

B A

AIR CONDITIONER HARNESS - 6726888 EVAPORATOR (AC) PRESSURE SWITCH

2 1 3

2785

6700

2780 6440 6540

E A C D F B

1730

C668 OR C670

TO OPTIONS (4 WAY FLASHER)

2775

B A


TO MAINFRAME (ACCESSORY CONNECTOR)

TO OPTIONS

EXTERIOR CAB HARNESS 6718872

1720 2720

A B

C402

7010

C609

KEY "RUN" UNSW POWER CAN SHIELD

ALARM HORN

SW POWER TO HANDLE CONNECT0R 2730 7200

FRONT HORN HARNESS 6727498

B A

CAN LOW CAN HIGH GROUND

Connector on Loader Boom

D 2 C 1 B A 3

D F C E A B G

9800 1160 9700 1710 9600 9500 2700 7-PIN

ATTACHMENT C426 CONNECTOR C666 CONTROL HARNESS - 6718426



WIRES CONNECT BY LETTER ACROSS CONNECTORS A B A B SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY

BATTERY FEED 1000-1999 RED, RED/WHT, RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR

V-0442 (7-12-05)

OPEN

2550

OPEN

A B C D E F 6610

A B C D E F G H

6710

A B C

6230

B A

6510

A B

2620

LEFT FLASHER LIGHT

STROBE OR BEACON

DIODE

7020

OPEN

A B C D E F

TO OLDER MODEL ATTACHMENTS

D C E F G H L K

C412

AIR CONDITIONER CLUTCH SOLENOID

B A

C612

2310

2640

6330

2785

B A

OPEN 2630

HARNESS 6713994

GRADER HARNESS 6707303

TO OPTIONS (HVAC)

B A

2660

HARNESS 6713993 FRONT WIPER MOTOR

V M

RED

6430

A B

HARNESS 6713994

7100

2735

C B A

HARNESS 6713993

2650

C B E A D F

D OUTPUT

6240

2 2 1 1

4720


REGISTRATION STOP LIGHT

ACCESSORY

2510

7180

40

DOME LIGHT SWITCH

C631

C608

A B

2 1

41


OPEN

C OUTPUT

C704 5900 5500

LEFT WORK

C604 A B C D E F

46

BACKUP ALARM

F G H K

ACD Output Connector to Engine Compartment

H OUTPUT

RIGHT TAILLIGHT

A B C D E F DOOR SENSOR

E D G TO MAINFRAME

TO OPTIONS

2 1

B C A

C F

RNG RNG/DGN

BACK-UP ALARM HARNESS - 6715659

L X

ID #1

G OUTPUT

11 14-PIN ATTACHMENT CONNECTOR

Rev. none

6800

LEFT TAILLIGHT

J A B C D E

J2 - 10-PIN BLACK

F OUTPUT


FRONT WIPER BOTTLE AND TANK

C622

5450

E OUTPUT

BACK-UP ALARM

H A

6320

5510

6250

7190 4710

B C A

2790

2610

5000

12

2520

7160

7210

PARK

2755

7150

C610

2735

C623

RIGHT TAILLIGHT

5910

C H J B G D F E A K

2640

6210

5200

5200

1370

6200

2630

OPEN

6310

6210 LEFT WORKLIGHT

5250

5250

1320

2600

5150

1020

6200

5300

5150

2650

2620

F B

5050

5300

6360

RIGHT WORKLIGHT

M

5400

5050

7310

BACK-UP ALARM

REAR LIGHT HARNESS 6716419

5400

6210

B A

OPEN

LEFT TAILLIGHT

WIPER HARNESS - 6730885

ADDITIONAL POWER CONNECTOR

1740

5350

DELUXE ATTACHMENT CONTROL HARNESS 6732730

6700

POWER BOB-TACH HARNESS 6730770

5100

5350

6340

2720

TO REAR AUX. DIVERTER SOLENOID

1020

A B

1730

BACK-UP ALARM SWITCHES HARNESS 6718820 or 7107544

C402

1720 9.8 ohms

1 2

OPEN

C703

2740 5100

6200

TO MAINFRAME

C B E A F D

C103

7110

2450

1740

BACK-UP ALARM SWITCHES POWER BOB-TACH SOLENOID

4455

CAN HIGH

2745


C667

B A

4451

4450

2450

CAN LOW

V M

OPEN

C404

B A

7100

2480

ACD Machine Connector to Engine Compartment

SW POWER

FRONT WIPER MOTOR

OPEN

TO MAINFRAME

9.8 ohms

2480

TO REAR AUX. RELIEF SOLENOID

CAN SHIELD

BOOM-MOUNTED ACD CONNECTORS


1 2

REAR AUX. JUMPER HARNESS 7101973

FRONT WIPER BOTTLE AND TANK

M

OPEN

C491

2770

C606

B A

7010

A B

C607

C601

A B

4485

ID #2 ID #3

L X

TO OPTIONS

1 2

4481

4480

ID #1

C622

POWER BOB-TACH SOLENOID

TO MAIN FRAME HARNESS

1 2

13

BLK

J1 - 8-PIN

GROUND

1740

C506

J OUTPUT

J A B C D E F G H K

5900

1140

2720

5450

B OUTPUT

C B A

2740

1720

5000

5510

C B A

2670

5910

14-PIN ATTACHMENT CONNECTOR

A OUTPUT

6350

5200

D OUTPUT

ID (K TO P)

1320

5200

C OUTPUT


2530

5250

ID (K TO L) TO OPTIONS (HVAC)

6240

5150

5250

A OUTPUT M OUTPUT

ACD Output Connector

H OUTPUT

1020

5150

D OUTPUT

G OUTPUT

2540

5300

C OUTPUT

F OUTPUT

OPEN

5300

DELUXE ATTACHMENT CONTROL HARNESS - 6729380

2760

G OUTPUT

2540

5050

9510

OPEN

H J B G D F E A K

5400

9610

14

6400

5350

5400

1720

9

6500

5350

5050

9

6310

C E OUTPUT

PUR

6370

5100

5100

5500

7000

GROUND

AWS HORN/BLINKER HARNESS - 6726662

PUR

9520 2730 7-PIN

K B E F G H C D A M L P

E OUTPUT

6010

RNG

9620

J N

F OUTPUT

J2 - 10-PIN BLACK

1730

H F B E D C A G

C666 ATTACHMENT CONNECTOR

SW POWER

1740

C506

A D C B E

1720

6640

ID (K TO L) ID (K TO P)

B A

2720

C497

OPEN

M OUTPUT

30

87A

B C A

GROUND


6515

6810

A OUTPUT

86

TO MAINFRAME

6410

D OUTPUT

85 87

2790 6510

C417

C OUTPUT

OPEN

C418

H OUTPUT

TO AWS CONTROLS

RIGHT BLINKER RELAY

OPEN

2740

F G H C D A M L P

F OUTPUT G OUTPUT

6020

C669

E OUTPUT

6510

1740

C642

GROUND

A

87A

B A

2740

6415

7200 or YEL

SW POWER

OPEN

86 30

9710

1370

J N K B E

6000

6410

2720

PUR

2520

BLK

B

85 87

2780

RED/WHT

9710

7100

2730 7-PIN

C666 ATTACHMENT CONNECTOR

CAN HIGH

CAN LOW

LEFT BLINKER RELAY

2530

9510

6410

ACD Machine Connector

SW POWER

6600

9610

PUR

E D C

CAN SHIELD

1730

PUR

9520

GROUND

2730

9620

H F B E D C A G

ADDITIONAL POWER CONNECTOR

C705

PUR

1160

2660

1720

CAN HIGH

2760


9800

1320

9710

RNG

CAN LOW

7200

C490

2710

9600

9500

1710

9700

2720

PUR

1730

7150 or DGN

GROUND

RED/WHT

9710

86 30

87A

HIGH

CAN LOW CAN HIGH

1160

2750 TO OPTIONS (DELUXE ACCESSORY)

J1 - 8-PIN

2795

SW POWER

CAN SHIELD SW POWER

85 87

2770

C705

C411

CAN SHIELD

PUR

C636

UNSW POWER

9800

1160

9800

D 2 C 1 B A 3

KEY "RUN"

D F C E B A G

KEY "RUN" UNSW POWER

C412

B A

2750 HORN RELAY

C489 C401or C402

C426 D F C E A B G

C431

M

RNG

HVAC HARNESS - 6725933


4640

ADVANCED HAND CONTROL G SERIES FLOAT HARNESS - 6727328

ADVANCED HAND CONTROL G SERIES JUMPER HARNESS - 6728742

F

(TO "B" PIN)

+

C410

-

(TO "D" PIN)

BLK

M

BLOWER MOTOR

YEL

LGN

2710

1200

BLK

A C B

RNG

9600

DELUXE EUROPEAN TAILLIGHT HARNESS - 6718198

3 2 1 4 5 6

5000

WHT

A C B

9500

L

10 8 7

RED

1710

1000 RIGHT WORK

M

RIGHT TAILLIGHT

2130

2110

POTENTIOMETER

B

H

LEFT TAILLIGHT

7200

HEATER VALVE

A D C B E

OPEN

LEFT WORK

A D C B E

1300

9700

F E D C B A

6210

REGISTRATION LAMP

BLK

1110

3200

7100

E F C A B D

2630

7000 C

A B C

2500

C605

C

C433

A B C

WHT

C611

F E D C B A

C604

C

2205

HERE OR TO OPTIONS (HVAC JUMPER)

2620

6340

6320

6610

2610

2640

6330

6620

E F C A B D

2310

TO OPTIONS (AC)

HIGH

DBL


B

C630

LOW

A B

1160

6200 2600

A D H B

7010

C433

6500

A

C617

6310

OFF

C614

6400

BACK-UP ALARM

THERMOSTAT

A B

3100

C612

6600

C F G E

C103

7100 2650

C613

OPTIONS S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED JULY 2005) V-0442

WIRING SCHEMATIC OPTIONS S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE)

FLASHER

1

HAZARD SWITCH 1130

3 1


C670

WIRES CONNECT BY LETTER ACROSS CONNECTORS B A B A SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY

E D

6700

B F A C

6540

2

7000

2

1180

2

6010 X

L

1

7010

3 6430

5

4

3 4 5

6

6

6530 2750

TO MAINFRAME

ACS SWITCH 1

2755

2780

2 2745 2755

6440

E

4550

3

R

4

D C K G B J

4235 4275

5 6

2730

S L M H N P F A

1700 6400 6500 BATTERY FEED 1000-1999 RED, RED/WHT, RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR

C488

V-0443


1150

STANDARD ACCESSORY HARNESS - 6727468 TO OPTIONS (HVAC OR HVAC/ACCESSORY) 1140 1740 2740 TO OPTIONS (POWER BOB-TACH)

5

3 1

2

1180

X

L

6010

HAZARD SWITCH 1 2

4

6700

B F A

6540

C

6300

6

7000

6520

3

6430 5

V M REAR WIPER SWITCH

7220

2

4

5

6530 2750

7010

3

4

E D A C B

1710

1720

1

6

5

2725

2

4

2710 1110

TO LEFT HANDLE CONNECTOR

6510 6000

D A B C E

POWER PLUG

5

B A

1770

2 2755

TO MAINFRAME 4550

E R

4235 4275

D C K G B J L M H N P

3 4

5 6

2730 6400 6500 1150 6300 6600 TO EUR0. LIGHTS CONNECTOR

4730 1140 1700

4730 2715

3 4 5 7310 6

6

1190 2700 2790

TO OPTIONS (FRONT WIPER)

7210 ACS SWITCH 1

1

4710 1760 2735

C F A D E B

C488

6410

2 1

2

1730 1750

TO OPTIONS (DOME LIGHT)

6440

1 3 4

6

2780

TRAVEL CONTROL LOCKOUT SWITCH

FRONT WIPER SWITCH

3

6

C411

C670

E D

5

1 2

3

2770 2760

6420

2 1130


POWER BOB-TACH SWITCH

1 6 4

C608

2745

C601

LIGHT SWITCH

BEACON SWITCH

REAR WIPER MOTOR

C667

FLASHER

B A C

C617 OR C642


2760

BEACON SWITCH 6 5 4

(PRINTED JULY 2005)

E D A C B

2770

C601

TO OPTIONS (POWER BOB-TACH) POWER BOB-TACH SWITCH

F A S

DELUXE ACCESSORY HARNESS - 6727190 Printed in U.S.A.

V-0443 (7-12-05)

ELECTRICAL SYSTEM INFORMATION

S175 WIRING SCHEMATIC


(WITHOUT ACS OPTION)

(WITHOUT ACS OPTION)

S/N 525211001 AND ABOVE S/N 525311001 AND ABOVE (PRINTED NOVEMBER 2003) V-0440




(WITH ACS OPTION)

(WITH ACS OPTION)





OPTIONS

OPTIONS

S/N 525211001 AND ABOVE S/N 525311001 AND ABOVE (PRINTED MAY 2004) V-0442

S/N 525011001 AND ABOVE S/N 525111001 AND ABOVE (PRINTED MAY 2004) V-0442



OPTIONS

OPTIONS



60-10-1


60-10-2


ELECTRICAL SYSTEM INFORMATION (CONT’D)

WARNING


Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0199

PROBLEM

CAUSE

Battery will not take a charge. Alternator will not charge. Starter will not turn the engine.

1, 2, 3, 4, 5 1, 2, 5 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE 1. Alternator belt is loose or damaged. 2. 3. 4. 5. 6. 7. 8. 9.

Battery connections are dirty or loose. Battery is damaged. The ground connection is not making a good contact. The alternator is damaged. The engine is locked. The starter is damaged. The wiring or solenoid is damaged. Check the fuses.

60-10-3


Figure 60-10-3

ELECTRICAL SYSTEM INFORMATION (CONT’D) Description Figure 60-10-1

1 1 P-26323

The electrical system is also protected by fuses and relays under the fuse panel cover (Item 1) [Figure 60-103] located in the cab on the control panel.

P-24651

Figure 60-10-2

The fuse panel cover (Item 1) [Figure 60-10-3] & [Figure 60-10-5] has a decal inside to show the location and amp ratings.

IMPORTANT Do Not use silicone base sprays and/or sealants on harness connectors or components. I-2123-0397

1 P-13848A

The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by a 100 amp master fuse (Item 1) [Figure 60-10-1] & [Figure 60-10-2] to protect against serious system overloads that could lead to burned up harness or loader damage. This fuse is located in the left-hand side engine compartment, just forward of the engine harness connector.

60-10-4


The location and sizes are shown in [Figure 60-10-4] & [Figure 60-10-5].

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse Location

REF

Figure 60-10-4

1

P-28846

Description

F1

Heater

F2

Front & Marker Lights

F3

Rear Lights

F4

Bobcat Controller

F5

Traction

F6

Fuel Shutoff

F7

Not Used

F8

Not Used

F9

Unswitched Attach.

F10

Switched Attach.

F11

Alternator & Kits

F12

ACS Power

Amp.

25 15 15 25 30 30 --25 25 25 25

Relay Switch Location F5

F1

F6

F2

F7

F3

F8

E

D

B

F9

Remove the cover to check or replace the relays. The location is shown in [Figure 60-10-4] & [Figure 6010-5].

F10 F

G

H

J

F11

REF B C D E F G H J

F12

F4

Fuses

C

Relays

Fuses N-18465A

Figure 60-10-5

Description Switch Power Rear Lights Front & Marker Lights Not Used Glow Plugs Fuel Shutoff Traction Starter

1

P-28903

Remove the cover to check or replace the fuses (Item 1) [Figure 60-10-5].

60-10-5


60-10-6


Figure 60-20-2

BATTERY Removal And Installation

WARNING Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1

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. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-1296

P-48528

Disconnect the positive (+) battery cable (Item 1) [Figure 60-20-2]. Figure 60-20-3

Figure 60-20-1

2

1

P-48529 P-48527

Remove the battery from the loader [Figure 60-20-3].

Open the rear door. Disconnect the negative (-) battery cable (Item 1) [Figure 60-20-1]. Remove the battery hold down clamp (Item 2) [Figure 60-20-1].

60-20-1


Servicing

BATTERY (CONT’D) Removal And Installation (Cont’d)

WARNING

Installation Figure 60-20-4

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. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-1296

Figure 60-20-6

P9589

Figure 60-20-5

P9588

P9590

Always clean the terminals and cable ends when installing a new battery [Figure 60-20-4] & [Figure 6020-5]. When installing the battery in the loader, do not touch any metal parts with the battery terminal posts. Connect and tighten the battery cables. Connect the negative (-) cable last to prevent sparks. Install the battery holddown clamp.

The battery cables must be clean and the connections tight. Remove acid or corrosion from the battery and cables with a sodium bicarbonate (baking soda) and water solution [Figure 60-20-6]. Clean the terminals and cable ends as shown in figure [Figure 60-20-4] and [Figure 60-20-5]. Check the electrolyte level in the battery. Add distilled water as needed. Put battery saver or grease on the battery terminals and cable ends to prevent corrosion.

60-20-2


BATTERY (CONT’D)

Figure 60-20-7

Using A Booster Battery (Jump Starting) 2

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator's seat and one person to connect and disconnect the battery cables. The key switch must be OFF (Standard Panel) OR the STOP Button must be pressed (Deluxe Panel). The booster battery must be 12 volt.

41 P-31861

WARNING Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

3

1

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. P-31860

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-1296

WARNING Keep arcs, sparks flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Connect the end of the first cable (Item 1) to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) [Figure 60-20-7] to the positive terminal on the loader starter. Connect the end of the second cable (Item 3) to the negative (-) terminal of the booster battery. Connect the other end of the same cable (Item 4) [Figure 60-20-7] to the engine. Keep cables away from moving parts. Start the engine. (See REMOTE START on Page 10-60-1.) After the engine has started, remove the ground (-) cable (Item 4) [Figure 60-20-7] first. Remove the cable from the positive terminal (Item 2) [Figure 60-20-7].

Battery gas can explode and cause serious injury. W-2066-1296

60-20-3


BATTERY (CONT’D) Using A Booster Battery (Jump Starting) (Cont’d)

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

60-20-4


ALTERNATOR

Alternator Identification

Adjusting The Alternator Belt

Figure 60-30-2

Figure 60-30-1 2

2 P-24416

1

4 1 3

1 P-24543

P-24417

Figure 60-30-3

Stop the engine.

4

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Loosen the alternator mounting bolt (Item 1) [Figure 6030-1].

3

Loosen the adjustment bolt (Item 2) [Figure 60-30-1] Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span with 15 lb. (66 N•m) of force.

1

1

1 2

Tighten the adjustment bolt and mounting bolt. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

P-24542

The black cover has been removed to show alternator rectifier/regulator assembly. The alternator contains field coil diodes (low current) (Item 1) [Figure 60-30-2], grounded heat sink (Item 2) [Figure 60-30-2] & [Figure 60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] & [Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] & [Figure 60-30-3], and four pair of large power diodes (Item 1) [Figure 60-30-3] on the underside of the rectifier. NOTE: The rectifier/regulator assembly has been removed from the alternator and flipped over for component identification [Figure 60-30-3].

60-30-1


ALTERNATOR (CONT’D) Charging System Check

WARNING Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-1296

WARNING Keep arcs, sparks flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury. W-2066-1296

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

60-30-2


2. If the test light lights up, there is a short (drain) in the electrical system of the loader. The short must be repaired before the charging system can be checked.

ALTERNATOR (CONT’D) Charging System Check (Cont’d) Figure 60-30-4

3. Disconnect the alternator B+ terminal (Item 1) and L & S terminal connector (Item 2) [Figure 60-30-4] and if the test light goes out, the alternator is faulty. If the test light stays on, find the short in the system and repair it.

2

Alternator Voltage Test 1

Figure 60-30-5

P-24547

If the charging system malfunctions check the following: Check the condition and tension of the alternator belt. (See Adjusting The Alternator Belt on Page 60-30-1.) If belt is worn or deteriorated replace. Inspect the alternator wiring harness and connectors at alternator. Harness and connectors must be clean and tight. 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.

P-34676

Open the rear door. Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.) Turn the engine on with the remote start tool and run at idle. With a voltmeter, check the voltage between the B+ terminal and ground at the starter [Figure 60-30-5]. 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. If the voltage is lower than 13.5 volts, run the engine at high idle and recheck voltage. If voltage is still below 13.5 volts, proceed with the following low voltage test.

With the key off, connect a test light between the negative battery post and the disconnected negative cable clamp. 1. If the test light does not light up, reattach the clamp and proceed to alternator voltage test. (See Below.)

60-30-3


ALTERNATOR (CONT’D)

High Voltage Test

Low Voltage Test

Figure 60-30-8 1

Figure 60-30-6

P-24568

1

2

P-34678

P-34679 P-24547

Turn engine OFF and remove the L & S terminal connector (Item 1) [Figure 60-30-6] off the alternator. Turn the remote start tool key to the ON position. Figure 60-30-7

Turn engine OFF and remove the L & S Terminal connector (Item 1) [Figure 60-30-6] off the alternator. Check the continuity between the "S" terminal (Item 1) [Figure 60-30-8] and the positive (+) terminal on the battery or starter terminal (Item 2) [Figure 60-308]. There should be continuity. If no continuity, replace wire harness. If voltage is still above 14.7 volts at 70°F (Alternator Temperature), then remove alternator for replacement or repair. To repair, (See Rectifier Continuity (Diode) Test on Page 60-30-5.) for further component testing.

2 1

P-24566 P-24566

Removal And Installation Place jackstands under the rear corners of the loader.

2

P-34677

Check the voltage across the "L" terminal (Item 1) and ground (Item 2) [Figure 60-30-7]. The voltage should be what the battery voltage is. If not, check wire harness, relay and fuses. If the wire harness, relay and fuses are ok then remove alternator for replacement or repair. To repair, (See Rectifier Continuity (Diode) Test on Page 6030-5.) for further component testing.


60-30-4


Figure 60-30-10

ALTERNATOR (CONT’D) Removal And Installation (Cont’d)

1

IMPORTANT Damage to the alternator can occur if: • Engine is operated with battery cables disconnected. • Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.) • Extra battery cables (booster cables) are connected wrong.

2 3 P-24543

I-2023-1285

Remove the adjustment bolt (Item 1) [Figure 60-30-10] from the mounting bracket.

Figure 60-30-9

Remove the alternator belt (Item 2) [Figure 60-30-10] from the alternator pulley. 2

Remove the mounting bolt (Item 3) [Figure 60-30-10]. Rectifier Continuity (Diode) Test Figure 60-30-11 1

3 2

P-24547


1


1 P-24416

Disconnect the negative (-) cable from the battery. Disconnect the red wire (Item 1) [Figure 60-30-9] from the alternator which comes from the battery. Disconnect the wiring harness connector (Item 2) [Figure 60-30-9] from the alternator.

Remove the two screws (Item 1), nut/washer (Item 2) and the plastic cover (Item 3) [Figure 60-30-11] from the alternator. NOTE: In the diode tests there should be continuity in one direction only. Meter readings should be different when probes are reversed. If the diode being tested shows no continuity or continuity in both directions, replace the rectifier assembly.

60-30-5


Figure 60-30-14

ALTERNATOR (CONT’D) Rectifier Continuity (Diode) Test (Cont’d) Figure 60-30-12

1

1

P-24558

Touch one probe to the diode (Item 1) [Figure 60-30-14] and the other probe to each heat sink and read the meter.

P-24532

NOTE: Use the diode function (Item 1) [Figure 60-3012] on the multimeter.

Reverse the probes to check the diode in the other direction.

Figure 60-30-13

Meter readings should be different when probes are reversed. Alternator Regulator Test

1

Figure 60-30-15

1

1 2

P-24527

1

Touch the probes to the terminals (Item 1) [Figure 60-3013] of each diode and read the meter.

P-24533

Reverse the probes to check the diode in the other direction. Meter readings should be different when probes are reversed.

Touch one probe to the "L" terminal (Item 1) and the other probe to the ground (Item 2) [Figure 60-30-15].

60-30-6



Disassembly

Alternator Regulator Test (Cont’d)

Figure 60-30-17 1.Alternator 2.Nut 3.Pulley 4.Spacer 5.Bolt 6.Bracket 7.Bolt 8.Bearing 9.Retainer 10.Rotor

Figure 60-30-16

11. 12. 13. 14. 15. 16. 17. 18. 19.

Bearing Stator Bracket Sleeve Regulator Rectifier Cover Spacer 3 Nut

6 4 7 12

2

1

10 8

P-24535

7

13 14 5

11

9 1819

Reverse the probes to check in the other direction [Figure 60-30-16].

17

There should be continuity in one direction only. Meter readings should be different when probes are reversed. If there is no continuity or continuity in both directions, replace regulator.

15

16 C-3529

Disassemble the alternator. (See Parts Identification Figure [Figure 60-30-17].) Remove the regulator cover. Remove the four bolts holding halves together. Pry the halves apart (use a press if needed). Use a soft jaw vise to hold rotor while removing pulley nut. Remove front case half from the rotor using a plastic hammer or press. Unsolder the stator leads from the rectifier. Remove the stator. Unsolder the two leads between the rectifier and regulator. Remove the regulator from rectifier.

60-30-7



Rotor Continuity Test

Stator Continuity Test

Figure 60-30-20

Figure 60-30-18

P-24524 P-24537

Touch the probes to the slip rings [Figure 60-30-20].

Use an ohmmeter to test the stator.

The ohmmeter should read between 3.0-4.0 ohms.

Touch the probes to two of the bare stator wires [Figure 60-30-18].

If there is no continuity, replace the rotor.

Move one of the probes to the third wire.

Rotor Ground Test

The readings should be the same.

Figure 60-30-21

If there is no continuity, replace the stator. Stator Ground Test Figure 60-30-19

P-24525

Touch one probe to one of the slip rings and the other probe to the rotor shaft [Figure 60-30-21]. There should be no continuity.

P-24538

Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [Figure 6030-19].

Replace the rotor if there is continuity.

There should be no continuity. Replace the stator if there is continuity. 60-30-8


ALTERNATOR (CONT’D) Assembly Figure 60-30-22

1 P-24557

Reverse the order of disassembly. Do not assemble the rear case half. Place the rotor in soft jaws when tightening the shaft nut (Item 1) [Figure 60-30-22]. Tighten to 72 + 14.5 ft.-lb. (98 + 20 N•m) torque. Install the rear case half and the remaining parts.

60-30-9


60-30-10


Figure 60-40-3

STARTER Checking Figure 60-40-1

2

1

Bat S M

Cranking Motor P-34673

Disconnect the negative cable from the battery. (See Removal And Installation on Page 60-20-1.)

A-1992

Disconnect the S terminal on the starter (Item 1) [Figure 60-40-3].

The key switch must be in the OFF position. The battery must be at full charge. The cable connections on the battery must be clean and tight. Connect a jumper wire between S terminal and BAT terminal [Figure 60-40-1].

Hold-In Test: Use circuit tester, touch one probe to the S terminal (Item 1) and one probe to the mounting bolt (Item 2) [Figure 60-40-3] on the magnetic switch (solenoid). If there is no continuity replace the magnetic switch (solenoid). Figure 60-40-4

If the starter turns but does not turn the engine, the starter drive has a defect.

2

Figure 60-40-2

1 P-34675

1

Bat S M

2 Cranking Motor

P-34674

Disconnect the negative cable from the battery. (See Removal And Installation on Page 60-20-1.) A-1991

Connect a jumper wire (of at least 4 gauge in size) between the M terminal and the BAT terminal [Figure 6040-2]. If the starter turns, the defect is in the solenoid.

Disconnect the S terminal on the starter (Item 1) [Figure 60-40-4]. Pull-In Test: Use circuit tester, touch one probe to the S terminal (Item 1) and one probe to the starter motor terminal (Item 2) [Figure 60-40-4]. If there is no continuity replace the magnetic switch (solenoid).

If the starter does not turn, the starter is defective. 60-40-1


STARTER (CONT’D) Removal And Installation Figure 60-40-5

4 2 5

3 1

P-34385

Stop the engine and open the rear door. Remove the negative (-) and positive (+) cables from the battery. Disconnect the ground wire (Item 1) [Figure 60-40-5] from the starter. Disconnect the engine harness power wire and positive (+) battery cable from the starter solenoid terminal (Item 2) [Figure 60-40-5]. Installation: Tighten the nut to 10.8-12.3 ft. lb. (14,716,7 N•m) torque. Disconnect the tan wire (Item 3) [Figure 60-40-5] from the R terminal on the starter solenoid. Disconnect the brown wire (Item 4) [Figure 60-40-5] from the S terminal on the starter solenoid. Remove the mounting bolts (Item 5) [Figure 60-40-5] from the starter. Remove the starter from the engine. Installation: Tighten the three mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque. Reverse the removal procedure to install the starter.

60-40-2


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. 24.

34 13

36 8* 10*

9*

11*

31

21

7*

32

Lever Gear Bracket Spring Gear Stop Stop Ring Ball Armature Washer Seal Yoke

15 14 16 19 18

37 20

17 5

8 12 14

6 1

29

4

3

28

2 27 35 22 23

25 23

24 * Not serviceable parts

26

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Holder Bracket Ring Bolt Bolt Switch Seal Bolt Washer Nut Boot Bracket Bearing B-16488

60-40-3


Figure 60-40-8

STARTER (CONT'D) Disassembly and Assembly Figure 60-40-6

2 1

1 1

2

P-34596

Remove the bolts (Item 1) from the brush cover (Item 2) [Figure 60-40-8].

P-34594

Remove the cable (Item 1) [Figure 60-40-6] from the magnetic switch.

Remove the cover (Item 2) [Figure 60-40-8]. Figure 60-40-9

Remove the bolts (Item 2) [Figure 60-40-6]. 2

Installation: Tighten the bolts to 63-129 in.-lb. (7,1-14,6 N•m) torque. Figure 60-40-7

1

1

2

4 3

3

N-00980

Using a needle nose pliers, pull the brush springs (Item 1) back and remove the brushes (Item 2) [Figure 60-409]. P-34595

Remove the armature, yoke, brush holder and rear bracket assemblies (Item 1) from the front assembly (Item 2) [Figure 60-40-7]. NOTE: When separating the parts there will be a steel ball (Item 3) located at the end of the armature shaft (Item 4) [Figure 60-40-7].

NOTE: The brushes are non-replaceable. If the brushes are worn order a new brush holder (for the negative brushes) and yolk (for the positive brushes). Remove the brush holder (Item 3) [Figure 60-40-9] from the end of the armature.

Installation: Apply grease to the steel ball (Item 3) and install into the end of the armature shaft (Item 4) [Figure 60-40-7] . 60-40-4


Figure 60-40-12

STARTER (CONT'D) Disassembly and Assembly (Cont'd)

1

Figure 60-40-10

2

3

1

2

P-34600

Inspect the magnetic switch (Item 1), the spring (Item 2),and the plunger (Item 3) [Figure 60-40-12] for wear and replace as needed.

P-34598

Remove the armature (Item 1) [Figure 60-40-10] from the frame.

Figure 60-40-13

Remove the bearing (Item 2) [Figure 60-40-10] from the end of the armature. Figure 60-40-11

3

2

1 1 P-34601

Remove the center bracket (Item 1) [Figure 60-40-13]

P-34599

Remove the bolts (Item 1) [Figure 60-40-11] from the magnetic switch. Installation: Tighten bolts to 34-69 in.-lb. ( 3,8-7,8 N•m) torque. Remove the front assembly (Item 2) from the magnetic switch (Item 3) [Figure 60-40-11].

60-40-5


Figure 60-40-16

STARTER (CONT'D) Disassembly and Assembly (Cont'd) Figure 60-40-14

1

3

2 2

2

4 P-34604

Remove the snap ring (Item 3) [Figure 60-40-15] & [Figure 60-40-16]

1 P-34602

Remove the rubber retainer (Item 1) [Figure 60-40-14]. Remove the planetary gears (Item 2) [Figure 60-40-14] and inspect for damage. Figure 60-40-15

Remove the retainer (Item 2) [Figure 60-40-15] & [Figure 60-40-16] and pinion (Item 1) [Figure 60-40-15] & [Figure 60-40-16]. Remove the spring (Item 4) [Figure 60-40-16]. Installation: Inspect all parts for wear and replace as needed.

3

2 1

P-34603

Press down on the pinion (Item 1) [Figure 60-40-15] & [Figure 60-40-16] and retainer (Item 2) [Figure 60-4015] & [Figure 60-40-16].

60-40-6


Figure 60-40-19

STARTER (CONT'D) Inspection And Repair Figure 60-40-17

N-00997

B-14455

Inspect the brush cover for discoloration, indication the starter has been overheated.

Armature Winding Continuity Test: Use a circuit tester, touch the probes to two commutator segments [Figure 60-40-19]. There should be continuity at any point. If there is no continuity, the winding is open-circuited, replace the armature. Figure 60-40-20

Inspect the pinion teeth for wear and damage. Armature Short-Circuit Test: Use a growler tester, put the armature on the growler and hold a hack saw blade against the armature core while slowly rotating the armature [Figure 60-40-17]. A short circuited armature causes the blade to vibrate and be attracted to the core. An armature which is short-circuited must be replaced. Figure 60-40-18

B-14458

Commutator Run-Out Test: check the commutator runout as shown in [Figure 60-40-20]. Service Limit - 0.003 inch (0,07 mm) If the commutator exceeds the service limit, repair as needed. N-00996

Armature Winding Ground Test: Use a circuit tester, touch one probe to a commutator segment and the other probe to the armature core [Figure 60-40-18]. There should be no continuity. If there is continuity, the armature is grounded and must be replaced.

60-40-7


Figure 60-40-22

STARTER (CONT'D) Inspection And Repair (Cont'd) Figure 60-40-21

1

N-00999

Check the field windings for wear and damage. B-14460

Measure the segment mica depth (Item 1) [Figure 60-4021]. Service Limit - 0.012 inch (0,3 mm) If it is worn, replace the armature. Check the commutator surface for burned spots which usually indicates an open-circuit, and correct it using #400 sand paper.

Check all the connections for clean and tight solder joints. Field Winding Ground Test: Use a circuit tester, touch one probe to the field winding end of the brush and the other probe to the surface of the frame [Figure 60-4022]. There should be no continuity. If there is continuity, the field windings are grounded. Replace the frame. Figure 60-40-23

N-15005

Field Windings Continuity Test: Use a circuit tester, touch one probe to the wire and the other probe to the brush [Figure 60-40-23]. There should be continuity. If there is no continuity, the field windings are open-circuited. Replace the frame.

60-40-8


STARTER (CONT'D)

No Load Test

Inspection and Repair (Cont'd)

Figure 60-40-25 Ammeter

Figure 60-40-24

S M.T.

Starter N-15006

B-14440

The following test should be done after reassembling the starter:

Inspect the brushes for wear and damage. Replace the brush holder and yoke if the brushes need replacement. Check brush spring, for damage or rust. Replace as needed. Brush Holder Insulation Test: Use a circuit tester, touch one probe to the positive brush holder plate and the other probe to the holder plate [Figure 60-40-24]. There should be no continuity. If there is continuity, replace or repair.

Clamp the starter in a vise. Using a 12 volt battery and ammeter, connect the positive wire of the battery, and the ammeter to the terminal [Figure 60-40-25]. Connect the negative wire to the starter body. Using a jumper wire, connect the S terminal to the main terminal. The starter should show smooth and steady rotation immediately after the pinion is engaged, it should draw less than the specified current. Service Limit - 1150 Amp. Maximum @ Stall Condition Clean all parts and apply high temperature grease to the armature bearing, return spring, steel ball, over running clutch, and idler gear rollers.

60-40-9


60-40-10


INSTRUMENT PANEL

The left instrument panel is the same for both the Standard and Deluxe Instrument Panels [Figure 60-501].

Left Panel Figure 60-50-1

The table below shows the DESCRIPTION and FUNCTION/OPERATION for each of the components of the left panel.

2 1 3 4

6

5

13

9

7

10

14

8

11

Press and hold LIGHTS button (Item 4) [Figure 60-50-1] for two seconds to view SERVICE CODES in the HOURMETER/CODE DISPLAY (Item 2) [Figure 60-501]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER/CODE DISPLAY.

12

B-15551

REF. NO

DESCRIPTION

FUNCTION / OPERATION

1

TEMPERATURE GAUGE

Shows the engine coolant temperature.

2

HOURMETER / CODE DISPLAY / GLOW PLUG COUNTDOWN

HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES* relating to the loader monitoring system. COUTNTDOWN - Glow Plug time remaning

3

FUEL GAUGE

Shows the amount of fuel in the tank.

4

LIGHTS / HOLD FOR CODES

LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time to turn all lights off. HOLD FOR CODES - Press and hold two seonds for display of SERVICE CODES (Item 2). (CODES* show only when there is an error found by loader monitoring system.)

5

BUCKET POSITIONING (Option)

Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold 2 seconds to view BASE or SHTDN (◆ SHUTDOWN) feature in HOURMETER/CODE DISPLAY.

ATTACHMENT AUXILIARY HYDRAULICS 6

HIGH FLOW (Option)

7

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.]

Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.

8

AUXILIARY PRESSURE RELEASE

Press and hold for two seconds. The engine wil stop. Hydraulic pressure will be released in the rear auxiliary (If so equipped) or right side front auxiliary circuit (If so equipped).

BOBCAT INTERBLOCK CONTROL SYSTEM (BICS™)

(SEE TROUBLESHOOTING GUIDE ON PAGE 60-90-4.) 9

PRESS TO OPERATE LOADER

Press to activate BICS™ System when the Seat Bar is down and operator is seated in operating position.

10

SEAT BAR

The light comes ON when the seat bar is down.

11

LIFT & TILT VALVE

The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is pressed. The lift and tilt functions can be operated when the light is ON.

12

TRACTION

The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can be moved forward or backward when the light is ON.

13

TRACTION LOCK OVERRIDE

(Function Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See TRACTION LOCK on Page 60-110-1.) Press a second time to lock the brakes.

14

ALARM

The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.

60-50-1


INSTRUMENT PANEL (CONT’D)

The right instrument panel shown [Figure 60-50-2] is the Standard Panel.

Right Panel (Standard) (With Key Switch)

The table below shows the Icons and other components of the Right Standard Panel

Figure 60-50-2 15 17 19 21 23 25 27

* These functions are monitored and have SERVICE CODES associated with them. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)

16 18 20 22 24 26 28

29 B-15552B

REF.

ICON/ LIGHT

FUNCTION

ALARM

CODE

CONDITION

DESCRIPTION

Advanced Control System 15 (ACS)

ON

3 Beeps

*

Error

Error with Advanced Control System (ACS)

Attachment 16 Control Device (ACD)

FLASHING 3 Beeps

*

Error

Error with Attachment Control Device (ACD)

General 17 Warning

ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *

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.

Fuel 19 Level

ON 3 Beeps FLASHING 3 Beeps

* *

Error WARNING

Fuel level sender system fault. Fuel level low.

Glow 20 Plugs

ON --FLAHSING 3 Beeps

*

--Error

Glow plugs are energized. Error with glow plugs

System Voltage

ON

3 Beeps

*

WARNING

Voltage low, high or very high.

Seat Belt

ON

---

-

---

Light stays on for 45 seconds to remind operator to fasten seat belt.

18 NOT USED

21 22 Engine 23 Oil Pressure


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 24 Charge Pressure


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 25 Coolant Temperature

3 Beeps * ON 3 Beeps * ON 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 26 Oil Temperature


Error Hydraulic oil temperature out of range. WARNING Hydraulic oil temperature high. SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.

Engine 27 Air Filter


* *

Error WARNING

Air filter with high restriction. Air filter switch not connected.


* *

Error WARNING

Hydraulic filter with high restriction. Hydraulic filter switch not connected.

-

-

-

Used to start and stop the engine.

28

Hydraulic Filter

29 Key Switch

-

60-50-2


Figure 60-50-4

INSTRUMENT PANEL (CONT'D) Right Panel (Deluxe) (With Keyless Start) Figure 60-50-3

3

1

ENTER PASSWARD

2 LANGUAGES

B-16165

4

The first screen you will see on your new loader will be as shown in [Figure 60-50-4].

6 5

B-15553B

The right instrument panel shown [Figure 60-50-3] is the Deluxe Panel. 1. Display Panel: The Display Panel is where all system setup, monitoring, troubleshooting, and error conditions are displayed. 2. Function Icons: The lower left area of the Deluxe Panel has the same Icons as the Standard Panel (See Right Panel (Standard) (With Key Switch) on Page 60-50-2.) These Icons are only visible when the monitoring system has detected an error. 3. Selection Buttons: The four Selection Buttons allow you to select items from the Display Panel and scroll through screens. 4. Keypad: The numeric keypad (Item 4) [Figure 60-503] has two functions: (a) To enter a number code (password) to allow starting the engine (Keyless Start).

When this screen is on the display you can enter the password and start the engine or change the Display Panel setup features. NOTE: Your new loader (with Deluxe Instrument Panel) will have a Owner Password. Your dealer will provide you with this password. Change the password to one that you will easily remember to prevent unauthorized use of your loader. (See ELECTRICAL SYSTEM SERVICE MANUAL.) Keep your password in a safe place for future needs. Start Engine: Use the Keypad to enter the numbers (letters) of your password and press the RUN / ENTER key (Item 5) [Figure 60-50-3]. Press and hold the START Button (Item 6) [Figure 6050-3] until the engine starts. Change Language: Press the Selection Button at the end of the arrow [Figure 60-50-4] to go to the next screen.

(b) To enter a number as directed for further use of the Display Panel.

60-50-3


INSTRUMENT PANEL (CONT'D) Right Panel (Deluxe) (With Keyless Start) (Cont’d) Figure 60-50-5

ENGLISH / INGLES Use keypad to select languages

1. English 2. Espanol 3. Francaia 4. Deutsch 5. Italiano 6. Nederlands

EXIT B-16160

Use the Keypad to select the number of the language [Figure 60-50-5] Press EXIT. The screen will return to [Figure 60-50-4]. You can then enter the password and start the engine.

60-50-4


INSTRUMENT PANEL (CONT'D) Right Panel Setup Display Options (Deluxe)

ICON

Icon Identification

DESCRIPTION LOCK/UNLOCK: Allows machine to be locked/unlocked. You must lock machine to activate security system.

Figure 60-50-6

When system is unlocked, the user can press RUN/ENTER then press START to begin operation.

SELECTION BUTTON

A valid password will need to be entered at startup to run a locked machine. TOOL/SETUP: Access system options. EXAMPLE

Use to set clock, check system warnings, select language, set passwords, etc.

?

B-16162

HELP: Access help on current menu item.

EXIT

EXIT returns you to previous level menu.

11:23 0.0

CLOCK/JOB CLOCK: Press to clear or lock job clock; TOOL/SETUP to set time. UP ARROW: Goes backward one screen. DOWN ARROW: Goes forward one screen.

Make selection by pressing SELECTION BUTTON opposite the Icon [Figure 60-50-6].

OUTLINE ARROWS: No screen available (backward/forward). SELECTION ARROW: Use to select menu item. NEXT

Goes to the NEXT screen in series. EXAMPLE: the next Active Warning screen.

INFO

Goes to more information about an attachment.

YES/NO Answer yes/no to current setup question. CLEAR Removes previously installed password. SET

60-50-5

Set accepts current installed password.


All new machines with Deluxe Instrumentation arrive at Bobcat Dealerships with the panel in locked mode. This means that a password must be used to start the engine [Figure 60-50-7].

INSTRUMENTATION PANEL (CONT’D) Deluxe Panel Setup Display Options

Passwords (Deluxe)

Figure 60-50-7

Press

For security purposes, your dealer may change the password and also set it in the locked mode. Your dealer will provide you with the password.

TOOL/SETUP

Owner Password: Allows for full use of the loader and to setup the Deluxe Panel. Owner can select a password to allow starting & operating the loader and modify the setup of the Deluxe Panel. Owner should change the password as soon as possible for security of the loader.

Press LOADER FEATURES

User Password: Allows starting and operating the loader; cannot change password or any of the other setup features.

Press DISPLAY OPTIONS

Press ADJUST CONTRAST

Press

UP OR DOWN

Arrow to change contrast. Press EXIT to return to previous level menu. B-16163/B16164/B-16161/B-16166/B-16167

60-50-6


INSTRUMENTATION PANEL (CONT’D)

More EXAMPLES:

Passwords (Deluxe) (Cont’d)

Clocks

Figure 60-50-8 Changing the Password

TOOL/SETUP [Figure 60-50-8]

Right Instrument Panel Display Screen

LOADER FEATURES. DISPLAY OPTIONS CLOCKS SET CLOCK Use the keypad to set time. Press RUN/ENTER to set clock. Press EXIT to return to previous level menu.

Press TOOL/SETUP

RESET JOB CLOCK (Password required) Press CLEAR to reset job clock to zero. Press LOCK/UNLOCK to unlock. Enter Password and press RUN/ENTER.

Press PASSWORD UTILITIES

Languages Press MODIFY OWNER or MODIFY USER

TOOL/SETUP LOADER FEATURES. DISPLAY OPTIONS LANGUAGES Select the language, press RUN/ENTER. Press EXIT to return to previous level menu. Vitals (Monitor engine, hydraulic/hydrostatic, electrical functions when engine is running.) TOOL/SETUP LOADER FEATURES. VITALS Press SELECTION ARROW to select METRIC or ENGLISH (M/E) readouts

Enter Password on Keypad

You can monitor real-tim readouts of: Engine Oil Pressure Engine Coolant Temperature Hydraulic Charge Pressure Hydraulic Ouil Temperature System Voltage Engine Speed

Press Enter to Continue

Re-enter new password. Press Enter to Continue (See left.)

The Display Panel is easy to use. Continue to set your own preferences for running/monitoring your Bobcat loader. Press Enter to Continue (See left.)

B-16163/B16164/B-16171/B-16172/B-16173/B-16174

60-50-7


INSTRUMENTATION PANEL (CONT’D) Option And Field Accessory Panels (If Equipped)

Side Accessory Panel [Figure 60-50-9] and [Figure 6050-10]. REF. NO.

Figure 60-50-9

1.

SIDE ACCESSORY PANEL

2. 3.

4.

5. 6. 7.

8.

1

2

4

3

6

5

P-16000 P16000

Figure 60-50-10

9.

REF. NO. 10.

11. 12.

13. 14.

7

8

9

P16000

15.

Figure 60-50-11

17

POWER PLUG NOT USED FRONT WIPER

FUNCTION/OPERATION Provides a 12V receptacle for accessories.

--Press the top of the switch to start the front wiper (press and hold for washer fluid). Press the bottom of the switch to stop the wiper. REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of the switch to provide washer fluid to clean the rear window. NOT USED --NOT USED --FAN MOTOR Turn clockwise to increase fan speed; counterclockwise to decrease. There are four positions; OFF-1-2-3. AIR COND. Press top of switch to start; bottom to stop. Fan SWITCH Motor (Item 7) must be ON for A/C to operate. TEMP. Turn clockwise to increase the temperature; CONTROL counterclockwise to decrease.

Front Accessory Panel [Figure 60-50-11]

SIDE ACCESSORY PANEL

10

DESC.

16.

FRONT ACCESSORY PANEL 11 12 13 14 15 16

17.

DESC.

FUNCTION/OPERATION

ADVANCED CONTROL SYSTEM (ACS) NOT USED POWER BOB-TACH (If Equipped)

Press the top to select Hand Controls; bottom to select Foot Controls.

PARKING BRAKE TURN SIGNAL INDICATORS HAZARD LIGHTS ROTATING BEACON

--Press and hold the up arrow to disengage the 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 left side (or top) to turn the HAZARD LIGHTS ON; right side (or bottom) to turn OFF. Press the left side (or top) to turn the ROTATING BEACON ON; right side (or bottom) to turn OFF. SELECTABLE Press the top to select ‘ISO’ Control Pattern; JOYSTICK bottom to select ‘H’ Control Pattern. CONTROL (SJC)

OR

B-15993C B-15993

60-50-8


Figure 60-50-14

INSTRUMENTATION PANEL (CONT’D) Standard Panel Removal And Installation (Right Side)

1

Figure 60-50-12

1

1 N-20140

Ignition Switch Removal and Installation (Standard Panel) P-28360A

Remove the three mounting bolts (Item 1) [Figure 60-5012].

Disconnect the key switch wiring harness (Item 1) [Figure 60-50-14] from the back of the control panel. Figure 60-50-15

Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels. Figure 60-50-13 2

1 1

P-28360

Remove the ignition key (Item 1) from the switch. Remove the ignition switch retaining nut (Item 2) [Figure 60-50-15] from the switch. N-20158

Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-13] from the panel. Remove the panel from the loader cab.

60-50-9


Figure 60-50-18

INSTRUMENTATION PANEL (CONT’D) Standard Panel Removal And Installation (Right Side) (Cont’d) Ignition Switch Removal And Installation Standard Panel (Cont'd) Figure 60-50-16 1

1

N-20163

Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-18] from the panel. Remove the panel from the loader cab. N-20141

Figure 60-50-19

Remove the ignition switch (Item 1) [Figure 60-50-16] from the control panel. Deluxe Panel Removal And Installation (Right Side) Figure 60-50-17 1

1

1

N-20142

NOTE: The instrument panel (Item 1) [Figure 60-5019] must be replaced as a complete unit.

N-20103

Remove the three mounting bolts (Item 1) [Figure 60-5017]. Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels.

60-50-10


Figure 60-50-22

INSTRUMENT PANEL (CONT'D) Standard & Deluxe Panel Removal And Installation (Left Side) Figure 60-50-20

1 1

1

N-20144

Alarm Removal and Installation Remove the left side instrument panel.

N-18409

Remove the three mounting bolts (Item 1) [Figure 60-5020]. Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels.

Remove the retaining nut (Item 1) [Figure 60-50-22] from the loader alarm. Remove the alarm from the loader instrument panel. Figure 60-50-23

Figure 60-50-21

1 3

2

1 N-20145

Bulb Removal And Installation

N-20165

Pull the left instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-21] from the loader alarm.

Remove the left side instrument panel. Remove the two light bulb covers (Item 1) [Figure 60-5023] from the back of the instrument panel.

Disconnect the wire harness connector (Item 2) [Figure 60-50-21] from the loader instrument panel. NOTE: The wiring harness (Item 3) [Figure 60-50-21] is an optional accessory harness. Remove the instrument panel from the loader. 60-50-11


INSTRUMENT PANEL (CONT'D)

Front Accessory Panel Removal And Installation

Standard & Deluxe Panel Removal And Installation (Left Side) (Cont'd)

Figure 60-50-26

Figure 60-50-24

1

1

P-26255

Remove the two mounting bolts (Item 1) [Figure 60-5026].

N-20146

With a flat blade screw driver, turn the light bulb counterclockwise [Figure 60-50-24] and remove from the panel.

Installation: Be careful to not overtighten the front accessory panel mounting bolts to prevent damage to the plastic panel.

Figure 60-50-25

Figure 60-50-27

2 1

N-20147

P-26251

To install the bulbs, place them in the sockets and turn clockwise [Figure 60-50-25].

Pull the front accessory panel down and disconnect the wire harness connector(s) (Items 1 & 2) [Figure 60-5027] from the switches. Remove the panel. Reverse the procedure to install the front accessory panel.

60-50-12


Figure 60-60-3

LIGHTS Front Removal And Installation Figure 60-60-1

1

1

N-19351

Remove the bulb (Item 1) [Figure 60-60-3] from the socket.

N-19348

Reverse the above procedure to install the bulb.

Open the rear door. Disconnect the negative(-) cable from the battery. (See Removal And Installation on Page 60-20-1.). Remove the light housing (Item 1) [Figure 60-60-1] from the operator cab. Figure 60-60-2

1

N-19349

Remove the bulb assembly (Item 1) [Figure 60-60-2] from the light housing by turning bulb assembly a 1/4 turn.

60-60-1


LIGHTS (CONT’D) Rear Removal And Installation Figure 60-60-4 1

2

P-48519

Remove the bulb assembly (Items 1 & 2) from the light housing (Item 3) [Figure 60-60-4] by turning bulb assembly a 1/4 turn. Figure 60-60-5

N-19339

Using care press the rear light and housing from the door [Figure 60-60-5]. Reverse this procedure for installation.

60-60-2


BOBCAT CONTROLLER Identification Chart

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

Harness Connector View


50

41

40

31

21

30

21

30

11

20

11

20

J1

41 31

1 2 3 4

5

6

J2

1 2 3 4 5

7 8 9 10

50 40

6 7 8

9 10

V-171/V-172

60-70-1


BOBCAT CONTROLLER (CONT’D) Identification Chart (Cont’d) Harness Connector View

41 31 21 11

3420

7200

3520

X

8550

3500

2100

6320

8110

40

4730

4470

X

1120

4450

8210

30

9500

3400

6510

4200

4460

6210

8800

3430

4910

X

X

X

6410

8510

4110

3

4

8

9 10

8000

X

9800

X

X

8150

1130

9700

X

X

4150

3010

9600

X

8250

1110

X

X

2

1

J1

50

X

1400

5

6

7

20


41

4410

9410

4640

9340

3920

J2

50

4500

X

3300

X

X

4840

X

2110

X

4940

40

31

X

4420

X

9350

3910

21

4340

4430

9400

1900

3900

4830

X

3100

4320

4930

30

11

9110

4440

X

1200

9200

4820

X

3700

4310

4920

20

4360

X

4330

2900

9100

4810

9210

3200

4300

3600

1

2

3

4

5

6

7

8

9 10 V-172

60-70-2


Figure 60-70-2

BOBCAT CONTROLLER (CONT’D) Removal And Installation

WARNING

1

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-34842

Figure 60-70-1

Loosen the harness connectors mounting bolts (Item 1) [Figure 60-70-2] from the Bobcat controller. Remove the connectors.

1

NOTE: The connectors are keyed and will only plug in one way. 1

Figure 60-70-3 1 1 N-19390

2

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device 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-34843


Remove the top mounting bolt (Item 1) [Figure 60-70-3].

Remove the left front side panel (Item 1) [Figure 60-701].

Loosen the two mounting bolts (Item 2) [Figure 60-70-3] of the system controller. Installation: Tighten the nuts to 12-14 ft.-lb. (16,3-19 N•m) torque. Remove the system controller. Reverse the above procedure to install the system controller.

60-70-3


60-70-4


Figure 60-71-2

CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) Removal and Installation

WARNING 1


P-64327


Remove the inside access panel (right side) (Item 1) [Figure 60-71-2]. Figure 60-71-3

Figure 60-71-1 1

2

1

P-64297

P-64300

Remove the foot portion of the engine speed control (Item 1) [Figure 60-71-1]. (See Removal And Installation on Page 70-20-1.)

Remove the top controller mounting bolt (Item 1). Loosen the two bottom controller mounting bolts (Item 2) [Figure 60-71-3] from the right side fender. Lift and remove the controller from the fender. Installation: Tighten the mounting bolts to 12-14 ft.-lbs (16-19 N•m) torque.

60-71-1


Figure 60-71-6

CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Removal and Installation (Cont’d) Figure 60-71-4

1

P-64325

Remove the SJC controller [Figure 60-71-6]. Figure 60-71-7

P-64322

Pull the controller out from the fender and loosen the connector screw (Item 1) [Figure 60-71-4] to release the connector. Installation: Tighten the connector screw to 30-35 in.-lb. (3,39-3,96 N•m) torque. DO NOT OVERTIGHTEN!

S

J

Figure 60-71-5 1

P-64324

1 The wire location (Item 1) [Figure 60-71-7] is printed on the connector, in the locations shown.

P-64325

Installation: Note the keyed hole in the controller socket. (Item 1) [Figure 60-71-5]. The keyed hole matches a tab on the connector on the wire harness.

60-71-2


60-71-3


CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Identification Chart

P-64295

60-71-4


CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Identification Chart (Cont'd)

P-64296

60-71-5


60-71-6


DIAGNOSTICS SERVICE CODES Display Figure 60-80-1 2

1

B-15551B

The left instrument panel is the same for both the Standard and Deluxe Instrumentation [Figure 60-80-1]. NOTE: Corroded or loose grounds can cause multiple service codes and/or abnormal symptoms. All dash lights flashing, buzzer going off, headlights and taillights flashing, could indicate a bad ground. The same symptoms could apply if the voltage is low, such as loose or corroded battery cables. If you observe these symptoms, check grounds and positive leads first. Press and hold LIGHTS Button (Item 1) [Figure 60-80-1] for two seconds to view SERVICE CODES in the HOURMETER/CODE DISPLAY (Item 2) [Figure 60-801]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER/CODE DISPLAY. The following word errors may be displayed. REPLY One or both instrument panel(s) communicating with the controller.

not

INPUT

The controller not communicating with the left instrument panel.

CODE

The controller is asking for a password. (Deluxe instrument panel only.)

ERROR The wrong password was entered. (Deluxe instrument panel only.)

60-80-1


DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List CODE

CODE

01-16 01-17

Air filter not connected Air filter plugged

10-16 10-17

Hydraulic Charge filter not connected Hydraulic Charge filter plugged

02-16 02-17

Hydraulic implement filter not connected Hydraulic implement filter plugged

11-05 11-06

Seat bar sensor short to battery Seat bar sensor short to ground

03-09 03-10 03-11 03-14 03-22

Battery voltage low Battery voltage high Battery voltage extremely high Battery voltage extremely low Battery voltage out of range low

12-21 12-22 12-23

Front auxiliary PWM switch out of range high Front auxiliary PWM switch out of range low Front auxiliary PWM switch not in neutral

04-09 04-14 04-15 04-21 04-22

Engine oil pressure low Engine oil pressure extremely low Engine oil pressure shutdown level Engine oil pressure out of range high Engine oil pressure out of range low

13-05 13-06 13-07

Fuel shut-off hold solenoid short to battery Fuel shot-off hold solenoid short to ground Fuel shut-off solenoid open circuit

14-02 14-03

Fuel shut-off pull solenoid error ON Fuel shut-off pull solenoid error OFF

15-02 15-03

Traction lock pull solenoid error ON Traction lock pull solenoid error OFF

16-05 16-06 16-07

Traction lock hold solenoid short to battery Traction lock hold solenoid short to ground Traction lock hold solenoid open circuit

17-05 17-06 17-07

Hydraulic lock valve solenoid short to battery Hydraulic lock valve solenoid short to ground Hydraulic lock valve solenoid open circuit

18-05 18-06 18-07

Spool Lock Solenoid short to battery Spool Lock Solenoid short to ground Spool Lock Solenoid open circuit

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

Hydraulic charge pressure low Hydraulic charge pressure high Hydraulic charge pressure extremely high Hydraulic charge pressure extremely low Hydraulic charge pressure shutdown level Hydraulic charge pressure out of range high Hydraulic charge pressure of range low Engine speed high Engine speed extremely high Engine speed no signal Engine speed shutdown level Engine speed out of range Hydraulic oil temperature high Hydraulic oil temperature extremely high

07-15

Hydraulic oil temperature shutdown level

19-02

Bucket position solenoid error ON

07-21

Hydraulic oil temperature out of range high

19-03

Bucket position solenoid error OFF

07-22

Hydraulic oil temperature out of range low 20-02

Two-speed solenoid error ON

20-03

Two-speed solenoid error OFF

08-10

Engine coolant temperature high

08-11

Engine coolant temperature extremely high

08-15

Engine coolant temperature shutdown level

21-02

Glow plug error ON

08-21 08-22

Engine coolant temperature out of range high Engine coolant temperature out of range low

21-03

Glow plug error OFF

22-02 22-03

Starter error ON Starter error OFF

23-02

Rear base solenoid error ON

23-03

Rear base solenoid error OFF

09-09

Fuel level low

09-21

Fuel level out of range high

09-22

Fuel level out of range low

60-80-2


DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE

CODE

24-02 24-03

Rear rod solenoid error ON Rear rod solenoid error OFF

32-57 32-58 32-59 32-60

Lift actuator reduced performance Tilt actuator reduced performance Lift actuator wrong direction Tilt actuator wrong direction

25-02 25-03

Rear auxiliary relief solenoid error ON Rear auxiliary relief solenoid error Off

32-61 32-62

Handle lock short to ground Handle lock short to battery

26-02 26-03

Front base solenoid error ON Front base solenoid error OFF

27-02 27-03

Front rod solenoid error ON Front rod solenoid error OFF

28-02 28-03

Diverter solenoid error ON Diverter solenoid error OFF

32-63 32-64 32-65 32-66 32-67 32-68 32-69 32-70 32-71 32-75

Pedal lock short to ground Pedal lock short to battery Sensor supply voltage out of range Battery voltage out of range Switch flipped while operating Lift handle information error Control pattern switch flipped while operating Right drive handle short to ground Right drive handle short to battery Interrupted unswitched power

29-02 29-03

High flow solenoid error ON High flow solenoid error OFF

33-23

Main Controller (Bobcat Controller) not programmed

30-28

Controller Memory failure

34-04

Deluxe panel no communication to Bobcat controller

31-28

Interrupted power failure

35-02 35-03

Hydraulic fan error ON Hydraulic fan error OFF

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

ACS not communicating with Bobcat Controller ACS Not calibrated Tilt actuator fault Tilt actuator wiring fault Tilt handle wiring fault Tilt actuator not in neutral Tilt handle/pedal not in neutral Lift actuator fault Lift actuator wiring fault Lift handle wiring fault Lift actuator not in neutral Lift handle/pedal not in neutral No communication Lift actuator short to ground Tilt actuator short to ground Lift actuator short to battery Tilt actuator short to battery Lift handle/pedal short to ground Tilt handle/pedal short to ground Lift handle/pedal short to battery Tilt handle/pedal short to battery

36-48

ACD multiple controllers present

37-02 37-03

Two-speed secondary error ON Two-speed secondary error OFF

60-80-3



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

No communication from joystick controller Left joystick X axis not in neutral Right joystick X axis not in neutral Left joystick Y as not in neutral Right joystick Y axis not in neutral Control pattern switch - Short to Battery or Ground Lift actuator not in neutral Tilt actuator not in neutral Lift actuator fault Tilt actuator fault Right wheel speed fault Left wheel speed fault Tilt actuator reduced performance Lift actuator reduced performance Left joystick X axis out of range high Right joystick X axis out of range low Left joystick Y axis out of range high Right joystick Y axis out of range high Front right steering sensor out of range high Front left steering sensor out of range high Rear right steering sensor out of range high

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

Rear left steering sensor out of range high Lift actuator out of range high Tilt actuator out of range high Left joystick X axis out of range low Right joystick X axis out of range low Left joystick Y axis out of range low Right joystick Y axis out of range low Front right steering sensor out of range low Front left steering sensor out of range low Rear right steering sensor out of range low Rear left steering sensor out of range low 5 volt sensor supply 1 out of range low 5 volt sensor supply 2 out of range low Lift actuator short to ground / out of range low Tilt actuator short to ground / out of range low Tilt actuator wrong direction Lift actuator wrong direction Left forward drive solenoid error ON Left reverse drive solenoid error ON Right forward drive solenoid error ON Right reverse drive solenoid error ON Front right steering solenoid error ON Front left steering solenoid error ON Rear right steering solenoid error ON Rear left steering solenoid error ON Steering pressure solenoid error ON

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

Back-up alarm error ON

60-80-4

Left forward drive solenoid error OFF Left reverse drive solenoid error OFF Right forward drive solenoid error OFF Right reverse drive solenoid error OFF Front right extend steering solenoid error OFF Front right retract steering solenoid error OFF Front left extend steering solenoid error OFF Front left retract steering solenoid error OFF Rear right extend steering solenoid error OFF Rear right retract steering solenoid error OFF Rear left extend steering solenoid error OFF Rear left retract steering solenoid error OFF Steering pressure solenoid error OFF Back-up alarm error OFF No communication from Bobcat controller Wheel angles (alignment) not calibrated Lift & tilt actuators not calibrated Interrupted power Battery out of range Drive pump not calibrated Steering mode / drive mode switch flipped while operating Uncommanded right wheel speed error ON Uncommanded left wheel speed error ON Undercurrent steer pressure solenoid Undercurrent front right extend steer solenoid Undercurrent front right retract steer solenoid Undercurrent front left extend steer solenoid Undercurrent front left retract steer solenoid Undercurrent rear right extend steer solenoid Undercurrent rear right retract steer solenoid Undercurrent rear left extend steer solenoid Undercurrent rear left retract steer solenoid 5 Volt sensor supply 1 out of range high 5 Volt sensor supply 2 out of range high Front right wheel blocked (steering mechanical failure) Front left wheel blocked (steering mechanical failure) Rear right wheel blocked (steering mechanical failure) Rear left steering error Right speed sensor missing pulses Left speed sensor missing pulses Unresponsive right speed sensor Unresponsive left speed sensor Left speed sensor reverse direction Right speed sensor reverse direction Controller in drive calibration mode Controller in wheel position calibration mode.



CODE

39-04

Left joystick no communication to Bobcat controller

40-04

Right joystick no communication to Bobcat controller

44-02 44-03

Horn error ON Horn error OFF

45-02 45-03

Right blinker error ON Right blinker error OFF

46-02 46-03

Left blinker error ON Left blinker error OFF

47-21 47-22

8 volt sensor supply out of range high 8 volt sensor supply out of range low

48-02 48-03

Front light relay error ON Front light relay error OFF

49-02 49-03

Rear light relay error ON Rear light relay error OFF

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

Travel pedal out of range high Travel pedal out of range low Travel pedal not calibrated Brake Pedal out of range high Brake Pedal out of range low Brake Pedal not calibrated Drive selector switch no signal Drive selector switch multiple inputs Front wheel speed sensor out of range high Front wheel speed sensor out of range low Rear wheel speed sensor out of range high Rear wheel speed sensor out of range low Front wheel speed sensor no signal Rear wheel speed sensor no signal Dual wheel speed sensor fault Battery voltage over voltage 5V sensor #1 over voltage 5V sensor #1 under voltage 5V sensor #2 over voltage 5V sensor #2 under voltage Front PWM error on Front PWM no signal Front PWM not calibrate Front forward error ON Front forward error OFF Front reverse error ON

50-38

Front reverse error OFF

50-39 50-41

Rear PWM error on Rear PWM no signal

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

Rear PWM not calibrate Rear forward error ON Rear forward error OFF Rear reverse error ON Rear reverse error OFF Two speed error OFF Two speed error ON Brake solenoid error ON Brake solenoid error OFF Brake solenoid no signal Brake light relay error ON Brake light relay error OFF Differential lock error ON Differential lock error OFF CAN communications fault Drive controller not calibrated

50-59 50-60

Front speed sensor missing pulses Rear speed sensor missing pulses

50-63

Front angle sensor not calibrated

50-66 50-67 50-68 50-69 50-70 50-99

Rear angle sensor not calibrated Front forward no signal Front reverse no signal Rear forward no signal Rear reverse no signal In calibration mode

60-21 60-22 60-23

Rear auxiliary control out of range high Rear auxiliary control out of range low Rear auxiliary control not returning to neutral

62-04

Load moment monitoring in error

63-05 63-06

Short to battery Short to ground

64-02 64-03

Switched power relay error ON Switched power relay error OFF

60-80-5



CODE

65-02 65-03 65-05 65-06 65-07

Workgroup lockout error on Workgroup lockout error off Workgroup lockout short to battery Workgroup lockout short to ground Workgroup lockout open circuit

66-05 66-06

Pilot pressure short to battery Pilot pressure short to ground

74-72 74-73

Bobcat controller in boot code Left hand panel system RX error

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

No communication from Drive Controller Left joystick X-Axis not in neutral Left joystick Y-Axis not in neutral Right joystick Y-Axis not in neutral ISO/H pattern switch short to ground or battery Left swash plate not in neutral Right swash plate not in neutral Left joystick X-Axis out of range high Left joystick Y-Axis out of range high Right joystick Y-Axis out of range high Left swash plate out of position Right swash plate out of position Left joystick X-Axis out of range low Left joystick Y-Axis out of range low Right joystick Y-Axis out of range low 5 volt sensor supply 1 out of range low Left swash plate sensor out of range high Left swash plate sensor out of range low Right swash plate sensor out of range high Right swash plate sensor out of range low Left forward drive solenoid error ON Left reverse drive solenoid error ON Right forward drive solenoid error ON Right reverse drive solenoid error ON Backup alarm error ON Left forward drive solenoid error OFF Left reverse drive solenoid error OFF Right forward drive solenoid error OFF Right reverse drive solenoid error OFF Backup alarm error OFF No communication from Bobcat Controller Battery voltage out of range high Interrupted power (also occurs after software update) Battery voltage out of range low Drive pump not calibrated ISO/H pattern switch flipped while operating

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

Left wheel speed uncommanded motion Right wheel speed uncommanded motion No communication from ACS Controller Left speed sensor out of range high Right speed sensor out of range high Left speed sensor out of range low Right speed sensor out of range low 5 volt sensor supply 1 out of range high Left swash plate sensor reversed Right swash plate sensor reversed Unresponsive right speed sensor Unresponsive left speed sensor Left speed sensor reversed direction Left speed sensor reversed direction Controller in Calibration Mode

76-73

Left display panel RX error

77-48

Key Switch - Multiple

78-74

Door/Transport Lock - Open/Active

60-80-6



CODE

80-02 80-03

ACD output ‘A’ error ON ACD output ‘A’ error OFF

81-02 81-03

ACD output ‘B’ error ON ACD output’ B’ error OFF

82-02 82-03

ACD output ‘C’ error ON ACD output ‘C’ error OFF

83-02 83-03

ACD output ‘D’ error ON ACD output ‘D’ error OFF

84-02 84-03

ACD output ‘E’ error ON ACD output ‘E’ error OFF

85-02 85-03

ACD output ‘F’ error ON ACD output ‘F’ error OFF

86-02 86-03

ACD output ‘G’ error ON ACD output ‘G’ error OFF

87-02 87-03

ACD output ‘H’ error ON ACD output ‘H’ error OFF

90-02 90-03

Service tool output ‘C’ error ON Service tool output ‘C’ error OFF

91-02 91-03

Service tool output ‘D’ error ON Service tool output ‘D’ error OFF

92-02 92-03

Service tool output ‘E’ error ON Service tool output ‘E’ error OFF

93-02 93-03

Service tool output ‘F’ error ON Service tool output ‘F’ error OFF

60-80-7


60-80-8


NOTE: Record what lights are blinking (if any) and number of light flashes. See Troubleshooting Guide on Page 60-90-4.

BICS™ SYSTEM Inspecting The BICS™ Controller (Engine STOPPED - Key ON)

Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)

Figure 60-90-1

3. Sit in the operator's seat, lower the Seat Bar, and press the PRESS TO OPERATE LOADER Button. Press the auxiliary hydraulics FLOW Button. The auxiliary FLOW Button light will come ON. Raise the Seat Bar. The light should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING) 4. Sit in the operator's seat, lower the seat bar, engage the parking brake pedal and fasten the seat belt. 5. Start the engine and operate at low idle. Press the PRESS TO OPERATE LOADER Button. While raising the lift arms, raise the Seat Bar fully. The lift arms should stop. Repeat using the tilt function.

N-18409

Inspecting The Traction Lock (Engine RUNNING)

1

2

3

4

6. Fasten the seat belt, disengage the parking brake pedal, press the PRESS TO OPERATE LOADER Button and raise the Seat Bar fully. Move the steering levers slowly forward and backward. The TRACTION lock should be engaged. Lower the Seat Bar. Press the PRESS TO OPERATE LOADER Button.

B-15551G

7. Engage the parking brake pedal and move the control levers slowly forward and backward. The TRACTION lock should be engaged.

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

1. Sit in the operator's seat. Turn key ON (Standard Panel), press RUN / ENTER Button (Deluxe Panel, lower the Seat Bar and disengage the parking brake pedal. Press the PRESS TO OPERATE LOADER Button. Three BICS™ lights (Items 1, 2, & 3) [Figure 60-90-1] [PRESS TO OPERATE LOADER, SEAT BAR, and LIFT & TILT VALVE] on left instrument panel should be ON [Figure 60-90-1].

NOTE: * The TRACTION light on the left instrument panel will remain OFF until the engine is started, the PRESS TO OPERATE LOADER Button is pressed and the parking brake is disengaged. Inspecting The Lift Arm By-Pass Control 8. Raise the lift arms 6 feet (2 meters) off the ground. Stop the engine. Turn the lift arm by-pass control knob clockwise 1/4 turn. Pull up and hold the lift arm by-pass control knob until the lift arms slowly lower.

2. Raise the Seat Bar fully. All four BICS™ lights (Items 1, 2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE LOADER, SEAT BAR, LIFT & TILT VALVE and TRACTION*] on left instrument panel should be OFF [Figure 60-90-1] 60-90-1


BICS™ SYSTEM (CONT'D) Additional Inspection For Loaders With Advanced Hand Controls (ACS) 9. Sit in the operator's seat and fasten the Seat Belt. Lower the Seat Bar, start the engine and press the PRESS TO OPERATE LOADER Button. 10. Raise the lift arms about 6 feet (2 meters) off the ground. 11. Turn key OFF (Standard Panel), press the STOP Button (Deluxe Panel, and wait for the engine to come to a complete stop. 12. Turn key ON (Standard Panel), press RUN /ENTER Button (Deluxe Panel. Press the PRESS TO OPERATE LOADER Button, move the left hand control toward the operator. The lift arms should not lower. 13. Move the right hand control away from the operator. The bucket (or attachment) should not tilt forward.

60-90-2


BICS™ SYSTEM (CONT'D)

WARNING

Troubleshooting Chart The following troubleshooting guide 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

SOLUTION#

All indicator lights flashing. One of the indicator lights flashing. Intermittent indicator lights.

5 1 2, 3, 4

SOLUTION SUGGESTIONS 1. Refer to BICS™ troubleshooting guide.(See Troubleshooting Guide on Page 60-90-4.) 2. 3. 4. 5.

Check wire connections on Bobcat controller to make sure connectors are locked into place. Check pins in connectors for pins pushed back or bent. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring. Possible low or high voltage.

60-90-3


Figure 60-90-2

BICS™ (CONT'D) Troubleshooting Guide The following chart shows the effects which can happen to the loader, and the probable causes when the BICS™ Instrument Panel lights are off. See [Figure 60-90-2] for location of BICS™ lights and Icons. Have service procedures performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

6

5

Press and hold LIGHTS Button (Item 5) [Figure 60-90-2] for two seconds to view SERVICE CODES in the HOURMETER / CODE DISPLAY (Item 6) [Figure 60-902]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER / CODE DISPLAY.

Indicator Light

1

2

3

4

Light ON

Light OFF

Effect on Operation of Loader When Light is OFF

2 1

3

4 B-15551

SERVICE CODES Means System Error (See Your Bobcat Dealer for Service) No. of Service Flashes Code

Causes

PRESS TO OPERATE LOADER Button is pressed.

PRESS TO OPERATE LOADER Button is not pressed.

Lift, tilt and traction functions will not operate.

----

----

Seat Bar is down.

Seat Bar is up.

Lift and tilt functions will not operate.

2

11-05

3

11-06

Seat Bar sensor circuit shorted to battery voltage*. Seat Bar sensor circuit shorted to ground.

1 2 3 3

17-07 17-05 17-06 17-06

Valve output circuit is open. Valve output circuit shorted to battery voltage*. Valve output circuit shorted to ground. Controller not grounded or intermittent ground.

1 2

16-07 16-05

3

16-06

5

15-02

6

15-03

Traction lock hold solenoid circuit is open. Traction lock hold solenoid circuit shorted to battery voltage*. Traction lock hold solenoid circuit shorted to ground. Traction lock pull solenoid circuit is shorted to battery voltage* - ERROR ON (Should be OFF). Traction lock pull solenoid circuit ERROR OFF (Should be ON). System voltage low System voltage high

Control valve can be used.

Control valve Lift, tilt and cannot be used. traction functions will not operate.

Loader can be Loader cannot moved forward & be moved backward forward and backward.

SEAT BAR

LIFT & TILT VALVE

Loader cannot be moved forward and backward.

TRACTION

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.

60-90-4


SEAT BAR SENSOR

WARNING

Troubleshooting Chart 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.

Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death.

PROBLEM

W-2004-1285

SOLUTION #

Indicator light does not come ON when seat bar is lowered.

1, 2, 3, 4, 5

SOLUTION SUGGESTIONS 1. Check sensor wire connection. 2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL1567 to check sensor and controller. 3. Check for loose hardware. 4. Check keyed bushing to make sure magnet collar rotates with seat bar. 5. Check magnet collar magnets for contamination such as metal particles.

60-100-1


Figure 60-100-3

SEAT BAR SENSOR (CONT'D) Test Figure 60-100-1

2

1 1 P-4698

If there is no power light (Item 1) [Figure 60-100-3] on the sensor tester, check the tester or wiring harness.

N-18463

Use Sensor Tester (MEL1428) and seat bar sensor tester adatper (MEL1567) for the following procedure:

Figure 60-100-4

Connect the seat bar adapter sensor leads (MEL1567) to the sensor tester.

1

Disconnect the seat bar sensor connector (Item 1) [Figure 60-100-1]. Figure 60-100-2

P-4699

1

Lower the seat bar. The Sensor Test light (Item 1) [Figure 60-100-4] should illuminate.

N-19557

Raise the seat bar. The Sensor Test light (Item 1) [Figure 60-100-4] should go off. If the above test fails, there is a problem with the seat bar sensor.

N-19558

Connect the Sensor Tester (Item 1) [Figure 60-100-2] inline, to the seat bar sensor connectors. See inset [Figure 60-100-2]. Turn the key to the ON position. DO NOT START THE ENGINE.

Disconnect the Sensor Tester. Replace the Seat Bar Sensor. (See Removal And Installation on Page 60-100-3.) If the above test passes, run the seat bar sensor BICS™ circuit test. (See BICS™ Circuit Test on Page 60-100-5.)

The toggle switch (Item 2) [Figure 60-100-3] can be in either the Absent or Present position.

60-100-2


Figure 60-100-6

SEAT BAR SENSOR (CONT'D) Removal And Installation Figure 60-100-5

3 1 1

2

N-19224

Remove the seat bar (Item 1) [Figure 60-100-5] from the loader. (See Removal And Installation on Page 50-10-1.)

N-19219

Remove the mounting bolt (Item 1) from the seat bar mount (Item 2) [Figure 60-100-6]. Installation: Tighten the mounting bolt to 50-70 in.-lb. (5,6-7,9 N•m) torque. Remove the sensor mounting bolt (Item 3) [Figure 60100-6] and nut.

60-100-3


SEAT BAR SENSOR (CONT'D) Removal And Installation (Cont’d) Figure 60-100-7

1

2 3

N-19383

Remove the keyed plastic bushing (Item 1) magnetic bushing assembly (Item 2) and sensor bracket (Item 3) [Figure 60-100-7].

IMPORTANT Be careful to not overtighten the sensor mounting bolt and nut to prevent breakage of the sensor. I-2088-1095

Installation: Be sure the tabs on the pivot bushing are positioned in the slotted hole (Item 1) [Figure 60-100-7] of the seat bar. Inspect all parts for damage and wear and replace if necessary. Reverse the removal procedure to install the seat bar sensor.

60-100-4


Figure 60-100-9

SEAT BAR SENSOR (CONT'D) BICS™ Circuit Test Figure 60-100-8

3

2

1 1 P-4703

Connect Sensor Tester (Item 1) [Figure 60-100-9] inline to the seat bar sensor connectors.

N-18463

Use Sensor Testers (MEL1428) and seat bar sensor tester adapter (MEL1567) for the following procedure: Connect the seat bar sensor tester adapter MEL1567 to the sensor tester. Disconnect the seat bar sensor connector (Item 1) [Figure 60-100-8].

Turn the key to the ON position. DO NOT START THE ENGINE. If there is no power light on the sensor tester, check the tester or wiring harness. When the power light is illuminated, move the toggle switch (Item 2) [Figure 60-100-9] on the sensor tester to the Present position. NOTE: The sensor test light (Item 3) [Figure 60-100-9] is only activated by the seat bar. It will be off with the seat bar up or on with the seat bar down.

60-100-5


SEAT BAR SENSOR (CONT'D) BICS™ Circuit Test (Cont’d) Figure 60-100-10

1

N-18409

The BICS™ seat bar indicator light (Item 1) [Figure 60100-10] should illuminate. Figure 60-100-11

1

P-4699

Move the toggle switch (Item 1) [Figure 60-100-11] on the sensor tester to the Absent position. The Seat Bar light (Item 1) [Figure 60-100-10] should go off. If the above test fails, there is a problem with the Bobcat controller or the wiring harness.

60-100-6


TRACTION LOCK

WARNING

Troubleshooting Chart 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.

Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death.

PROBLEM

W-2004-1285

CAUSE

Traction lock stays engaged.

1, 2, 3, 4, 5, 6, 7,11,12,13

Intermittent activation of traction lock.

8, 9, 10, 11

KEY TO CORRECT THE CAUSE 1. Make sure brake pedal is not engaged. 2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract. 3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp. fuse. 4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.) 5. To test the solenoid, the 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.

60-110-1


TRACTION LOCK (CONT'D)

Inspecting The Control System

Description Of The Control System

Fasten the seat belt, disengage the parking brake button, press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-110-1] and raise the Seat Bar fully. Move the steering levers slowly forward and backward. The TRACTION lock (Item 4) [Figure 60-110-1] should be engaged. Lower the Seat Bar. Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-110-1].

Figure 60-110-1

Engage the parking brake pedal and move the steering levers slowly forward and backward. The TRACTION lock should be engaged. NOTE: The TRACTION light on the left instrument panel will remain OFF until the engine is started, the PRESS TO OPERATE LOADER Button is pressed and the parking brake is disengaged. Figure 60-110-2

1

1

2

3

4

B-15551G P-48521

The Traction Lock Control System will lock the traction drive system when the engine stops. The Traction Lock Control System is incorporated into the BICS™ System.

Check the wire connections at the engine flywheel rpm speed sensor (Item 1) [Figure 60-110-2]. NOTE: When the Traction Lock Override Button is activated, the Traction Lock Override Control System will NOT engage the Traction Lock if the engine stops. (See Adjustment on Page 60-140-1.), for Flywheel rpm sensor adjustment.

60-110-2


Solenoid Removal And Installation

TRACTION LOCK (CONT'D) Inspecting Fasten the seat belt, disengage the parking brake pedal, press the green PRESS TO OPERATE Button and raise the Seat Bar fully. Move the control levers slowly forward and backward. The Traction lock should be engaged. Lower the Seat Bar. Press the green PRESS TO OPERATE Button. Engage the parking brake pedal and move the control levers slowly forward and backward. The Traction lock should be engaged.

WARNING AVOID INJURY OR DEATH Do not modify the electrical wiring connected to the traction lock solenoid or any part of the traction lock system. The traction lock provides the locking function of the parking brake. Service work on the traction lock system should only be performed by a qualified technician. Use only genuine Bobcat Company parts if repair is necessary. W-2165-0100

Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Figure 60-110-3

2

P-4712

1

P-34256

NOTE: The loader control panel and crossbar linkage has been removed for clarity purpose only. The traction lock can be removed without removing the control panel. Remove the two mounting screws (Item 1) [Figure 60110-3] from the electric solenoid mounting bracket. Installation: Tighten the mounting screws to 80-90 in.-lb. (9-10 N•m) torque. Remove the electric solenoid (Item 2) from the chaincase cover [Figure 60-110-3].

60-110-3


Figure 60-110-6

TRACTION LOCK (CONT'D) Solenoid Removal And Installation (Cont'd) Figure 60-110-4

1 1

N-19079

Inspect the guides (Item 1) [Figure 60-110-6] for wear or damage. Replace if necessary .

P-34377

Remove the bracket (Item 1) [Figure 60-110-4] from the chaincase cover.

Figure 60-110-7 1 2

Installation: Tighten the mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque. 3

Be sure the solenoid mounting bracket is installed in the same position. The solenoid mounting surface has a slight angle which tips the top of the solenoid toward the rear of the loader when installed correctly. See inset photo [Figure 60-110-3]. Figure 60-110-5

P7926

1

Remove and inspect the compression spring (Item 1) and spring cap washer (Item 2) [Figure 60-110-7] for wear or damage. Replace if necessary. The spring may also stay with the shaft when the electric solenoid and bracket are removed from the chaincase. Installation: Install the compression spring (Item 1) [Figure 60-110-7] on the collar located on the electric solenoid. Remove the traction lock assembly (Item 3) [Figure 60110-7] from the chaincase.

N-19108

Remove the traction lock assembly (Item 1) [Figure 60110-5] from the chaincase.

60-110-4


TRACTION LOCK (CONT'D)

Guide Removal

Solenoid Removal And Installation (Cont'd)

The part number listed below will be needed to do the following procedure:

Figure 60-110-8

P/N 6633583 - Polyurethane 2

Raise the loader lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.)

3

WARNING

1


P-7964

W-2059-0598

Remove the shaft mounting bolt (Item 1), spring from the assembly shaft (Item 2). Remove the wedge (Item 3) [Figure 60-110-8] and inspect all parts for damage or wear. Replace if necessary. Installation: Thoroughly clean and dry the shaft mounting bolt (Item 1), the shaft (Item 2) and wedge (Item 3) [Figure 60-110-8]. Use LOCTITE #242 when assembling these parts to the traction lock assembly.

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel from the loader. (See Removal and Installation on Page 50-100-1.) Remove the traction lock solenoid assembly. (See Solenoid Removal And Installation on Page 60-110- 3.)

IMPORTANT

WARNING

Failure to use LOCTITE may allow the traction lock assembly to loosen up which can cause damage to the traction lock system. I-2090-1095

Install the engine speed control. (See Removal And Installation on Page 70-20-1.) Lower operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

AVOID INJURY OR DEATH Do not modify the electrical wiring connected to the traction lock solenoid or any part of the traction lock system. The traction lock provides the locking function of the parking brake. Service work on the traction lock system should only be performed by a qualified technician. Use only genuine Bobcat Company parts if repair is necessary. W-2165-0100

Perform the BICS™ inspection procedure. (See BICS™ SYSTEM on Page 60-90-1.)

60-110-5


Figure 60-110-11

TRACTION LOCK (CONT'D) Guide Removal Figure 60-110-9

1

1 P11330

To remove the traction lock guides remove the four bolts (Item 1) [Figure 60-110-11].

N-19079

Remove the center chaincase cover [Figure 60-110-9] (See Center Cover Removal And Installation on Page 4030-3.)

Figure 60-110-12 1

3

Figure 60-110-10

1

2

2 P11332

Thoroughly clean the polyurethane from the chaincase cover (Item 1), bolts (Item 2) and traction lock guides (Item 3) [Figure 60-110-12] and dry.

P11331

NOTE: Bolt (Item 1) is on the rear of the chaincase cover, notice the direction of the groove (Item 2) [Figure 60-110-10] in the traction lock guides.

60-110-6


Figure 60-110-15

TRACTION LOCK (CONT'D) Guide Installation

INCORRECT

CORRECT

Figure 60-110-13 3 2

1 N-19106

N-19105

Install the traction lock guides (Item 1) to the chaincase cover (Item 2) [Figure 60-110-15] using the four bolts (removed earlier).

P11333

Apply a bead of polyurethane (P/N 6633583) on the traction lock guides and bolts [Figure 60-110-13].

Do not tighten at this time. Figure 60-110-16

Figure 60-110-14

1 2 3

2 4

4 1

P11337 P11334

Install the electric solenoid/bracket assembly (Item 1) to the center chaincase cover (Item 2) [Figure 60-110-14].

Install the traction wedge assembly (Item 1) into the solenoid and traction lock guides (Item 2) [Figure 60110-16].

NOTE: Bolt (Item 3) [Figure 60-110-14] & [Figure 60110-15] represents the rear of the chaincase cover.

After the bolts have been tightened recheck to make sure the shaft assembly is moving freely in the guides.

Install and tighten the two bolts (Item 4) [Figure 60-11014].

Remove the wedge assembly (Item 1) [Figure 60-11016]. NOTE: The wedge assembly must slide freely in the grooves of the guides. Tighten the four guide bolts to 90-100 ft.-lb. (123-135 N•m) torque.

60-110-7


Figure 60-110-19

TRACTION LOCK (CONT'D) Guide Installation (Cont'd) Figure 60-110-17

1

2

1

2

1

N-19109

Install the wedge assembly (Item 1) [Figure 60-110-19] into the grooves in the traction lock guides making sure that there is no binding.

P11334

Remove the two bolts (Item 1) and remove the electric solenoid (Item 2) [Figure 60-110-17] from the center chaincase cover.

Install the gasket (Item 2) [Figure 60-110-19].

Figure 60-110-18

1 2

N-19079

Install the chaincase cover (Item 1) using the ten mounting bolts (Item 2) [Figure 60-110-18]. Tighten to 15-20 ft.-lb. (20-27 N•m) torque. NOTE: Thoroughly clean and dry the bolts and apply polyurethane sealant to the bolt threads. Install a new gasket between the chaincase cover and the chaincase. Apply polyurethane sealant to the gasket also.

60-110-8


Figure 60-120-2

ADVANCED CONTROL SYSTEM (ACS) Components Identification

2

Figure 60-120-1

1

11

2 P-21938

P-21939

Foot control/sensor assembly (Item 1) [Figure 60-120-2]. P-16536

P-21879

Foot sensor (Item 2) [Figure 60-120-2].

The Advanced Control System (ACS) is a selectable foot/ hand control system. The ACS system allows the operator to quickly switch between foot and hand control modes.

NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.) Figure 60-120-3

Control Handle (Item 1) [Figure 60-120-1]. Handle sensor (Item 2) [Figure 60-120-1].

1

NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)

1 P-24203

Control Valve Actuators (Item 1) [Figure 60-120-3]. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)

60-120-1


Figure 60-120-5

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Components Identification (Cont'd) Figure 60-120-4

1

P-21769

1

ACS error indicator (Item 1) [Figure 60-120-5]. P-21767

ACS Controller (Item 1) [Figure 60-120-4]. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)

NOTE: The ACS icon will illuminate when an error occurs. The error is stored as a service code. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)

60-120-2


ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Troubleshooting Guide The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code. The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will stop its check at the first problem and then luminate the icon. The system starts its diagnostics and calibration when the ignition key is turned ON. The following list shows the probable causes when the icon is luminated. Advanced Control System

General Warning

Fuel Level

System Voltage

Engine Oil Pressure

Engine Coolant Temperature

Air Filter

Attachment Control Device

Two Speed

Glow Plugs

Seat Belt

Hydraulic Charge Pressure

Hydraulic Oil Temperature

Hydraulic Filter

Advanced Control System Errors-lights solid with 3 beeps 32-04- ACS in error 32-23- ACS not calibrated 32-31- Tilt actuator fault 32-34- Tilt actuator not calibrated 32-35- Tilt handle/pedal not calibrated 32-36- Lift actuator fault 32-39- Lift actuator not calibrated 32-40- Lift handle/pedal not calibrated 32-49- Lift actuator short to ground 32-50- Tilt actuator short to ground 32-51- Lift actuator short to battery 32-52- Tilt actuator short to battery 32-53- Lift handle/pedal short to ground

32-54- Tilt handle/pedal short to ground 32-55- Lift handle/pedal short to battery 32-56- Tilt handle/pedal short to battery 32-57- Lift actuator reduced performance 32-58- Tilt actuator reduced performance 32-59- Lift actuator wrong direction 32-60- Tilt actuator wrong direction 32-61- Handle lock short to ground 32-62- Handle lock short to battery 32-63- Pedal lock short to ground 32-64- Pedal lock short to battery 32-65- Sensor supply voltage out of range 32-66- Battery out of range 32-67- Switch flipped while operating

To see what error occurred. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)

60-120-3


ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Controller, Connector And Wire Identification

H J K

G F E D

F E D C

J3

A B C

J1

H J K

G F E

G H A B

D

C J2

B

J3

J2

A

J1 J1

J3

J2

P-21843

P/N

PIN

DESCRIPTION

P/N

PIN

J3 Red

A

J1 Orange

A

CONNECTOR, METRI-PACK 5V HALL EFFECT SUPPLY

Orange Green Purple Purple Purple

B C D E F

SWITCHED ACS POWER HAND/FOOT INPUT CAN SIGNAL HIGH ACS CAN SIGNAL LOW ACS CAN SHIELD ACS

Red/White Red/White Black Green Red

B C D E F

Black Black J2

G H

ACS GROUND ACS 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

Green Black Black Black

G H J K

Green Green Green Green Green Green

A B C D E F G H J K

60-120-4

DESCRIPTION CONNECTOR, METRI-PACK TILT ACTUATOR FORWARD UNSWITCHED ACS POWER UNSWITCHED ACS POWER LIFT ACTUATOR REVERSE HANDLE LOCK POWER LIFT ACTUATOR FORWARD PEDAL LOCK POWER ACS GROUND ACS GROUND TILT ACTUATOR REVERSE


Figure 60-120-8

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) ACS Controller Removal And Installation Figure 60-120-6

1

1 P-21840

Remove the two mounting bolts (Item 1) [Figure 60-1208] from the controller.

P-21839

Loosen the bottom bolts and remove the top bolt on the right front panel [Figure 60-120-6]. Remove the right front panel (Item 1) [Figure 60-120-6] from the loader.

Remove the controller from the loader. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)

Figure 60-120-7

1

P-21843

Disconnect the wiring harness connectors (Item 1) [Figure 60-120-7] from the controller.

60-120-5


Figure 60-120-11

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Handle Sensor Connector Figure 60-120-9

1 2

3

1

1 P13733

With a pointed tool, lift the tab (Item 1) [Figure 60-12011] and pull the wire from the connector.

P16578

The wire connector (Item 1) [Figure 60-120-9] can be removed from the handle sensor wires, using the following procedure.

Installation: Install the wires into the connector as listed below [Figure 60-120-11]:

Figure 60-120-10

1-Terminal - Red 2-Terminal - Black 3-Terminal - Green

1 1

P13725

P13732

Remove the wedge (Item 1) [Figure 60-120-10] from the connector.

60-120-6


Figure 60-120-14

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Removal Figure 60-120-12

1

3 2 1

P13735

1

2

Using a pointed tool, press down on the tab (Item 1) [Figure 60-120-14] and pull the wire from the connector.

P-21879

NOTE: Switch handle can be removed and installed while in loader.

Figure 60-120-15

Disconnect the harness connector (Item 1) [Figure 60120-12] from the handle sensor connector. Disconnect the harness connector (Item 2) [Figure 60120-12] from the handle lock solenoid connector. 1

Figure 60-120-13

1 P13725

P13732

Remove the wedge (Item 1) [Figure 60-120-15] from the harness connector (Black) that connects to the handle lock solenoid connector.

1

1 P13725

P13732

Remove the wedge (Item 1) [Figure 60-120-13] from the harness connector (Gray) that connects to the handle sensor connector.

60-120-7


Figure 60-120-18

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Removal (Cont'd) Figure 60-120-16

1

3

2

3

4

1 2 N-17772

1 Disconnect the left switch handle connectors (Items 1, 2, 3 & 4) [Figure 60-120-18] from the loader wiring harness connectors.

P13735

Using a pointed tool, press down on the tab (Item 1) [Figure 60-120-16] and pull the wire from the connector.

Figure 60-120-19

Figure 60-120-17 1 2

2

1

N-22783

2

Roll the pistol grip handle cover (Item 1) [Figure 60-12019] down.

N-17779

Disconnect the right switch handle connectors (Items 1 & 2) [Figure 60-120-17] from the loader wiring harness connectors.

Using a small screwdriver, lift the handle tabs (Item 2) [Figure 60-120-19] and slightly rotate the switch handle.

60-120-8


ADVANCED CONTROL SYSTEM (ACS) (CONT'D)

Switch Handle Installation

Switch Handle Removal (Cont'd)

Figure 60-120-22

Figure 60-120-20

2

Tape 1/2 of Wires Tape back 1/2 of Wires

P-24233

1

P-21699 N-22784

Pull the switch handle and wiring harness assembly (Item 1) [Figure 60-120-20] from the control lever. Cut the wires (Item 2) [Figure 60-120-20] below the switch handle and remove switch handle. NOTE: Only cut the wires if the switch handle is bad and needs replacement. If the switch handle is good and just needs to be removed for control handle or lever replacement, then remove the connectors on the end of the harness and pull switch handle and harness up through the top of the lever tube.

When installing the new switch handle, tape the wire terminals together. The switch handle comes with a 6 inch piece of heat shrink tube slid over the end of the wires. Remove the heat shrink tube from the end of the wires before routing the harness through handle and control lever tube. NOTE: Leave all the other heat shrink tube on the wires for protection. Tape half of the wires back and half forward [Figure 60120-22] to keep the harness small enough to route through the control lever tube.

Figure 60-120-21

1

P-24234

If the harness has been cut: pull the harness (Item 1) [Figure 60-120-21] out through the bottom of the control lever tube.

60-120-9



Install the wires into the connectors as listed below:

Switch Handle Installation (Cont'd)

Right Switch Handle

Figure 60-120-23

Ten-Pin Connecter 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

1

Three-Pin Connector A-Terminal - Red/White B-Terminal - Black/White C-Terminal - Purple/White

P-21700A

Install the new switch handle and wires from the top of the control lever. Route wire (Item 1) [Figure 60-120-23] 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 60-120-24

Left Switch Handle Ten-Pin Connector A-Terminal - Orange B-Terminal - Dk. Blue C-Terminal - White D-Terminal - Purple E-Terminal - Yellow/Red F-Terminal - Tan G-Terminal - Pink H-Terminal - Orange/Black J-Terminal - Blank K-Terminal - Blank Three-Pin Connector A-Terminal - Red/White B-Terminal - Black/White C-Terminal - Purple/White

2

Two-Pin Connector A-Terminal - Black B-Terminal - Red Five-Pin Connector A-Terminal - Dk. Green B-Terminal - Brown C-Terminal - Blank D-Terminal - Yellow E-Terminal - Blank

1

P-21695

Remove tape from wires for installation and install the 6 inches of heat shrink tube (Item 1) [Figure 60-120-24] approximately 3 inches into the control lever. Apply heat to the exposed heat shrink tube. Inspect the wire terminal tabs (Item 2) [Figure 60-12024] and re-bend tabs if necessary. 60-120-10


Figure 60-120-27

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation (Cont'd) Figure 60-120-25 1

3

1 2

P13735

1

Install the wires into the connectors as listed below: N-17779

Left and Right Control Lever Switch Handle [Figure 60120-27]

Figure 60-120-26

1-Terminal - Red/White 2-Terminal - Black/White 3-Terminal - Purple/White

1

Figure 60-120-28

3

N-17772

1 2

Connect the handle harness connectors (Item 1) [Figure 60-120-25] & [Figure 60-120-26] to the loader harness connectors.

P13735

Left and Right Control Lever Switch Handle [Figure 60120-28] 1-Terminal - Yellow/Red 2-Terminal - Open 3-Terminal - Orange/Black

60-120-11


Figure 60-120-31

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation (Cont'd)

1

Figure 60-120-29

N-18940

Check the mounting block (Item 1) [Figure 60-120-31] and bolts for wear and replace as needed.

P-21804

Connect the handle harness connectors to the sensor and lock solenoid connectors [Figure 60-120-29]. Actuators Disassembly and Assembly Figure 60-120-30

1

N-18912

Remove the control panel. (See Removal and Installation on Page 50-100-1.) Remove the actuator (Item 1) [Figure 60-120-30] from the hydraulic control valve. (See Actuator Removal And Installation on Page 20-41-12.) Installation: Tighten the mount bolts to 90-100 in.-lb. (10,2-11,3 N•m) torque.

60-120-12


ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Actuators Disassembly and Assembly (Cont’d) Figure 60-120-32

2

1 N-17742

N-17741

Check the actuator wiring harness connector (Item 1) [Figure 60-120-32] and replace if broken. Installation: Install the wires into the connector as listed below. The terminal numbers are written on the back of the connector (Item 2) [Figure 60-120-32]. Lift and Tilt Actuator 1. Terminal-Black/Green-Larger diameter wire (16 gauge) 2. Terminal-Green-Larger diameter wire (16 gauge) 3. Terminal-Red/Green-Larger diameter wire (16 gauge) 4. Terminal-Open 5. Terminal-Red-Smaller diameter wire (18 gauge) 6. Terminal-Open 7. Terminal-Open 8. Terminal-Black-Smaller diameter wire (18 gauge) NOTE: The calibration procedure must be followed when replacing a handle sensor, foot pedal sensor, actuator or ACS controller. (See Calibration Procedure on Page 60-120-16.)

60-120-13



Handle Lock Solenoid Disassembly And Assembly

Handle Lock Solenoid Removal And Installation

Figure 60-120-35

Figure 60-120-33

2

1 2 P-21878A

1 P-21836

Disconnect the harness connector (Item 1) [Figure 60120-33] from the handle sensor connector. Disconnect the harness connector (Item 2) [Figure 60120-33] from the handle lock solenoid connector.

Remove solenoid (Item 1) from the solenoid mount (Item 2) [Figure 60-120-35]. Installation: Apply a drop of oil to the solenoid threads and tighten solenoid to 35-40 ft.-lb. (47-54 N•m) lubed torque. Figure 60-120-36

Figure 60-120-34

1

1

P-21789 P-21832

Remove the two screws (Item 1) [Figure 60-120-34] holding the handle lock solenoid to the handle.

Check the O-ring (Item 1) [Figure 60-120-36] for damage. Replace as necessary.

Installation: Tighten the screws to 32-38 in.-lb. (3,6-4,3 N•m) torque. Remove handle lock solenoid assembly from handle.

60-120-14


Figure 60-120-39

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Connector Figure 60-120-37

1

2

3

1

P-21802

1

With a pointed tool, lift the tab (Item 1) [Figure 60-12039] and pull the wire from the connector.

P-21787

The wire connector (Item 1) [Figure 60-120-37] can be removed from the solenoid, using the following procedure: Figure 60-120-38

1

Installation: Install the wires into the connector as listed below [Figure 60-120-39]. 1 - Terminal - Black 2 - Terminal - Open 3 - Terminal - Black

1

P-21801


60-120-15


Figure 60-120-42

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Calibration Procedure The new controller uses a calibration sequence to optimize the control system. The optimizing ensures full spool stroke (full flow) while preventing over stroke (loading) of the actuator. NOTE: This calibration procedure must be followed when replacing a handle sensor, actuator or ACS controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s).

2

1

Figure 60-120-40 B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure 60-120-42] to unlock the hand controls. Figure 60-120-43 1

Stroke Both Handles Fully In and Hold Them

P-24182

Update the loader service software to the latest version. Place the rocker switch (Item 1) [Figure 60-120-40] in the hand control mode. B-16628

Figure 60-120-41

Fully stroke both control handles in toward the center of the cab and hold the handles [Figure 60-120-43]. Lift the seat bar, high enough for the PRESS TO OPERATE light (Item 2) [Figure 60-120-42] to go OFF.

Turn the Key On or

Lower the seat bar.

Press the RUN/ENTER

B-16626

With the seat bar down, turn the ignition key ON (keyless panel press RUN/ENTER) [Figure 60-120-41]. NOTE: Do not start the engine. 60-120-16


Figure 60-120-45

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Calibration Procedure (Cont'd)


Figure 60-120-44

2

2

1

1 B-16628

Fully move both handles in toward the center of the cab and hold the handles for one second (Item 1) [Figure 60120-45].

B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure 60-120-44] to begin calibration.

Fully move both handles out toward the cab side screens and hold for one second (Item 2) [Figure 60-120-45].

NOTE: The ACS icon will light up and if you listen closely the cycling of the actuators can be heard. The ACS icon will stay lit until the ignition key is cycled or the loader is started and a function is operated.

Allow both handles to return to neutral. Figure 60-120-46

NOTE: During the calibration cycle, the system will beep three times. The calibration process generates two codes 32-35 (tilt handle not in neutral) and 32-40 (lift handle not in neutral). Ignore these two codes, this is normal during the calibration procedure.

1

Release the control handles.

2

NOTE: The remaining portion of the procedure must be completed in twenty seconds or less. If not the handles and pedals will lock and the procedure must be started over from the beginning.

B-16628

Fully press the toe of the lift and tilt pedals (Item 1) [Figure 60-120-46] down and hold for one second. Fully press the heel of the lift and tilt pedals (Item 2) [Figure 60-120-46] down and hold for one second. Allow both pedals to return to neutral. At the end of the twenty second time frame, the handles and pedals will lock. Calibration is complete.

60-120-17



Foot Sensor Connector

Foot Sensor Disassembly And Assembly

Figure 60-120-49

Figure 60-120-47

1

1 P-24271

1

P-24269

Remove the two bolts (Item 1) [Figure 60-120-47] from the end of the foot sensor. Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m) torque. Apply LOCTITE 242 to the threads.

The wire connector (Item 1) [Figure 60-120-49] can be removed from the sensor wires, using the following procedure: Figure 60-120-50

1

Figure 60-120-48 5

1

1

4 2 1

P-24272

3

P-24273 P-24273


P-24270

Remove the boot retainer (Item 1), boot (Item 2), spool stop plate (Item 3), O-ring (Item 4) [Figure 60-120-48]. NOTE: Do not disassemble the sensor assembly (Item 5) [Figure 60-120-48]. The sensor assembly is a calibrated assembly and cannot be serviced. Order through Bobcat Parts.

60-120-18


Figure 60-120-53

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Connector (Cont'd)

1

Figure 60-120-51

1

1

2 3

2

P-21939

Disconnect the foot lock solenoid connector (Item 1) [Figure 60-120-53] from the harness.

P-24274

With a pointed tool, lift the tab (Item 1) [Figure 60-12051] and pull the wire from the connector. Installation: Install the wires into the connector as listed below [Figure 60-120-51]:

Remove foot lock solenoid (Item 2) [Figure 60-120-53]. Installation: Apply a drop of oil on the solenoid threads and tighten the solenoid to 35-40 ft.-lb. (47-54 N•m) lubed torque. Figure 60-120-54

1 - Terminal - Red 2 - Terminal - Black 3 - Terminal - Green Foot Lock Solenoid Removal And Installation Figure 60-120-52

2

1

P-21790

Check the O-ring (Item 1) [Figure 60-120-54] for damage. Replace as necessary. 1

P-21938

Remove the two bolts (Item 1) [Figure 60-120-52] from the foot sensor shield. Installation: Tighten the bolts to 80-90 in.-lb. (9,0-10,2 N•m) torque.

60-120-19


ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Foot Lock Solenoid Connector The wire connector (Item 2) [Figure 60-120-54] can be removed from the solenoid wires, using the following procedure: Figure 60-120-55

1

1

P-21800

P-21801

Remove the wedge (Item 1) [Figure 60-120-55] from the connector. Figure 60-120-56

3

1 2 1

P-21802

With a pointed tool, lift the tab (Item 1) [Figure 60-12056] and pull the wire from the connector. Installation: Install the wires into the connector as listed below [Figure 60-120-56]: 1 - Terminal - Black 2 - Terminal - Open 3 - Terminal - Black

60-120-20


ELECTRICAL/HYDRAULIC CONTROLS REFERENCE Controls Identification Chart

Left Side Control Handle Switches

B-16447

xxxxxxxxx Switch Number

Solenoid Number Activated RH

HFH

Attachment Harness Attachment Harness Terminal Connector Activated

1

1

1

1, 8

K

2

2

2

2

K

3

1

1

1, 8

K

4

2

2, 3

6, 7

K, A, D

5

1

1, 3

5, 7

K, A, C

6

1

1, 3

5, 7

K, E

7

1

1, 3

5, 7

K, F

8

1

1, 3

5, 7

K, G

9

1

1, 3

5, 7

K, H

10, 11, 12, 13, 14

-

--

--

K

Fourteen Pin Connector Viewed from front (pin side of connector) of loader.

Right Side Control Handle Switches

B-16449 B-16448

1

NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). The ACD (Attachment Control Device), automatically recognizes the use of the seven or fourteen pin connector when connected. If the ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab flashes, check for diagnostic service codes. See the Electrical System Service Manual for the proper procedure. 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.

60-130-1


ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (CONT’D) Solenoid Number

Controls Identification Chart (Cont’d)

1

S175, S185

2

6

3

4

1

4

2

5 6 3

Hydraulic Coupler Front Female (Base) Front Male (Rod) Diverter & Bleed Rear Aux Base Rear Aux Rod High Flow

Wiring Number 4340

4330 4450/4480 4440 4430 4460

5

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 3 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 6 on the High Flow valve.

60-130-2


ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) Controls Identification Chart

RIGHT HAND

17

18 1

2 8

10 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

3

P-28316

LEFT HAND

19 4

20 5

4. Rear Aux. (Side Shift 5. Rear Aux. (Side Shift) 6. Left Skit (Up) 7. Left Ski (Down) 12. Two-Speed (High) 13. Two-Speed (Low) 14. Horn 15. Inching Control (Grey in Color) 19. Future Function 20. Future Function

12 6 7

13 15

14

P-24820

P-28317

60-131-1


ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Controls Identification Chart (Cont’d)

xxxxxxxxx Switch Number

Left Side Control Handle Switches

4

Solenoid Number Activated

Attachment Harness Terminal Activated

STD

RH

HFH

HRH

1

1

1

1, 6

1, 6

K

2

2

2

2

2

K

3

1

1

1, 6

1, 6

K

4

2

3, 5

2

3, 5

K, A, D

5

1

3, 4

1

3, 4

K, A, C

6

1

3, 4

1

3, 4

K, E

7

1

3, 4

1

3, 4

K, F

8

1

3, 4

1

3, 4

K, G

9 1 3, 4 Attachment Harness Connector

1

3, 4

K, H

5

6

7

Fourteen Pin Connector Viewed from front (pin side of connector) of loader.

Right Side Control Handle Switches

8

9 2

1

3

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.

60-131-2


ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Controls Identification Chart (Cont’d) Solenoid Number

S175, S185

1 6 4

1

2

2

3

3

4 5

5 6

Hydraulic Coupler Front Female (Base) Front Male (Rod) Diverter & Bleed Rear Aux Base Rear Aux Rod High Flow

Wiring Number 4340

4330 4450/4480 4440 4430 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 3 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 6 on the High Flow valve.

60-131-3


60-131-4


Figure 60-140-2

FLYWHEEL RPM SENSOR Adjustment Figure 60-140-1

1

1

2

P-48666

P-48665

When reinstalling the RPM sensor, turn the rpm sensor (Item 1) [Figure 60-140-1] in until it makes contact with the engine flywheel. Turn the jam nut (Item 2) [Figure 60-140-1] until it contacts the flywheel housing. The jam nut should not be tightened, it needs to turn with the RPM sensor when the sensor is turned back out for adjustment.

Turn the RPM sensor and the jam nut out from the flywheel. Set a clearance of .050 inch (1,27 mm) between the jam nut and the housing with a feeler gauge (Item 1) [Figure 60-140-2]. NOTE: New RPM sensors have a plastic tip which is used as a gauge during installation. The plastic tip is designed to come off after the engine is started.

60-140-1


60-140-2


SERVICE PC (LAPTOP COMPUTER) Connecting The Service PC To Remote Start Tool Figure 60-150-1 2

1

3

P16119

Tools that will be needed to complete the following steps are: MEL1563 - Remote Start Tool MEL1565 - Service Tool Harness Control MEL1566 -Service Tool Harness Communicator (Computer Interface) NOTE: Make all connections with the key in the OFF position. The Service PC (Item 1) with the remote start tool (Item 2) [Figure 60-150-1]. When connected to the loader, the Service PC is used to monitor, conduct diagnostic and load software. Connect the Service Tool Harness Communicator (MEL1566) (Item 3) [Figure 60-150-1] to the designated serial port on the Service PC. NOTE: The recommended serial cable length should not exceed 15 feet. A serial cable longer than 15 feet will create a degraded signal causing communication errors. Connect the other end to the connector on the remote start tool. Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.)

60-150-1


60-150-2


CALIBRATION

Actuator Testing

Description

The Actuator Test is performed with the Service PC and Remote Start Tool. The Actuator Test should be used if reduced performance codes are present and when replacing a controller or actuator. The Actuator Test should be used as the preferred method of actuator and valve spool calibration.

Calibration procedures must be followed when replacing a handle sensor, actuator, or any controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s). Figure 60-160-1

NOTE: Warm the hydraulic oil to room temperature 72oF (22oC), stop the engine and clear all active service codes before running the test.

Control Valve Actuators

Once the test is initiated, an automatic calibration sequence will start. When calibration is complete, the test will be performed and the results can be viewed on the Service PC (Laptop) monitor. This test will engage both actuators to fully stroke the spools then allow the centering springs to return the spools to neutral. Next, both actuators are engaged to move the spools just past the neutral points then allow the centering springs to return the spools to neutral. P-24203

[Figure 60-160-1] Excessive actuator loading can occur if the actuator and valve spool components are misaligned. Misalignment may reduce spool stroke performance and reduce the life of the actuator. Starting with version 36, the Bobcat Service Analyzer software will be able to perform tests to diagnose actuator and valve spool misalignment. The Actuator Test is performed with the Service PC and Remote Start Tool. The Actuator Test should be used if reduced performance codes are present and when replacing a controller or actuator. The Actuator Test should be used as the preferred method of actuator and valve spool calibration.

When complete, the Actuator Test will show a pass mode or fail mode. The pass mode indicates that no problems were detected. The fail mode indicates one or a combination of three problems below. •

Actuator slow return to neutral. The spool returns to neutral too slowly.

•

Actuator did not fully extend/retract. During the test, the spool was not able to fully stroke in both directions.

•

Actuator out of neutral. The spool did not return to the neutral window during the test.

NOTE: A time out will occur if the test cannot be completed within 8 seconds. If this happens, retry the test.

If a Service PC is not available,: See Lift and Tilt Calibration Procedure (SJC) on page 60-160-4 or See Calibration Procedure (ACS) on page 60-160-11.

60-160-1


Figure 60-160-3

CALIBRATION (CONT’D) Actuator Testing (Cont’d)

Actuator

Pin

Spool Hole

Figure 60-160-2 Run Actuator Test Pass

Fail

Retest With Warm Hydraulic Oil Pass

Fail

Adapter Bolts

Loosen Actuator Pass

Column 1 Probable Cause 1 - Misaligned Assembly 2 - Adapter / Pin 3 - Spool

Fail

N-18940

[Figure 60-160-3] If the Actuator Test fails after the hydraulic oil is warmed, go to the next step and loosen the bolts that mount the actuator to the control valve. Loosen the bolts just enough so the actuator can be moved slightly up/down or side/side.

Column 2 Probable Cause 1 - Actuator 2 - End Cap / Center Spring 3 - Wire Harness 4 - Controller

[Figure 60-160-2] If the initial Actuator Test results in a fail mode due to a slow return to neutral, follow the troubleshooting tree to pinpoint the probable cause.

Rerun the Actuator Test, if the test passes, check the following probable causes in Column 1 [Figure 60-1602]. Check the probable causes in the order they are listed. Repairing one cause may be all that is required. Rerun the test to verify. 1. Actuator and spool misalignment. Re-tighten the two bolts evenly, turn the first bolt one turn, then turn the other bolt one turn until both bolts are tight. Figure 60-160-4

Thickness Difference on Opposite Sides Must be Within 0.004” (0.102mm)

P-54928B

2. [Figure 60-160-4] The adapter may not be machined correctly. Adapters with a large difference in thickness measured on opposite sides should be replaced. The pin may be too large. Oversized pins exceeding 0.248” (6.30mm) in diameter should be replaced. 60-160-2


If the initial Actuator Test results in the fail mode actuator did not fully extend/retract, check the following.

CALIBRATION (CONT’D) Actuator Testing (Cont’d) Figure 60-160-5

1. The actuator connectors may be reversed between the lift and tilt actuator. Reverse the connectors and rerun the Actuator Test.

This spool hole is not centered.

2. The actuator may be weak, replace the actuator. 3. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary.

The Hole is Shifted Off Center

If the initial Actuator Test results in the fail mode actuator out of neutral, check the following. 1. The actuator may be defective, replace the actuator. P-54927

3. [Figure 60-160-5] The spool hole may not be centered, visually inspect both sides. Replace the spool if the hole is not centered.

2. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary. This letter is provided as technical information. Normal warranty applies.

NOTE: Later model spools have a slotted hole to reduce misalignment. If the Actuator Test failed due to a slow return to neutral after checking the probable causes in Column 1 [Figure 60-160-2], check the following probable causes in Column 2 [Figure 60-160-2]. 1. The actuator may be weak, replace the actuator. 2. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary. 3. The wire harness or connectors may have an intermittent short. Check the connections and wire harnesses. 4. The controller may be defective, replace the controller.

60-160-3


Figure 60-160-8

CALIBRATION (CONT’D) Lift and Tilt Calibration Procedure (SJC) NOTE: This calibration procedure must be followed when replacing the lift or tilt actuator, SJC controller or joystick. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s). Figure 60-160-6

1

P-26475

1

Figure 60-160-9

P-45240

With an operator in the seat and the seat bar down. Close the cab door. (If loader is so equipped.)

1

Place the loader Control Pattern Switch (Item 1) [Figure 60-160-6] in the ISO position.

P-26480

Figure 60-160-7 Turn the key (Item 1) [Figure 60-160-8] to the RUN position or press the RUN/ENTER button (Item 1) [Figure 60-160-9] for power, without starting the loader. The loader Control Pattern Switch (Item 1) [Figure 60160-6] will start flashing and will continue to flash until the calibration procedure is completed. B-19874

P-28063

Move the right joystick to the forward-right corner position [Figure 60-160-7] and hold in position.

60-160-4


Hydrostatic Pump Calibration (SJC)

CALIBRATION (CONT’D) Lift and Tilt Calibration Procedure (SJC) (Cont’d)

WARNING

Figure 60-160-10

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.

2

W-2017-0286

Place the loader on jackstands. (See Procedure on Page 10-10-1.) Operator must be in the seat and the seat bar down. Figure 60-160-11

1 P-26477A

At the left panel, press the PRESS TO OPERATE Button (Item 1) [Figure 60-160-10] while holding the right joystick in position.

1

Release the joystick. 2 An audible beep will sound and an error code (Item 2) [Figure 60-160-10] (32-35 & 32-40) will be displayed if the operator presses the HOLD FOR CODES, (LIGHTS) switch. The SJC controller will cycle the actuators. The lift and tilt calibration is complete.

P-45238

Close the cab door. (If loader is so equipped.) Place the loader Control Pattern Switch (Item 1) [Figure 60-160-11] in the ISO position. Verify the parking brake (Item 2) [Figure 60-160-11] is OFF.

60-160-5


Figure 60-160-14

CALIBRATION (CONT'D) Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-12

1

P-45238

1

The Control Pattern ISO Switch (Item 1) [Figure 60-16014] will start flashing.

P-26475

Figure 60-160-15

Figure 60-160-13

1

B-19873 P-26476

P-26480

Turn the key (Item 1) [Figure 60-160-12] to the RUN position or press the RUN/ENTER button (Item 1) [Figure 60-160-13] for power, without starting the loader.

Move the left joystick to the forward-left corner position [Figure 60-160-15] and hold in position.

60-160-6


CALIBRATION (CONT'D)

Figure 60-160-18

Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-16

1 P-26477A

1

Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-18] while holding the left joystick in position.

P-26477A

Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-16] while holding the left joystick in position.

Three audible beeps will sound. Figure 60-160-19

Three audible beeps will sound. Figure 60-160-17

B-19873

P-26474

Allow the left joystick to go to the neutral position [Figure 60-160-19].

P-26476

Move the left joystick to the reverse-right corner position [Figure 60-160-17] and hold in position.

60-160-7


Figure 60-160-22


1 2

75-98

3 P-34548

1

Move the throttle (Item 1) [Figure 60-160-22] to high idle. P-26477A

Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-20].

NOTE: If at any time, during calibration, the operator needs to stop the loader, turn the key OFF, lift the seat bar, or return the joystick to the neutral position.

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 60-160-20].

The calibration procedure will stop. To return to calibration mode, the operator must start the complete procedure from the beginning.

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


1

P-45238

The Control Pattern ISO Switch (Item 1) [Figure 60-16021] will stop flashing, and will remain ON for the rest of the calibration procedure.

60-160-8


Figure 60-160-24


1

2

B-19873 P-64321

The loader speed will “ramp up” quickly (Item 1) [Figure 60-160-24] and slow down 3 times in a row.

P-26482

Move and hold the left joystick to the forward position [Figure 60-160-23] until the forward calibration is completed.

The loader will then “stair step” the speed (Item 2) [Figure 60-160-24] until it reaches full speed and then come to a stop. Continue to hold the left joystick in the forward position until the loader tracks come to a stop and an audible beep is heard. Forward calibration is complete. NOTE: If the wheels do not stop moving in Full Speed Forward in 2 minutes or less, there was an error in the calibration procedure. The operator must shut the loader OFF, and start the calibration procedure from the beginning. Figure 60-160-25

B-19873

P-26483

Move and hold the left joystick to the reverse position [Figure 60-160-25] until the reverse calibration is completed.

60-160-9


NOTE: If the wheels do not stop moving in Full Speed Reverse in 2 minutes or less, there was an error in the calibration procedure. The operator must shut the loader OFF, and start the calibration procedure from the beginning.


1

There will be an audible beep and the PRESS TO OPERATE LOADER and TRACTION lights will go out. The SEAT BAR and LIFT AND TILT lights will remain on. The 75-98 error code will clear. There should be no other codes in the display area.

2

Allow the joystick to go to the neutral position. The calibration procedure is completed. Press the PRESS TO OPERATE LOADER button. Move the left joystick to forward position [Figure 60-160-23] and check for normal forward wheel rotation. P-64321

The loader speed will “ramp up” quickly (Item 1) [Figure 60-160-26] and slow down 3 times in a row. The loader will then “stair step” the speed (Item 2) [Figure 60-160-26] until it reaches full speed and then come to a stop.

Move the left joystick to the reverse position [Figure 60160-25] and check for normal reverse wheel rotation. Stop the engine, and remove the loader from jackstands. Start the loader, press the PRESS TO OPERATE LOADER button and return to normal loader operation.

Continue to hold the left joystick in the reverse position until the loader wheels come to a stop and an audible beep is heard. Reverse calibration is complete.

60-160-10


Figure 60-160-29

CALIBRATION (CONT’D) Calibration Procedure (ACS) The new controller uses a calibration sequence to optimize the control system. The optimizing ensures full spool stroke (full flow) while preventing over stroke (loading) of the actuator.

2

NOTE: This calibration procedure must be followed when replacing a handle sensor, actuator or ACS controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s).

1

Figure 60-160-27

B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure 60-160-29] to unlock the hand controls. Figure 60-160-30 1 Stroke Both Handles Fully In and Hold Them

P-24826

Update the loader service software to the latest version. Place the rocker switch (Item 1) [Figure 60-160-27] in the hand control mode. Figure 60-160-28

B-16628

Fully stroke both control handles in toward the center of the cab and hold the handles [Figure 60-160-30]. Lift the seat bar, high enough for the PRESS TO OPERATE light (Item 2) [Figure 60-160-29] to go OFF.

Turn the Key On or

Lower the seat bar.

Press the RUN/ENTER

B-16626

With the seat bar down, turn the ignition key ON (keyless panel press RUN/ENTER) [Figure 60-160-28]. NOTE: Do not start the engine.

60-160-11


Figure 60-160-32

CALIBRATION (CONT’D) Calibration Procedure (ACS) (Cont'd)


Figure 60-160-31

2

2

1

1 B-16628

Fully move both handles in toward the center of the cab and hold the handles for one second (Item 1) [Figure 60160-32].

B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure 60-160-31] to begin calibration.

Fully move both handles out toward the cab side screens and hold for one second (Item 2) [Figure 60-160-32].

NOTE: The ACS icon will light up and if you listen closely the cycling of the actuators can be heard. The ACS icon will stay lit until the ignition key is cycled or the loader is started and a function is operated.

Allow both handles to return to neutral. Figure 60-160-33

NOTE: During the calibration cycle, the system will beep three times. The calibration process generates two codes 32-35 (tilt handle not in neutral) and 32-40 (lift handle not in neutral). Ignore these two codes, this is normal during the calibration procedure.

1

Release the control handles.

2

NOTE: The remaining portion of the procedure must be completed in twenty seconds or less. If not the handles and pedals will lock and the procedure must be started over from the beginning.

B-16628

Fully press the toe of the lift and tilt pedals (Item 1) [Figure 60-160-33] down and hold for one second. Fully press the heel of the lift and tilt pedals (Item 2) [Figure 60-160-33] down and hold for one second. Allow both pedals to return to neutral. At the end of the twenty second time frame, the handles and pedals will lock. Calibration is complete.

60-160-12


SPEED SENSOR

Testing

Description

Figure 60-170-2

Figure 60-170-1

1 P-28302 P-64765

On SJC equipped loaders, the speed sensor [Figure 60170-1] is used by the loader’s controllers to sense if the drive motor is rotating. The end of the sensor is magnetic and counts the magnetic pulses as a rotating disc attached to the motor carrier shaft rotates by the sensor end. The speed sensor is sealed with an o-ring (Item 1) [Figure 60-170-1] to keep hydraulic oil inside the motor carrier and dirt out.

The tools listed will be needed to do the following procedure: MEL1609-Wheel Speed Sensor Test Harness [Figure 60-170-2] MEL1563-Remote Start Tool Multimeter Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. ((See Procedure on Page 10-60-1.)

60-170-1


Figure 60-170-4

SPEED SENSOR (CONT'D) Testing (Cont’d) Figure 60-170-3

3 2 1 2 1

P-64976

Connect the speed sensor test harness (Item 1) [Figure 60-170-4] in line, between the loader wiring harness and the speed sensor harness.

P-64762

Locate the speed sensor (Item 1) [Figure 60-170-3] on the top of the right or left hydrostatic motor carrier.

Turn the remote start key to ON position without starting the loader.

Remove the transmission cover screw (Item 2) [Figure 60-170-3], to loosen the connector clamp.

Take a voltage reading, with the multimeter, at the speed sensor test harness, between pin 1 and pin 3 (Item 2) [Figure 60-170-4].

Installation: Tighten screw to 15-20 ft.-lb. (20-27 N•m) torque. Disconnect the speed sensor wire connector (Item 3) [Figure 60-170-3] from the loader harness wire connector.

The voltage should be approximately 5 volts. Repeat the procedure for the opposite side speed sensor. (If needed.)

60-170-2


Disconnect the speed sensor electrical connector (Item 2) [Figure 60-170-6].

SPEED SENSOR (CONT'D) Removal and Installation

harness

Figure 60-170-7

Figure 60-170-5

1 2

1

P-64764 P-64762


Lift the speed sensor (Item 1) [Figure 60-170-7] out from the motor carrier. DO NOT pull on the wires, gently pry up with a screwdriver if necessary. Figure 60-170-8

Remove the two, speed sensor mount bolts (Item 1) [Figure 60-170-5] from the top of the hydrostatic motor carrier. Remove the mount plate (Item 2) [Figure 60-170-5]. Figure 60-170-6 2 1

P-64765

Remove the speed sensor [Figure 60-170-8].

P-64762

Remove the transmission cover screw (Item 1) [Figure 60-170-6], to loosen the connector clamp. Installation: Tighten screw to 15-20 ft.-lb. (20-27 N•m) torque.

60-170-3


Figure 60-170-11

SPEED SENSOR (CONT'D) Removal and Installation (Cont'd) Figure 60-170-9

1 1

P-26292

Installation: Be sure to install the speed sensor (Item 1) [Figure 60-170-11] pointing toward the transmission case.

P-26293

The electrical connector can be replaced.

Figure 60-170-12

Remove the connector wedge (Item 1) [Figure 60-1709]. Figure 60-170-10

1 2 1

P-26295

Installation: The alignment pin (Item 1) at the bottom of the speed sensor must be installed in the hole (Item 2) [Figure 60-170-12] in the motor carrier.

P-26294

With a thin screwdriver lift the tabs and remove the wires from the connector (Item 1) [Figure 60-170-10]. Wire Code 1 2 3 4

Red White Black Blue

60-170-4


ENGINE SERVICE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1 COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 Blower Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4 Blower Housing Grill Removal And Installation . . . . . . . . . . . . . . . . 70-60-4 Drive Tension Pulley Removal And Installation . . . . . . . . . . . . . . . . 70-60-1 Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12 Gearbox/Blower Housing Removal And Installation . . . . . . . . . . . . 70-60-2 Gearbox Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17 Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7 Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . . . . . . . . 70-70-1 Checking Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . 70-70-15 Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1 Fuel Injection Pump Removal And Installation (Non-Turbo) . . . . . . 70-70-8 Fuel Injection Pump Removal And Installation (Turbo) . . . . . . . . . . 70-70-5 Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-70-14 Fuel Shut-Off Solenoid, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3 Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . . . . 70-70-4 Glow Plugs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2 Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-70-2 Nozzle Spraying Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16 Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18

ENGINE SERVICE

ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2 Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 Continued On Next Page

70-01


ENGINE SERVICE (CONT’D) MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1 RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1 Camshaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14 Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . 70-100-19 Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . 70-100-25 Crankshaft And Bearings Removal And Installation . . . 70-100-25 Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . 70-100-27 Crankshaft Gear Removal And Installation . . . . . . . . . . 70-100-17 Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31 Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-100-4 Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-100-1 Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5 Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . 70-100-5 Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . 70-100-17 Fuel Camshaft Removal And Installation. . . . . . . . . . . . 70-100-16 Idler Gear And Camshaft Removal And Installation . . . 70-100-13 Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . 70-100-15 Oil Pump Removal And Installation . . . . . . . . . . . . . . . . 70-100-18 Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-18 Piston And Connecting Rod Removal And Installation . 70-100-20 Piston And Connecting Rod Servicing . . . . . . . . . . . . . . 70-100-22 Reconditioning The Valve And Valve Seat . . . . . . . . . . . 70-100-8 Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . 70-100-10 Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . 70-100-16 Timing Gearcase Cover Removal And Installation . . . . 70-100-10 Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6 Valve Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9 Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-20 Water Pump Disassembly And Assembly . . . . . . . . . . . 70-100-32 Water Pump Removal And Installation . . . . . . . . . . . . . 70-100-32 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .

70-02

70-110-1 70-110-1 70-110-1 70-110-2


TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only. PROBLEM Slow cranking speed. Engine will not start. Difficult to start. No power for engine. Engine is mis-firing. Too much fuel consumption. Black exhaust. Blue/white exhaust. Low oil pressure. Engine knocking. Engine running rough. Vibration. High oil pressure warning. Overheating. Too much crankcase pressure. Poor compression. Start and stop.

CAUSE 1, 2, 3, 54 2, 5, 6, 7, 8, 9, 10, 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

70-10-1


TROUBLESHOOTING (CONT’D) Chart (Cont’d) KEY TO CORRECT THE CAUSE 1. Alternator belt is loose or damaged. 2. Bad electrical connections. 3. Faulty starter motor. 4. Incorrect grade of oil. 5. Low cranking speed. 6. Fuel tank empty. 7. Faulty stop control operation. 8. Plugged fuel line. 9. Plugged fuel filter. 10. Restriction in the air cleaner. 11. Air in the fuel system. 12. Faulty fuel injection pump. 13. Faulty fuel injectors. 14. Broken injection pump drive. 15. Incorrect injection pump timing. 16. Incorrect valve timing. 17. Poor compression. 18. Plugged fuel tank vent. 19. Incorrect grade of fuel. 20. Exhaust pipe restriction. 21. Cylinder head gasket leaking. 22. Overheating. 23. Cold running. 24. Incorrect tappet adjustment. 25. Sticking valves. 26. Incorrect fuel lines. 27. Worn cylinder bores.

28. Worn valve and seats. 29. Broken or worn piston rings. 30. Worn valve stems or guides. 31. Worn or damaged bearings. 32. Not enought oil in the crankcase. 33. Switch/sensor is defective. 34. Oil pump worn. 35. Relief valve is sticking open. 36. Relief valve is sticking closed. 37. Broken relief valve spring. 38. Faulty suction pipe. 39. Plugged oil filter. 40. Piston seizure. 41. Incorrect piston height. 42. Faulty engine mounting. 43. Incorrect flywheel alignment. 44. Faulty thermostat. 45. Restriction in water jacket. 46. Loose alternator belt. 47. Plugged radiator. 48. Faulty water pump. 49. Plugged breather pipe. 50. Damaged valve stem deflectors. 51. Coolant level to low. 52. Plugged oil pump pipe strainer. 53. Broken valve spring. 54. Damaged Battery

70-10-2


Figure 70-20-2

ENGINE SPEED CONTROL Removal And Installation

1

WARNING

P-4072


Pull the speed control away from the loader frame and disconnect the speed control rod (Item 1) [Figure 70-202] from the control. Installation: Be sure to install the control rod in the bottom hole of the speed control. Figure 70-20-3

Figure 70-20-1

1

1

1

2

2 P-34156

N-18878

Raise the lift arms and install an approved lift arm device. (See Installing Lift Arm Support Device on Page 10-201.)

Installation: Install the stop bracket (Item 1) [Figure 7020-3] in the same location. It is necessary for the front and rear stop on the bracket to be located correctly.


Reverse the removal procedure to install the engine speed control.

Remove the two mounting bolts (Item 1) [Figure 70-201] and nuts from the speed control mounting bracket.

Disassembly

Installation: Tighten the mounting bolts and nuts evenly until the speed control lever moves back and forth at a comfortable tension.

Loosen the two control lever mounting bolts (Item 2) [Figure 70-20-1] and remove the mounting nuts (Item 2) [Figure 70-20-3]. Assembly: Do not lubricate the engine speed control. Replace any worn or damaged parts if necessary.

70-20-1


70-20-2


MUFFLER Removal And Installation Figure 70-30-1

3 3 2 1

P-48866

Open the rear door and raise the rear grill. Remove the exhaust pipe clamp (Item 1) from the muffler (Item 2) [Figure 70-30-1]. Disconnect the exhaust pipe from the muffler. Remove both muffler mounting bolts (Item 3) [Figure 70-30-1] from the muffler. Installation: Tighten the muffler mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque. Remove the muffler from the loader. Reverse the removal procedure to install the engine muffler.

70-30-1


70-30-2


Figure 70-40-3

AIR CLEANER Removal And Installation Figure 70-40-1

1 1

2 P-28915

2 Remove the lower mounting bolt (Item 1) and engine harness mounting bracket (Item 2) [Figure 70-40-3] from the air cleaner.

P-34449

Disconnect the wire harness connector (Item 1) [Figure 70-40-1] from the air cleaner sensor on the air cleaner.

Installation: Tighten the three mounting bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Loosen the clamp (Item 2) [Figure 70-40-1] from the hose on the engine manifold.

Remove the air cleaner from the engine compartment. Reverse the removal procedure to install the air cleaner.

Figure 70-40-2

2

1

P-34450

Loosen the hose clamp (Item 1) [Figure 70-40-2] on the air cleaner hose. Remove the two mounting bolts (Item 2) [Figure 70-402] from the top mount of the air cleaner.

70-40-1


70-40-2


Figure 70-50-2

RADIATOR Removal And Installation Stop the engine and open the rear door.

1

Remove the rear grill. (See Removal And Installation on Page 50-60-1.) Remove the oil cooler. (See Removal and Installation on Page 30-60-1.)

WARNING

P-48551

Do not remove radiator cap when the engine is hot. You can be seriously burned. W-2070-1285

Figure 70-50-1

Open the drain valve (Item 1) [Figure 70-50-2] on the engine block and drain the coolant into a container. Figure 70-50-3

1 1

1

P-45245

Loosen the radiator cap (Item 1) [Figure 70-50-1] from the pressurized expansion tank.

P-48242

Remove the two sta-straps (Item 1) [Figure 70-50-3] holding the pressurized expansion tank fill hose (Item 3) [Figure 70-50-4].

70-50-1


Figure 70-50-6

RADIATOR (CONT'D) Removal And Installation (Cont'd) Figure 70-50-4

1

1

3 2

2 P-48570

P-48554

Remove the hose clamp (Item 1) [Figure 70-50-6] from the inlet hose.

P-45245

Remove the two pressurized expansion tank mounting bolts (Item 1) [Figure 70-50-4]. Disconnect the pressurized expansion tank fill hose (Item 3) [Figure 70-50-4] at the radiator end. Remove the pressurized expansion tank (Item 2) with the pressurized expansion tank fill hose (Item 3) attached. [Figure 70-50-4].

Remove the radiator mounting bolt and block off plate (Item 2) [Figure 70-50-6]. Installation: Tighten the radiator mounting bolt to 11-13 ft.-lb. (15-17 N•m) torque. Use sealant on the block off plate and bolt head (Item 2) [Figure 70-50-6]. Figure 70-50-7

Figure 70-50-5

3

1 2 1 P-48553

Remove the clamp (Item 1) [Figure 70-50-7] from the hydraulic fill tube.

P-48552

Remove the hose clamp (Item 1) [Figure 70-50-5] from the outlet hose.

Remove the radiator mounting bolt (Item 2) [Figure 7050-7]. Remove the two hydraulic fill tube mounting bolts (Item 3) [Figure 70-50-7].

70-50-2


RADIATOR (CONT'D) Removal And Installation (Cont'd) Figure 70-50-8

1

P-48841

Remove the hydraulic fill tube (Item 1) [Figure 70-50-8]. Lift the radiator up and remove it from the loader. Reverse the above procedure to install the radiator.

70-50-3


70-50-4


Figure 70-60-3

COOLING FAN Drive Tension Pulley Removal And Installation Figure 70-60-1

1

1

P0581

P0580

Installation: Put a small amount of grease around the outside edge (Item 1) [Figure 70-60-3] on the grease rings.

P0585

Loosen the idler pulley bolt [Figure 70-60-1].

Figure 70-60-4

Installation: Install the retainer bracket (Item 1) [Figure 70-60-1] for the fan belt at the 3 o'clock position.

6

3

Figure 70-60-2 1

3

4

2 1 5

N-00303

Remove the bolt (Item 1) [Figure 70-60-2] & [Figure 7060-4] from the idler pulley pivot arm (Item 6) [Figure 7060-4].

P0582

Remove the spacers, bolt and washer from the arm [Figure 70-60-2].

Remove the thrust washer (Item 2), O-rings (Item 3) and spring (Item 4) [Figure 70-60-4]. Check all parts for damage or wear and replace them as needed. NOTE: When making any repairs, replace the bushing (Item 5) [Figure 70-60-4] with a new bushing, if worn. Clean all parts and assemble dry. Do not lubricate Installation: Reverse the removal procedure to install the tension pulley.

70-60-1


Figure 70-60-6

COOLING FAN (CONT'D) Gearbox/Blower Housing Removal And Installation

1 2

WARNING

N-19188


Remove the nuts (Item 1) [Figure 70-60-6] from the ubolt which mounts the fan belt shield (Item 2) [Figure 7060-6] to the blower fan. Remove the fan belt shield (Item 2) [Figure 70-60-6] from the blower fan. Installation: Be sure to tighten the shield so it does not interfere with the fan belt.

Figure 70-60-5

Figure 70-60-7

1 1

2 N-19169

Oil Level Put jackstands under the rear corners of the loader. Raise the lift arms and install an approved lift arm device. (See Installing Lift Arm Support Device on Page 10-201.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the left gas cylinder mounting bracket (Item 1) [Figure 70-60-5]. (See Gas Cylinder Removal And Installation on Page 50-20-1.)

N-19375

Disconnect the breather hose (Item 1) [Figure 70-60-7] from the electrical harnesses on the loader frame. Installation: Make sure the breather hose is unrestricted when routing. Remove the fan drive belt (Item 2) [Figure 70-60-7] from the pulley on the blower fan. NOTE: When checking the fan gearbox oil level, be sure the level does not go above the top of the shaft in the gearbox [Figure 70-60-7]. Use a light colored 90W gear lube if the level is low.

70-60-2


Figure 70-60-10

COOLING FAN (CONT'D) Gearbox/Blower Housing Removal And Installation (Cont'd) Figure 70-60-8 2 4

1

P13920

3

Lower the blower fan from the housing until it rests on the steering linkage plate [Figure 70-60-10].

1 N-19376

Figure 70-60-11

Figure 70-60-9

1

N-19378 P-4301

Remove the two mounting bolts (Item 1) [Figure 70-608] and the two spacer tubes (Item 2) [Figure 70-60-8] from the blower fan.

Remove the strip of sealant along the top of the blower housing [Figure 70-60-11]. Installation: Use R.T.V. sealant to reseal the blower housing.

Remove the rear mounting bolt (Item 3) [Figure 70-608].

Loosen the electrical harnesses from the frame of the loader.

Remove the front mounting bolt (Item 4) [Figure 70-608].

Slide the blower fan and housing forward and remove both from the loader.

NOTE: Mounting bolts (Items 3 & 4) [Figure 70-60-8] use wave washer (Item 1) [Figure 70-60-9] to prevent tubes and bolts from falling out of the housing during installation. Installation: Tighten the four mounting bolts 25-28 ft.-lb. (34-38 N•m) torque.

70-60-3


COOLING FAN (CONT'D)

WARNING

Blower Housing Grill Removal And Installation Figure 70-60-12

AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. W-2108-1186

Figure 70-60-14 1

2 1

P-43448

1

To replace the blower housing grill, remove the four mounting bolts (Item 1) [Figure 70-60-12] from the grill. Install the new grill and replace the mounting bolts.

P3006

Blower Disassembly And Assembly Use the following procedure to remove the fan from the shaft.

Figure 70-60-13

Install the nut (Item 1) [Figure 70-60-14] on the tapered shaft to protect the shaft and threads. Install the puller on the fan as shown [Figure 70-60-14]. As the center bolt (Item 2) [Figure 70-60-14] is tightened, periodically strike the bolt head to loosen the fan from the shaft.

CD-9952

Remove the lock nut and spacer [Figure 70-60-13]. Installation: Tighten the nut to 45-55 ft.-lb. (61-75 N•m) torque.

70-60-4


Figure 70-60-17

COOLING FAN (CONT'D) Blower Disassembly And Assembly (Cont'd) Figure 70-60-15

CD-8954

Installation: Clean the surface where the blower housing contacts the loader frame. Put a bead of R.T.V. sealant on the blower housing [Figure 70-60-17].

CD-9953

Remove the fan from the tapered shaft [Figure 70-6015]. Figure 70-60-16

1

1 1 CD-9954

To remove the blower housing mounting plate, remove the six bolts (Item 1) [Figure 70-60-16].

70-60-5


COOLING FAN (CONT'D) Gearbox Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Seal Snap Ring (Small) Shims (1.0 inch O.D.) Bearing Shaft (Long) Shims (2.0 inch O.D.) Long Key Shaft (Short) Short Key Long Housing Nut Gear Washer 1 Screw Square Shim Short Housing Bolt Snap Ring (Large) Cap Long Housing Assy. Short Housing Assy. Fill Plug

1 18

6

2

3

4

4

7

5

8 22 4

12

13

14

9

15

*16

10

21

11 17 12 20 3 4 13 14 18 19

TS-1002A

*Individal Part not available. (See Gearbox Disassembly on Page 70-60-7.)

70-60-6


Figure 70-60-19

COOLING FAN (CONT'D) Gearbox Disassembly Figure 70-60-18

Part Number Tag

2

P2983

3 1

Remove the four mounting bolts and the part number tag [Figure 70-60-19].

P-37891

NOTE: When repairing the following as needed. 1. 2. 3. 4. 5.

gearbox

order

the

Remove the oil from the gearbox.

WARNING

Complete Assembly Long Housing Assembly Long Housing Short Housing Assembly (See Note Below) Internal Parts

AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding.

NOTE: The short housing is only available as an assembly. (See Gearbox Parts Identification on Page 70-60-6.) (Order parts from Bobcat Parts.)

W-2108-1186

Figure 70-60-20

NOTE: Be sure to count the number and thickness of shims during disassembly. Install the shims in the original location during assembly. NOTE: Always replace seals during assembly. Replace the parts in the gearbox as needed. Remove the fan and blower housing mounting plate. (See Gearbox/Blower Housing Removal And Installation on Page 70-60-2.) Long Housing Loosen the set bolts (Item 1) and remove the pulley (Item 2) [Figure 70-60-18]. Remove the long key (Item 3) [Figure 70-60-18].

P2999

Drill an 1/8 inch (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [Figure 70-60-20].

70-60-7


Figure 70-60-23

COOLING FAN(CONT'D) Gearbox Disassembly (Cont'd) Figure 70-60-21

P2966

P2964

Remove the screw and washer from the shaft [Figure 70-60-23]. Figure 70-60-24

Remove the small snap ring [Figure 70-60-21]. Figure 70-60-22

P3004

P2963

Remove the small shims [Figure 70-60-22].

Support the lower flange and press the shaft from the bearing [Figure 70-60-24]. NOTE: The gear and the other bearing (pulley end) will be removed with the shaft.

70-60-8



WARNING

Gearbox Disassembly (Cont'd) Figure 70-60-25

AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. W-2108-1186

Figure 70-60-27

P3298

Support the bearing and press the shaft from the bearing [Figure 70-60-25]. Figure 70-60-26

P2996

Drill an 1/8 inch (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [Figure 70-60-27]. Figure 70-60-28

P2997

Short Housing Remove the end cap [Figure 70-60-26]. P2970

Use care not to damage the housing.

Remove the large snap ring from the flange end of the housing [Figure 70-60-28].

70-60-9


Figure 70-60-31

COOLING FAN (CONT'D) Gearbox Disassembly (Cont'd) Figure 70-60-29

P2973

Remove the snap ring from the cap end of the housing [Figure 70-60-31].

P2969

Remove the large shims from the housing [Figure 70-6029].

Figure 70-60-32

NOTE: Use the same size and thickness of shims during assembly. Figure 70-60-30

1 P2998

Press the shaft from the housing [Figure 70-60-32]. NOTE: Both bearings may come out of the housing with the shaft. If one bearing remains in the housing use a non metal object to tap the bearing from the housing.

P2978

Remove the screw and washer (Item 1) [Figure 70-6030] from the shaft.

70-60-10


Figure 70-60-35

COOLING FAN (CONT'D) Gearbox Disassembly (Cont'd) Figure 70-60-33

P2972

Remove the key from the shaft [Figure 70-60-35]. P3088

Press the bearing from the tapered end of the shaft [Figure 70-60-33]. Figure 70-60-34

P3001

Press the bearing, shims and gear from the shaft [Figure 70-60-34].

70-60-11


Figure 70-60-37

COOLING FAN (CONT'D) Gearbox Assembly Figure 70-60-36

P2960

Install the long housing on the shaft [Figure 70-60-37]. P2961

NOTE: When ordering parts for the Fan Gearbox, (See Gearbox Disassembly on Page 70-60-7.)

Be sure the bearing is seated in the bore at the lower end of the housing. Figure 70-60-38

NOTE: Do not install the seals and cap in the housing until after the backlash has been checked. NOTE: Use care when pressing the bearings into the aluminum housing. The housing can be damaged if too much pressure is used. NOTE: For procedures requiring the use of LOCTITE #242 adhesive, thoroughly clean and dry affected parts before the application of LOCTITE #242. Long Housing P2962

Press a bearing on the short keyed end of the long shaft [Figure 70-60-36].

Install a bearing on the long keyed end of the shaft [Figure 70-60-38]. Support the lower bearing and press the other bearing in the housing until the bearings seat in the housing [Figure 70-60-38].

70-60-12


Figure 70-60-41

COOLING FAN (CONT'D) Gearbox Assembly (Cont'd) Figure 70-60-39

P2965

Install the gear key in the flange end of the shaft [Figure 70-60-41].

P2963

Install on the bearing, the same number and size shims that were removed during disassembly [Figure 70-6039].

Figure 70-60-42

Figure 70-60-40

P2967

Align the key and gear. While supporting the bearing on the other end, press the gear on the shaft until it seats against the bearing [Figure 70-60-42].

P2964

Install the small snap ring in the groove above the shims [Figure 70-60-40].

70-60-13


Figure 70-60-45


1

P2969

Install the large shims on the bearing (flanged end) [Figure 70-60-45]

P2966

Figure 70-60-46

Install the washer (Item 1) [Figure 70-60-43]. Put liquid adhesive (LOCTITE #242) on the screw threads. Install and tighten the screw [Figure 70-60-43]. Short Housing Figure 70-60-44

P2970

Install the large snap ring in the groove above the shims [Figure 70-60-46].

P2968

Install a bearing in the flanged end of the housing [Figure 70-60-44].

70-60-14


Figure 70-60-49


P2976

1 Install the shaft in the housing, tapered end in the bearing at the round flange end of the housing [Figure 70-60-49].

P2971

Figure 70-60-50

Install the short key (Item 1) [Figure 70-60-47]. Align and press the gear on the shaft (teeth toward the tapered end of the shaft) [Figure 70-60-47]. Figure 70-60-48

P2977

Install on the shaft, the same number and size shims that were removed during disassembly [Figure 70-60-50]. P2975

After the gear is seated, drive the key down inside the gear key way [Figure 70-60-48]. NOTE: This will prevent damage to the shims when the bearing is installed later.

70-60-15


Figure 70-60-53


2

1

P2978

Install the washer (Item 1) on the shaft. Put liquid adhesive (LOCTITE #242) on the screw threads and install the screw (Item 2) [Figure 70-60-53].

P2974

Install a bearing on the gear end of the shaft [Figure 7060-51]. Figure 70-60-52

P2973

Install the snap ring in the groove above the bearing [Figure 70-60-52].

70-60-16


Figure 70-60-55

COOLING FAN (CONT'D) Gearbox Checking Backlash Figure 70-60-54

P2981

Install the same size and number of square shims (if present during disassembly) between the two housings [Figure 70-60-55].

P2987

NOTE: For procedures requiring the use of LOCTITE #518 adhesive, thoroughly clean and dry affected parts before the application of LOCTITE #518. LOCTITE #518 is a gasket eliminator that cures to a flexible seal between the mounting surfaces. The backlash tolerance between the gears should be 0.005-0.008 inch (0,127-0,203 mm).

Set the long housing on the short housing with the sealant. NOTE: If square shims are used, put a small amount of (LOCTITE 518) on both sides of all shims. Figure 70-60-56

To check the gear backlash use the following procedure: Put the short housing in a vise, square flange facing up as shown [Figure 70-60-54]. Part Number Tag

P2983

Install the four mounting bolts through the flange holes [Figure 70-60-56]. Install the part number tag [Figure 70-60-56]. Install and tighten the nut to 25-28 ft.-lb. (34-38 N•m) torque.

70-60-17


Figure 70-60-59

COOLING FAN (CONT'D) Gearbox Checking Backlash (Cont'd) Figure 70-60-57

1

2

1.000” (25,4mm) P-37893

1

Using a magnetic based dial indicator mounted on a bench vise, touch the dial stem on the bolt (Item 1) [Figure 70-60-59].

P-37894

Install the long key (Item 1) and the pulley (Item 2) [Figure 70-60-57]. Install a bolt in the set screw hole to maintain a 1.0 inch (25,4 mm) distance from the shaft center to the bolt head (to be used with a dial indicator) [Figure 70-60-57]. Figure 70-60-58

Hold the locking pliers against the long housing and rotate the pulley back and forth to read the dial gauge [Figure 70-60-59]. If the backlash is GREATER than 0.008 inch (0,203 mm), do the following: 1. Remove a square shim(s) (if present) between the two housings. 2. Remove a large shim(s) from the tapered end of the short shaft and add a small shim (s) of the same thickness between the bearing and the gear on the screw end of the shaft. If the backlash is LESS than 0.005 inch (0,127 mm) do the following:

1

1. Add a square shim(s) between the two housings. 2. Remove a small shim(s) between the bearing and the gear on the screw end of the short shaft and add a large shim(s) of the same thickness between the snap ring and the bearing on the tapered end of the shaft.

P-37892

Put the fan nut (Item 1) [Figure 70-60-58] on the shaft and tighten snugly. Install a locking pliers on the fan nut and support the handle against the long housing [Figure 70-60-58].

70-60-18


Figure 70-60-61


LONG HOUSING

Gearbox Checking Backlash (Cont'd) Figure 70-60-60

P2985

Figure 70-60-62 P3089

SHORT HOUSING

When the backlash is correct, install the seals, cap and gear oil as follows: Remove the bolts from the flanges and separate the two housings. Put liquid adhesive (LOCTITE #242) on the outside diameter of the seal(s) [Figure 70-60-60].

P2986

Install the seal(s) flush with the housing surface [Figure 70-60-61] & [Figure 70-60-62]. Clean any oil from the flange surface. Install the long housing on the short housing flange. Install the four bolts and part number tag. Install and tighten the nuts to 25-28 ft.-lb. (34-38 N•m) torque. NOTE: When filling the fan gearbox with oil, be sure the level does not go above the top of the shaft in the gearbox. Use a light colored 90W gear lube.

70-60-19


70-60-20


Figure 70-70-2

ENGINE COMPONENTS AND TESTING Compression Checking Figure 70-70-1

1

P-48710

Connect the compression gauge to the adapter [Figure 70-70-2].

P-48709

The tools listed will be needed to do the following procedure: MEL10630 - Engine Compression Kit MEL1631 - Compression Adapter

Make sure the engine speed control is fully backward (engine idle). Disconnect the fuel stop solenoid. Crank the engine with the starter cranking rpm.

The engine must be at operating temperature.

If the measurement is below the allowable limit, check the cylinder, piston ring, top clearance, valve and cylinder head.

Remove the glow plugs. (See Glow Plugs Removal And Installation on Page 70-70-2.)

Compression Pressure should be 427-469 PSI (2944,1 3233,6 kPa)

Install the correct compression adapter (Item 1) [Figure 70-70-1] into the cylinder head.

Allowable Limit (minimum) is 341 PSI (2351,1 kPa) No more than 10% variance among cylinders. Figure 70-70-3

P-48711

Push the button on the compression gauge to release pressure [Figure 70-70-3]. Connect the fuel stop solenoid.

70-70-1


ENGINE COMPONENTS AND TESTING (CONT'D)

Glow Plugs Removal And Installation

Glow Plugs Checking

Figure 70-70-6

Figure 70-70-4

1

2

3

P-48698 P-48702

Disconnect the negative (-) cable from the battery.

Disconnect the glow plug cables and leads. Use an ohmmeter to check the glow plugs [Figure 70-704].The resistance should be approximately one ohm. Figure 70-70-5

Remove the nut (Item 1) [Figure 70-70-6] from the top of each glow plug. Disconnect the engine harness wire (Item 2) [Figure 7070-6] from the glow plug. Remove the glow plug connecting strap (Item 3) [Figure 70-70-6]. Figure 70-70-7

1 1

P-48701

Touch one probe to the end of the glow plug and the other probe to the body of glow plug (Item 1) [Figure 7070-5]. Repeat the procedure for each glow plug.

P-48699

Loosen and remove the glow plug (Item 1) [Figure 7070-7]. Installation: Tighten the glow plug to 14.5-18.1 ft.-lb. (19,6-24,5 N•m) torque.

70-70-2


Figure 70-70-10

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Removal And Installation (Cont’d) Figure 70-70-8

P-48706

The reading between electrical connector terminal C and terminal A must be between approximately 15.6 ohms [Figure 70-70-10].

P-48708

Photo [Figure 70-70-8] shows the glow plug assembly removed from the engine. Inspect the glow plugs and replace when necessary.

The reading between electrical connector terminal C and terminal B must be between approximately .35-.4 ohms.

Fuel Shut-Off Solenoid, Checking Figure 70-70-9

1

P-48586

Stop the engine and open the rear door [Figure 70-70-9]. Disconnect the connector (Item 1) [Figure 70-70-9] from the fuel shut-off solenoid. Use an ohmmeter to check the fuel shut-off solenoid.

70-70-3


ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Shut-Off Solenoid Removal And Installation Stop the engine and open the rear door. Figure 70-70-11

1

P-48586

Disconnect the connector (Item 1) [Figure 70-70-11]. Figure 70-70-12

1

P-48704

Remove the mounting nuts (Item 1) [Figure 70-70-12] of the fuel shut-off solenoid. Reverse the above procedure to install the fuel shut-off solenoid.

70-70-4



Figure 70-70-14

Fuel Injection Pump Removal And Installation (Turbo) 1

Figure 70-70-13

2 3

1 1

3 P-48705

Disconnect the fuel inlet hose (Item 1) and the fuel return hose (Item 2) [Figure 70-70-14] from the injection pump vent .

P-48700

Clean the area around the injection pump thoroughly.

Cap the inlets on the injection pump vent where the hoses were removed [Figure 70-70-14].

Disconnect the high pressure fuel lines (Item 1) [Figure 70-70-13] from the fuel injectors.

Remove the four oil fill bolts (Item 3) [Figure 70-70-14]. Figure 70-70-15

IMPORTANT Do not bend the high pressure fuel injection tubes when removing or installing them.

1

I-2029-0289

P-48730

Remove the high pressure fuel lines (Item 1) [Figure 7070-15] from the injection pump.

70-70-5


Figure 70-70-17

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Turbo) (Cont'd) Figure 70-70-16

1 P-51683

2 Remove the high-idling body (Item 1) [Figure 70-70-17] from the engine block.

1 P-48826

Remove the seven mounting bolts (Item 1) from the intake manifold (Item 2) [Figure 70-70-16].

Installation: Tighten the high-idling body to 32.6-36.3 ft.lb. (44-49 N•m) torque. Figure 70-70-18

Installation: Tighten the mounting bolts to 16-20 ft.-lb. (22-27 N•m) torque. Remove the intake manifold from the engine. Installation: Replace the manifold gasket if it is worn or damaged. Remove the fuel shut-off solenoid. (See Fuel Shut-Off Solenoid Removal And Installation on Page 70-70-4.) 1

2 P-4357

Remove the four mounting bolts (Item 1) and two nuts (Item 2) [Figure 70-70-18] from the injection pump. Installation: Tighten the mounting bolts to 16-20 ft.-lb. (22-27 N•m) torque.

70-70-6


Figure 70-70-20

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Turbo) (Cont'd)

2

CORRECT

1

Figure 70-70-19

2

2

1

1 1

P-51628

1

Figure 70-70-21 INCORRECT

P-51626

NOTE: Before removing the injection pump assembly, be sure to remove the stop solenoid and high idling body. Also check to see if the stop solenoid guide (Item 1) touches the boost lever (Item 2) [Figure 70-70-19]. 1

Remove the injection pump and shim(s) from the engine.

P-51627

Installation: Check to see if the stop solenoid guide (Item 1) [Figure 70-70-20] and [Figure 70-70-21] touches the boost lever (Item 2) [Figure 70-70-20].

70-70-7



Fuel Injection Pump Removal And Installation (NonTurbo)

Fuel Injection Pump Removal And Installation (Turbo) (Cont'd)

Figure 70-70-24

Figure 70-70-22 1

1 1

P-51933 P-4364

Clean the area around the injection pump thoroughly.

Install the shim(s) (Item 1) [Figure 70-70-22] on the injection pump mounting surface. For information on the number of shims used. (See Timing The Injection Pump on Page 70-70-12.)

Disconnect the high pressure fuel lines (Item 1) [Figure 70-70-24] from the fuel injectors.

IMPORTANT

Figure 70-70-23

Do not bend the high pressure fuel injection tubes when removing or installing them.

2

I-2029-0289

1

P-64218

Install the injection pump in the engine. Ensure the control rack pin (Item 1) is to the left side of the fork lever (Item 2) [Figure 70-70-23].

IMPORTANT Do not attempt to maintain or adjust unless you are trained and have the correct equipment. I-2028-0289

70-70-8


Figure 70-70-27

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd)

2

Figure 70-70-25

1 1

2 3

P-48820

Remove the mounting bolts (Item 1) from the intake manifold (Item 2) [Figure 70-70-27].

3

P-51944

Disconnect the fuel inlet hose (Item 1) and the fuel return hose (Item 2) from the injection pump vent [Figure 7070-25].

Installation: Tighten the mounting bolts to 16-20 ft.-lb. (22-27 N•m) torque. Remove the intake manifold from the engine.(See Removal And Installation on Page 70-80-1.)

Cap the inlets on the injection pump vent where the hoses were removed [Figure 70-70-25].

Installation: Replace the manifold gasket if it is worn or damaged.

Remove the four oil fill tube bolts (Item 3) [Figure 70-7025].

Figure 70-70-28

Figure 70-70-26 1

1

2

P-51942

P-51945

Remove the high pressure fuel lines (Item 1) [Figure 7070-26] from the injection pump. Note:

Remove the fuel shut-off solenoid (Item 1) [Figure 7070-28]. (See Fuel Shut-Off Solenoid Removal And Installation on Page 70-70-4.)

Do not loosen the clamp screws (Item 2) [Figure 70-70-15] on the injection pump. This is to be done only when the entire injection pump is sent out to be serviced.

70-70-9


Figure 70-70-31

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd) Figure 70-70-29

P-51952

1

P-51953

1

Remove the stop solenoid guide (Item 1) [Figure 70-7031]. P-51683

Figure 70-70-32

Remove the high-idling body (Item 1) [Figure 70-70-29] from the engine block. Figure 70-70-30 1

1 3

2 P-4357

2

Remove the four mounting bolts (Item 1) and two nuts (Item 2) [Figure 70-70-32] from the injection pump. P-51951

Remove the cover plate bolts (Item 1) and nuts (Item 2) [Figure 70-70-30].

Installation: Tighten the mounting bolts to 16-20 ft.-lb. (22-27 N•m) torque.

Remove the cover plate (Item 3) [Figure 70-70-30].

70-70-10


Figure 70-70-35

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd)

1

Figure 70-70-33

2

P-4364

1 Install the shim(s) (Item 1) [Figure 70-70-35] on the injection pump mounting surface. For information on the number of shims used. (See Timing The Injection Pump on Page 70-70-12.)

P-4359

Remove the injection pump (Item 1) [Figure 70-70-33] and shim(s) from the engine.

Figure 70-70-36

NOTE: The pin (Item 2) [Figure 70-70-33] located on the control rack, needs to be installed correctly during installation. See the following procedure for correct installation.

IMPORTANT

1

Do not attempt to maintain or adjust unless you are trained and have the correct equipment. I-2028-0289

Figure 70-70-34

P-48779

The size of shims are identified by a symbol (Item 1) [Figure 70-70-36] on the shims. (1) Two holes means .0008 in (.20 mm) shim. (2) One hole means .0010 in (.25 mm) shim. (3) Without hole means .0012 in (.30 mm) shim.

1 2

(4) Three holes means .0014 in (.35 mm) shim.

1 P-51944

Installation: Remove the bolts (Item 1) that secure the fill cover (Item 2) [Figure 70-70-34] from the injection pump chamber. 70-70-11


Figure 70-70-38

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd) Figure 70-70-37

2 1

1

P-54133

Turn the fuel supply lever (Item 1) [Figure 70-70-38] to the ON position. P-64218

Figure 70-70-39

Install the injection pump in the engine. Ensure the control rack pin (Item 1) is to the left side of the fork lever (Item 2) [Figure 70-70-37].

1

Timing The Injection Pump

IMPORTANT Do not attempt to maintain or adjust unless you are trained and have the correct equipment.

P-4361

I-2028-0289

Timing the injection pump is done by changing the number of shims between the injection pump and the injection pump mounting surface.

Install a short plastic tube (Item 1) [Figure 70-70-39] in the number one cylinder port of the injection pump. The tube should fit securely in the port and point upward.

Disconnect the number one cylinder high pressure line from the injection pump.

70-70-12


Figure 70-70-41

ENGINE COMPONENTS AND TESTING (CONT'D) Timing The Injection Pump (Cont’d) Figure 70-70-40

Rotation Direction

1

1

P-4364

Add or subtract shim(s) (Item 1) [Figure 70-70-41] as needed to adjust the fuel delivery timing.

P-48726

Rotate the engine in the direction shown [Figure 70-7040]. Continue rotation until flywheel timing mark just appears in the window (Item 1) [Figure 70-70-40].

NOTE: Adding or removing one shim will vary the timing by 1.5°. Adding shims retards timing. Figure 70-70-42

NOTE: The flywheel has three timing marks. The first mark to appear in the window with the rotation is 9.25° which is used for loaders with the Kubota V2003T engine.

1

The second mark to appear in the window is 8.2° which is used for loaders with the Kubota V2203 engine. The third mark to appear in the window is 6.75° which is used for loaders with the Kubota V2403 engine.

P-48779

Rotate slowly until fuel just starts to flow upward into the plastic tube.

The size of shims are identified by a symbol on the shims.

At this instant, the 9.25° BTDC timing mark on the flywheel should be aligned with the mark in the window (Item 1) [Figure 70-70-40] for the V2003T engine.

(1) Two holes means .0008 in (.20 mm) shim.

OR

(3) Without hole means .0012 in (.30 mm) shim.

The 8.2° BTDC on the flywheel should be aligned with the mark in the window (Item 1) [Figure 70-70-40] for the V2203 engine.

(4) Three holes means .0014 in (.35 mm) shim.

(2) One hole means .0010 in (.25 mm) shim.

70-70-13



IMPORTANT

Fuel Injector Removal And Installation

Do not bend the high pressure fuel injection tubes when removing or installing them.

WARNING

I-2029-0289

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.

Figure 70-70-44

1

W-2072-0496

Figure 70-70-43

2 1

1 2

P-48727

Remove the four retainer bolts from the top of the fuel injectors (Item 1) [Figure 70-70-44]. Remove the fuel return tube (Item 2) [Figure 70-70-44] from the fuel injectors. Figure 70-70-45

P-48712

The following are some problems caused by faulty injectors:

1

-Engine is hard to start or will not start -Rough engine operation and idle -Engine will not have full power -Excessive exhaust smoke Disconnect the fuel return hoses (Item 1) [Figure 70-7043] from the injectors. Disconnect the high pressure fuel lines (Item 2) [Figure 70-70-43] from the fuel injectors and from the injection pump. Remove the high pressure fuel lines from the engine.

P-48728

Remove the injector nozzle holder bolt (Item 1) [Figure 70-70-45] from the cylinder head. Pull on the injector nozzle to remove the injector nozzle from the cylinder head.

70-70-14



Checking Nozzle Injection Pressure

Fuel Injector Removal And Installation (Cont'd)

The tool listed will be needed to do the following procedure:

Figure 70-70-46

OEM1064 - Injector Nozzle Tester Figure 70-70-47 1

2

P-37583

[Figure 70-70-46] shows the injector nozzle removed from the cylinder. Inspect the injector and replace if necessary. Check and replace the injector nozzle O-rings (Item 1) and the nozzle washer (Item 2) before installing new or used injectors. [Figure 70-70-46].

3EEABAC1P012A

Set the injection nozzle to the nozzle tester. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. If the measurement is not within the factory specifications, replace the injection nozzle assembly. NOTE: Injection nozzle gasket must be replaced when the injection nozzle is removed for checking. Injection pressure

70-70-15

Factory spec.

18.6 to 20.1 MPa 190 to 205 kgf/cm² 2702 to 2916 PSI



Valve Seat Tightness

Nozzle Spraying Condition

The tool listed will be needed to do the following procedure:

The tool listed will be needed to do the following procedure: OEM1064 - Injector Nozzle Tester

OEM1064 - Injector Nozzle Tester Figure 70-70-49

Figure 70-70-48 Correct

Incorrect

3EEABAC1P014A 3EEABAC1P013A

Set the injection nozzle to a nozzle tester.

Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/ cm², 2418 PSI) for 10 seconds.

If the spraying condition is defective, replace the injection nozzle assembly.

If any fuel leak is found, replace the injection nozzle assembly. Valve seat tightness

70-70-16

Factory spec.

No fuel leak at 16.67 MPa 170 kgf/cm² 2418 PSI


Figure 70-70-51

ENGINE COMPONENTS AND TESTING (CONT'D) Valve Clearance Adjustment Figure 70-70-50

1 2

2

3

4

5

6

7

8

1

B-05569

3

Figure 70-70-52 B-5568

1

Cylinder Number

Adjust the valve clearance as follows: Loosen the lock nut (Item 1) [Figure 70-70-50].

Valve Number

2

3

4

1

2

3

4

5

6

7

8

I

E

I

E

I

E

I

E

Turn the adjustment screw (Item 2) [Figure 70-70-50] until the correct clearance is obtained. Valve I=Intake E=Exhaust

NOTE: The clearance is measured between the rocker arm and valve stem tip (Item 3) [Figure 70-70-50].

Adjust the valve clearance as follows: 0.0071 -0.0087 inch (0,18 - 0,22 mm) Exhaust

Intake

&

Use the following sequence to set the valves [Figure 7070-51] & [Figure 70-70-52]: 1. With the rocker arm rocking (valves 7 & 8) on No. 4 cylinder set clearance at No. 1 cylinder (valves 1 & 2). 2. With the rocker arm rocking (valves 3 & 4) on No. 2 cylinder set clearance at No. 3 cylinder (valves 5 & 6). 3. With the rocker arm rocking (valves 1 & 2) on No. 1 cylinder set clearance at No. 4 cylinder (valves 7 & 8). 4. With the rocker arm rocking (valves 5 & 6) on No. 3 cylinder set clearance at No. 2 cylinder (valves 3 & 4).

70-70-17


ENGINE COMPONENTS AND TESTING (CONT'D) Valve Timing, Checking Figure 70-70-53

4 3 5

(1) Idle Gear (2) Idle Collar (3) External Snap Ring (4) Cam Gear (5) Camshaft

2

1

B-14341

Stop the engine and open the rear door. Remove the engine. (See Removal And Installation on Page 70-80-1.) Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Make sure the timing marks are in correct alignment [Figure 70-70-53].

70-70-18


Figure 70-80-1

ENGINE Removal And Installation

3

1 2 3 P-48519


Remove the nut from the speed control linkage (Item 1) and unplug the rear lights electrical connector (Item 2) [Figure 70-80-1]. Remove the bracket mounting bolts (Item 3) [Figure 7080-1] for the fuel fill to make installation easier.

W-2059-0598

Figure 70-80-2 Put jackstands under the rear corners of the loader. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

1

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) 2

Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-1.) Disconnect the steering linkage. (See Linkage Removal And Installation on Page 50-101-7.)

P-48580

Remove the battery from the loader. (See Removal And Installation on Page 60-20-1.) Drain the engine coolant from the cooling system. (See ENGINE COOLING SYSTEM on Page 10-90-1.)

Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 70-80-2].

Remove the air cleaner. (See Removal And Installation on Page 70-40-1.) Remove the muffler. (See Removal And Installation on Page 70-30-1.)

70-80-1


Figure 70-80-5

ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-3

1

2

1

P-26965

3 Remove battery cable bracket (Item 1) [Figure 70-80-5]. P-28237

Figure 70-80-6

Disconnect the wires from the charge pressure sender (Item 1) [Figure 70-80-3] from the filter housing. Disconnect the temperature sender connector (Item 2) [Figure 70-80-3] from the filter housing.

3

Disconnect the wire connector (Item 3) [Figure 70-80-3] from the differential pressure switch on the filter housing. Figure 70-80-4 1 2 P-34385

1

Disconnect negative battery cables from starter mount bolt (Item 1) [Figure 70-80-6]. Disconnect positive battery cable (Item 2) from starter terminal (Item 3) [Figure 70-80-6].

P-48581

Disconnect radiator hose (Item 1) [Figure 70-80-4].

70-80-2


Figure 70-80-9

ENGINE (CONT'D) Removal And Installation (Cont'd)

2

Figure 70-80-7

2

1

3 3

P-48595

2

1

Disconnect glow plug wire (Item 1) [Figure 70-80-9]. P-48586

Disconnect the fuel stop wire harness (Item 1) [Figure 70-80-7]. Remove the tie straps (Item 2) [Figure 70-80-7] from wiring harness clamp. Disconnect engine oil pressure wire harness (Item 3) [Figure 70-80-7].

Disconnect and plug fuel return line (Item 2) [Figure 7080-9]. Remove the tie strap (Item 3) [Figure 70-80-9] from wiring harness clamp and move the wire harness to the left side of loader to allow clearance for engine removal. Figure 70-80-10

Figure 70-80-8

1

3 4

P-48593

1 2

Disconnect engine coolant hose (Item 1) [Figure 70-8010].

P-48585

Cap or plug all hoses and fittings.

Disconnect fuel line (Item 1) [Figure 70-80-8]. Cut tie straps (Item 2) [Figure 70-80-8]. Mark and disconnect loader harness wire connectors (Item 3) [Figure 70-80-8]. Disconnect engine speed harness (Item 4) [Figure 7080-8].

70-80-3


Figure 70-80-13

ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-11 2

1

3 1 P-26957

Remove fan belt shield (Item 1) [Figure 70-80-13]. P-48845

Figure 70-80-14

Disconnect power Bob-Tach hoses (Item 1) [Figure 7080-11] and solenoid connectors (If so equipped). Disconnect outlet hose (Item 2) [Figure 70-80-11]. Disconnect high flow outlet hose (Item 3) [Figure 70-8011] (If so equipped). Cap or plug all hoses and fittings.

1

Figure 70-80-12

P-26958

1

Remove fan belt (Item 1) [Figure 70-80-14] from pulley.

P-28137

Disconnect inlet hydrostatic motor hose from hydraulic filter tubeline (Item 1) [Figure 70-80-12]. Cap or plug all hoses and fittings.

70-80-4


Figure 70-80-17

ENGINE (CONT'D) Removal And Installation (Cont'd)

1

Figure 70-80-15

1

P-28142

1 Mark and disconnect the left drive motor hoses (Item 1) [Figure 70-80-17].

P-26068

Disconnect inlet gear pump hose (Item 1) [Figure 70-8015]. Cap or plug all hoses and fittings. Figure 70-80-16

Cap or plug all hoses and fittings. NOTE: Due to the left drive motor hoses (Item 1) [Figure 70-80-17] orientation, hoses may not be completely removed from fittings until engine and pump is partially removed. Installation: Install the left drive motor hoses prior to alignment with engine mount bolts. Figure 70-80-18

1

1

P-26959

Mark and disconnect the two right drive motor hoses (Item 1) [Figure 70-80-16].

P-26068

Remove the mounting bolt and nut (Item 1) [Figure 7080-18] from the right front engine mount. Installation: Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.

70-80-5


Figure 70-80-20


1

2 P-28231

1

P-48583

Remove the mounting bolt and nut (Item 1) [Figure 7080-20] from the right rear engine mount.

P-28139

Remove the mounting bolt (Item 1) [Figure 70-80-19] and nut from the left front engine mount. Installation: Slide the engine mount slot (Item 2) [Figure 70-80-19] in between engine mount washer and nut. Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.

Installation: Tighten the mounting bolt to 70 ft-lb. (95 N•m) torque. Figure 70-80-21

NOTE: To aid in the removal of the left front engine mount bolt, remove the control panel. (See Removal and Installation on Page 50-100-1.) Use 1/2 inch drive impact wrench, with a 12 inch extension, on a 3/4 inch flex socket.

1

Removal will be accomplished by reaching under the hydraulic reservoir to the engine mount bolt.

P-28140

Remove the mounting bolt and nut (Item 1) [Figure 7080-21] from the left rear engine mount. Installation: Tighten the mounting bolt to 70 ft-lb. (95 N•m) torque.

70-80-6


Figure 70-80-23


13” 2.5” 1-1/2” I.S. Dia. 2-1/2” O.S. Dia.

1 2.5” 1/4” (4) Thick Gusset

1-1/2” Square Tubing

1”

P-48594 28”

Fasten securely one end of the chain to the lifting eye (Item 1) [Figure 70-80-23]. Figure 70-80-24

4”

2” 45°

9”

1”

4” 2”

1 1”

.5” .3125” (2)

.375”

Use Two 3/8” x 1-1/4” Bolts for Drilled and Tapped Holes.

MC-1799

A tool needs to be fabricated to use in the removal procedure. This tool allows the engine/hydrostatic pump assembly to be lifted evenly for easier removal. Use the dimensions shown in [Figure 70-80-22] to make the engine removal tool.

P-48592

Fasten securely one end of the chain to the other lifting eye (Item 1) [Figure 70-80-24]. NOTE: You may need to adjust the chain which fastens to the engine a couple of times to reach the correct lifting position.

70-80-7



1

P-48596

Install the chain hoist on the eyelet [Figure 70-80-25] of the removal tool. Fasten a chain to other end of the removal tool with two bolts as shown in (Item 1) [Figure 70-80-25]. Remove the engine/hydrostatic pump assembly from the loader. Reverse the removal procedure to install the engine.

70-80-8


Figure 70-80-27

ENGINE (CONT'D) Engine Mount Replacement Figure 70-80-26 1

Washer

2

Engine Mounting Bracket

Loader Frame

3

Engine Mount

4 5

Snubbing Washer

6

Spacer MC-1765

Install the new engine mount as shown in the cut away side view [Figure 70-80-27].

7 MC-1771

Use the following procedure to install new engine mounts:

Tighten the mounting bolts to 70 ft.-lb. (95 N•m) torque.

Remove the existing mount from the engine. Refer to engine removal and installation for engine mount locations. Replace all four engine mounts two front and two rear. Use the parts shown to install the new engine mounts [Figure 70-80-26]: Square Nut - (Item 1) - Used on left side engine mounts Hex Nut - (Item 2) - Used on right side engine mounts Mount Washer - (Item 3) Engine Mount - (Item 4) Tube Spacer - (Item 5) Snubbing Washer - (Item 6) Mounting Bolt - (Item 7)

70-80-9


70-80-10


FLYWHEEL AND HOUSING

Ring Gear Removal And Installation

Flywheel Removal And Installation

Figure 70-90-2

Remove the drive belt shield. (See Shield Removal And Installation on Page 30-50-1.) Remove the drive belt. (See Drive Belt Replacement on Page 30-50-3.) Remove the drive belt tension pulley. (See Tensioner Pulley Removal And Installation on Page 30-50-4.) Figure 70-90-1

1 P-48850

The ring gear (Item 1) [Figure 70-90-2] on the flywheel is an interference fit. Heat the ring gear enough to expand the gear. Hit the ring gear evenly around the gear to remove it from the flywheel.

1

Clean the outer surface of the flywheel thoroughly so the new ring gear will fit smoothly onto the flywheel. 2

Clean the new ring gear and heat it to a temperature of 450°-500° F. (232°-260° C.)

P-48649

Remove the six mounting bolts (Item 1) from the engine flywheel (Item 2) [Figure 70-90-1].

Fit the ring on the flywheel and be sure the gear is seated correctly.

Installation: Apply engine oil to the threads and seats before tightening. Tighten to 72-80 ft.-lb. (98-108N•m) torque. Remove the flywheel from the engine. Installation: Be sure to align the hole in the flywheel with the pin located on the crankshaft. Reverse the removal procedure to install the flywheel.

70-90-1


Figure 70-90-4

FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation Remove the drive belt shield. (See Shield Removal And Installation on Page 30-50-1.) Remove the engine/hydrostatic pump package from the loader.(See Removal And Installation on Page 70-80-1.) Remove the drive belt. (See Drive Belt Replacement on Page 30-50-3.) Remove the drive belt tension pulley. (See Tensioner Pulley Removal And Installation on Page 30-50-4.)

P-48651A

Remove the starter. (See Removal And Installation on Page 60-40-2.) Remove the flywheel. (See Flywheel Removal And Installation on Page 70-90-1.)

Install a puller in the drive pulley and remove the pulley from the hydrostatic pump shaft [Figure 70-90-4]. Installation: Install the pulley key in the shaft before installing the drive pulley.

Figure 70-90-3

1

P-48651

Remove the hydrostatic pump drive pulley mounting nut (Item 1) [Figure 70-90-3] and washer. Installation: Tighten the mounting nut to 175-200 ft.-lb. (237-271 N•m) torque.

70-90-2


Figure 70-90-7

FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation (Cont’d) Figure 70-90-5

2

1

1

1

1

1

P-48648

1 Remove the seven mounting bolts (Item 1) [Figure 7090-7] which fasten the housing on the engine.

P-48650

Remove the two mounting bolts (Item 1) [Figure 70-905] from the drive belt housing which mount the hydrostatic pump to the housing. Installation: Tighten the mounting bolts to 65-70 ft.-lb. (88-95 N•m) torque. Figure 70-90-6

Installation: Tighten the mounting bolts to 35-40 ft.-lb. (48-54 N•m) torque. Remove the bolt (Item 2) [Figure 70-90-7] which fasten the two drain hoses to the housing. Installation: Tighten the mounting bolts to 60-65 ft.-lb. (82-88 N•m) torque. Remove the housing. Reverse the removal procedure to install the housing.

2

1

P-4231

Remove the mounting bolt (Item 1) [Figure 70-90-6] from engine coolant tubeline mounting bracket which is attached to the belt shield housing. Installation: Tighten the mounting bolt to 25-28 ft.-lb. (34-38 N•m) torque. Remove the blower fan drive belt tensioner assembly (Item 2) [Figure 70-90-6] from the housing.

70-90-3


70-90-4


Figure 70-100-3

RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) Cylinder Head Removal And Installation Figure 70-100-1

1

4

2

2 3

1 P-47243

Remove the glow plugs (Item 1) and fuel injector holder assemblies (Item 2) [Figure 70-100-3]. P-47241

Remove the glow plug lead (Item 1), breather hose (Item 2), and valve cover bolts (Item 3) [Figure 70-100-1]. Remove the valve cover (Item 4) [Figure 70-100-1] and gasket.

Installation: Tighten the glow plugs to 11-14.5 ft.-lb. (1519.6 N•m) torque. Tighten the injector holders to 19-22 ft.-lb. (25.5-29.4 N•m) torque. Figure 70-100-4

Installation: Tighten the valve cover bolts to 5-8 ft.-lb. (711 N•m) 1 Figure 70-100-2 1

2 2

2

2 B-14332

Remove the rocker arm bolts and remove the rocker arm assembly (Item 1) [Figure 70-100-4]. P-47242

Loosen the bolts on the clamps (Item 1) and remove the injection tubes (Item 2) [Figure 70-100-2].

Installation: Tighten the bolts to 17-20 ft.-lb. (23.5 - 27.5 N•m) torque. Remove the pushrods (Item 2) [Figure 70-100-4].

Remove the overflow tube assembly.

70-100-1


Figure 70-100-7

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)

6

14

Cylinder Head Removal And Installation (Cont'd)

18

10

17

9

3

11

2

7

1

8

15

Figure 70-100-5

1 2

13

5

4

16 12 P-47247

Remove the cylinder head bolts in order of #18 to #1 [Figure 70-100-7]. P-47245

Installation: The push rod (Item 1) must be seated in the tappet (Item 2) [Figure 70-100-5] correctly or the push rods will be damaged. After installing the rocker arm assembly and push rods, the valve lash must be adjusted. (See Valve Tappets on Page 70-100-20.). Figure 70-100-6

NOTE: (A) is the gearcase side, (B) is the flywheel side. Installation: Put oil on the bolt threads. Tighten the bolts in the correct sequence in order of #1-#18 to 68-72 ft.-lb. (93-98 N•m). NOTE: Re-tighten the cylinder head bolts in the correct sequence after the engine has been run for 30 minutes. Figure 70-100-8

2

1 1

2 P-47246 P-47248

Remove the clamps (Item 1) and remove the hose (Item 2) [Figure 70-100-6].

Remove the cylinder head (Item 1) and gasket (Item 2) [Figure 70-100-8].

70-100-2


Figure 70-100-11


Gasket Size (Number)

Cylinder Head Removal And Installation (Cont'd) Figure 70-100-9

15 20 25 30 35

1

Piston Protrusion 0.475 to 0.525 mm 0.0187 to 0.0207 in. 0.525 to 0.575 mm 0.0207 to 0.0226 in. 0.575 to 0.625 mm 0.0226 to 0.0246 in. 0.625 to 0.067 mm 0.0246 to 0.0266 in. 0.675 to 0.725 mm 0.0266 to 0.0285 in.

Select the correct gasket size (thickness) from the chart [Figure 70-100-11]. P-47249A

When replacing just the gasket, use a new gasket that has the same mark (Item 1) [Figure 70-100-9] as the original gasket. When replacing the gasket after an engine rebuild, the piston protrusion must be measured. (See Cylinder Head Top Clearance on Page 70-100-5.)

Find the measurement of the highest piston protrusion and the lowest piston protrusion (recorded earlier) for each piston. If the highest measurement exceeds the piston protrusion of the selected gasket, use the gasket which is one size larger. If the measurement exceeds gasket size 35, the engine must be disassembled, clearances checked, and reassembled. If the measurement is two sizes smaller than the selected gasket or smaller than gasket size 15, the engine must be disassembled, clearances checked, and reassembled.

Figure 70-100-10

1

After the gasket and cylinder head have been installed, turn the crankshaft by hand to be sure there is no interference between the piston, cylinder, and valves.

P-47252

Measure and record the protrusion of each piston in the four places shown (Item 1) [Figure 70-100-10]. Find the average of each piston, then find the combined average of the four pistons.

70-100-3


Figure 70-100-14


1

2

Cylinder Head Disassembly And Assembly 1

Figure 70-100-12

3 4 5

7 6 5

5

7

8 P-47253

Remove the bolts (Item 1), housing (Item 2), gasket (Item 3) and thermostat (Item 4) [Figure 70-100-14]. PI-9987

Use a valve spring compressor to compress the valve spring [Figure 70-100-12].

Remove bolts (Item 5), nut (Item 6), top and bottom housing (Item 7), and gasket (Item 8) from the cylinder head [Figure 70-100-14].

Figure 70-100-13

1 Cap

2 Collets

6 Seal

3 Retainer

4 Spring

5 Valve

B-4122C

Remove the valve cap (Item 1) and valve spring collet (Item 2) [Figure 70-100-12] & [Figure 70-100-13]. Remove the valve spring retainer (Item 3) and the spring (Item 4) [Figure 70-100-12] & [Figure 70-100-13]. Remove the seal (Item 6) and the valve (Item 5) [Figure 70-100-12] & [Figure 70-100-13].

70-100-4


Cylinder Head Top Clearance


Figure 70-100-17

Cylinder Head Servicing Clean the surface of the cylinder head.

2

Figure 70-100-15 1

1

3

P-51631

2

Install the cylinder head gasket. Put the piston (Item 1) [Figure 70-100-17] being checked at T.D.C. P-51629

Put a straight edge (Item 1) [Figure 70-100-15] on the cylinder head. NOTE: Do not put the straight edge across combustion chambers. Put a feeler gauge (Item 2) [Figure 70-100-15] between the straight edge and the surface of the cylinder head. Figure 70-100-16

Put 3 pieces of 0.06 inch (1,5 mm) diameter solder (Item 2) [Figure 70-100-17] on the top of the piston. Use grease to hold them in position. NOTE: Put the solder in position so they do not touch the valves. Turn the piston to bottom dead center. Install the cylinder head and tighten to the correct torque in the correct sequence. (See Cylinder Head Removal And Installation on Page 70-100-1.) Turn the crankshaft until the piston exceeds T.D.C. Remove the cylinder head. Remove the solder wire (Item 3) [Figure 70-100-17] and measure it. If the measurement exceeds the specifications, check the oil clearance of the crank pin journal or the piston pin. Top Clearance

0.0236-0.0276 inch (0,6-0,7 mm)

PI-9988

Put the straight edge on the cylinder head's four sides and two diagonal as shown in figure [Figure 70-100-16]. The maximum distortion of the head surface is ± 0.002 inch (± 0,05 mm). If the measurement exceeds the specification, replace the cylinder head.

70-100-5


Figure 70-100-20

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Guide Checking Remove the valve and spring from the cylinder head. (See Cylinder Head Disassembly And Assembly on Page 70-100-4.) Clean the valve seat and combustion chamber. Figure 70-100-18

B-14335

Measure the valve stem O.D. [Figure 70-100-20]. Measure the valve guide I.D. [Figure 70-100-20]. Calculate the clearance. If the clearance exceeds the allowable limit, replace the valve and/or valve guide. Valve Guide I.D. P-51632

Valve Stem O.D. Install the valve into the guide. Measure the valve recessing or protrusion with a depth gauge [Figure 70100-18]. Figure 70-100-19

Clearance Between Valve Stem and Guide Allowable Limit

0.3156-0.3161 inch (8,015-8,03 mm) 0.3134-0.3140 inch (7,96-7,98 mm) 0.0016-0.0028 inch (0,04-0,07 mm) 0.004 inch (0,1 mm)

1. Cylinder Head Surface 2. Recessing 3. Protrusion PI-9990

If the measurement exceeds the allowable limit, replace the valve or cylinder head [Figure 70-100-19]. Protrusion Recessing Allowable Limit (Recessing)

0.002 inch (0,5 mm) 0.006 inch (0,15 mm) 0.016 inch (0,4 mm)

Remove the carbon from the valve guide. 70-100-6


Figure 70-100-22

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Guide Checking (Cont’d) Figure 70-100-21 8.86” (225 mm) 0.787”

2.76” (70mm)

0.460-0.468” (11,7-11,9 mm) 0.2” (5,0 mm)

0.263-0.275” 0.98” (6,7-7 mm) (25,0 mm)

1

1.77” (45 mm)

(20 mm)

2

0.256-0.259” (6,5-6,6 mm)

0.350-0.358” (8.9-9.1 mm)

0.787” (20,0 mm)

PI-9992

Press the used valve guide out of the cylinder head using the special driver tool [Figure 70-100-22].

0.490-0.50” (12.5-12.8 mm) MC-1364

To remove and replace the valve guide, make the driver tool as shown in figure [Figure 70-100-21].

Put oil on the outside diameter of the new valve guide. Press the new valve guide into the cylinder head from the top side. Use the special driver tools (Items 1 & 2) [Figure 70-100-22], press the new guide until the tool contacts the cylinder head. Ream the valve guide to the correct specifications.

70-100-7


Figure 70-100-25


2

1

Reconditioning The Valve And Valve Seat

15° Exhaust 30° Intake

Figure 70-100-23

3

PI-9995

Check the seat surface and valve face (Item 1) [Figure 70-100-25]. PI-9993

(a) identical dimensions above and below the valve seat Grind the valve face to the correct angle using a valve refacer [Figure 70-100-23]. Figure 70-100-24

If the seat surface (b) is too wide, use a 30 degree cutter (Item 2) on the intake, and a 15 degree cutter on the exhaust to get the correct width (Item 3) [Figure 70-10025]. Valve Seat Width Intake Exhaust

0.0835 inch (2,12 mm) 0.0835 inch (2,12 mm)

Valve Seat & Face Angle 15° Exhaust 30° Intake

45° Exhaust 60° Intake

Intake Exhaust

60° 45°

PI-9994

Grind the valve seat surface in the cylinder head to the correct angle [Figure 70-100-24].

70-100-8


Figure 70-100-27

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Spring Figure 70-100-26

A-2759

Put the spring on a tester and compress to specified length [Figure 70-100-27]. B-3680

Measure the length of the valve spring. If the measurement is less than the allowable limit, replace the spring [Figure 70-100-26]. Free Length Allowable Limit

Read the compressed load on the gauge. If the measurement exceeds allowable limit, replace the spring.

1.6417-1.6614 inch (41,7-42,2 mm) 1.622 inch (41,2 mm)

Setting Length Setting Load Allowable Limit

1.378 inch (35,0 mm) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N)

Put the spring on a flat surface, place a square on the side of the spring [Figure 70-100-26]. Rotate the spring and measure the maximum tilt. If the measurement excess the allowable limit, replace the spring. Tilt Allowable Limit

0.039 inch (1,0 mm)

70-100-9


Timing Gearcase Cover Removal And Installation


Remove the fuel injection pump. (See Fuel Injection Pump Removal And Installation (Turbo) on Page 70-705.)

Rocker Arm And Shaft Checking Figure 70-100-28

Remove the cylinder head, rocker arms and push rods. (See Cylinder Head Removal And Installation on Page 70-100-1.) Figure 70-100-29

1 2

7.87” (200 mm)

B-3697

Measure the rocker arm I.D. (Item 1) [Figure 70-100-28] with an inside micrometer. P-47254

Measure the rocker arm shaft O.D. (Item 2) [Figure 70100-28] with an outside micrometer. If the clearance exceeds the allowable limit, replace the bushing.

Bend a hook on the end of a 7.87 inch (200 mm) long, 0.050 inch (1.2 mm) diameter hard wire [Figure 70-10029].

If the clearance still exceeds the allowable limit after the bushing is replace, replace the rocker arm shaft.

Figure 70-100-30

Oil Clearance Between Rocker Arm & Shaft 0.0006-0.0018 inch (0,016-0,045 mm) Allowable Limit 0.004 inch (0,10 mm) Rocker Arm Shaft O.D. 0.5501-0.5506 inch (13,973-13,984 mm) Rocker Arm I.D. 0.5512-0.5519 inch (14,0-14,02 mm)

1

P-47255

Disconnect the two governor springs (Item 1) [Figure 70100-30].

70-100-10


Figure 70-100-33

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gearcase Cover Removal And Installation (Cont'd) Figure 70-100-31

P-47258

1 Use a puller and remove the crankshaft pulley. [Figure 70-100-33]. Figure 70-100-34

P-47256

Remove the speed control plate (Item 1) [Figure 70-10031]. Figure 70-100-32

2

1

1

B-14339

Remove the crankshaft pulley (Item 1) and key (Item 2) [Figure 70-100-34]. Remove the bolts from the timing gearcase cover.

P-47257

Remove the wire (Item 1) [Figure 70-100-32] from the springs.

Installation: Tighten the bolts to 13-15 ft.-lb. (18-20 nm) torque.

Installation: Do not drop the governor springs into the gear case. Remove the crankshaft pulley nut. Installation: Tighten the nut to 101-116 ft.-lb. (137-157 N•m) torque.

70-100-11


Figure 70-100-37

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gearcase Cover Removal And Installation (Cont'd) Figure 70-100-35

Oil Seal

O-Rings B-3617B

Installation: Install new O-rings and oil seal into the timing gearcase cover [Figure 70-100-37]. P-47259

Remove the timing gearcase cover [Figure 70-100-35]. Figure 70-100-36

3 2

1

B-14340

Remove the crankshaft collar (Item 1), O-ring (Item 2) and oil slinger (Item 3) [Figure 70-100-36].

70-100-12


Figure 70-100-40

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Idler Gear And Camshaft Removal And Installation

2

Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.)

1

Figure 70-100-38

2

1 P-47262

Align the holes (Item 1) on the camshaft gear with the camshaft retainer plate bolts (Item 2) [Figure 70-100-40]. Remove the bolts. Installation: Tighten the camshaft retainer bolts to 18-20 ft.-lb. (24-27 N•m) torque. P-47260

Remove the camshaft from the engine block. Remove the snap ring (Item 1) and collar from the idler gear shaft (Item 2) [Figure 70-100-38].

Figure 70-100-41

Installation: Make sure the timing marks are in correct alignment when installing the timing gears [Figure 70100-38]. Figure 70-100-39

1

PI-10002B

Installation: Check the camshaft end play. If clearance exceeds the allowable limit, replace the camshaft retainer plate [Figure 70-100-41]. B-3699

Camshaft End Play Remove the idler gear (Item 1) [Figure 70-100-39]. Installation: Check the idler gear end play. If the clearance exceeds the allowable limit, replace the gear collar. Idler Gear End Play Allowable Limit

Allowable Limit

0.0028-0.0087 inch (0,07-0,22 mm) 0.0118 inch (0,3 mm)

0.0047-0.0189” (0.12-0.48mm) 0.0354” (0,9 mm)

70-100-13


Figure 70-100-44

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Camshaft Servicing Figure 70-100-42

B-5001

Measure the cam lobes at their highest point [Figure 70100-44]. P-47263

Measure the cylinder block bore in the engine block [Figure 70-100-42].

If the measurement is less than the allowable limit, replace the camshaft. Cam Lobe Height Allowable Limit

Figure 70-100-43

1.3346 inch (33,9 mm) 1.3327 inch (33,85 mm)

Figure 70-100-45

A-2761 A-2760

Measure the camshaft journal [Figure 70-100-43]. Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the camshaft. Cylinder Block Bore I.D.

1.5748-1.5758 inch (40,0-40,03 mm) Journal O.D. 1.5722-1.5728 inch (39,93-39,95 mm) Oil Clearance of Camshaft Journal 0.002-0.0036 inch (0,05-0,091 mm) Allowable Limit 0.0059 inch (0,15 mm)

Put the camshaft in V-blocks. Install a dial indicator [Figure 70-100-45]. Turn the camshaft at a slow rate. If the misalignment exceeds the allowable limit, replace the camshaft. Camshaft Alignment Allowable Limit

70-100-14

0.0004 inch (0,01 mm)


Figure 70-100-47

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Idler Gear And Shaft Servicing

1.49” (38 mm)

Figure 70-100-46

6.89” (175 mm) 1.77” (45 mm)

1.575” (40 mm)

1.650-1.652” (41,9-41,95 mm)

1.494-1.495” (37,95-37,97 mm) MC-1366

To replace the idler gear bushing, make a driver tool as shown in figure [Figure 70-100-47]. PI-10003

Figure 70-100-48 Measure the O.D. of the idler gear shaft [Figure 70-10046]. Measure the I.D. of the idler gear bushing [Figure 70100-46]. If the clearance exceeds the allowable limit, replace the bushing. Idler Gear Shaft O.D.

1.4945-1.4951 inch (37,96-37,98 mm) Idler Gear Bushing I.D. 1.4961-1.4970 inch (38,0-38,03 mm) Clearance Between Idler Shaft & Gear Bushing 0.001-0.0026 inch (0,025-0,07 mm) Allowable Limit 0.0039 inch (0,1 mm)

PI-10004

Use a press and special driver tool, to remove the old bushing and install the new bushing [Figure 70-100-48].

70-100-15


Fuel Camshaft Removal And Installation

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gears Checking Backlash When the gears are installed, check the backlash of the gears. Figure 70-100-49

Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Remove the idler gear. (See Idler Gear And Camshaft Removal And Installation on Page 70-100-13.) Figure 70-100-50

2

1

P-47264

1 P-47265

Install a dial indicator [Figure 70-100-49]. Hold one gear while turning the other gear [Figure 70100-49]. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and gear. If the oil clearance is correct, replace the gear.

Remove the three bolts (Item 1) [Figure 70-100-50]. Remove the two bolts and fuel camshaft retainer plate (Item 2) [Figure 70-100-50]. Figure 70-100-51

Crank Gear & Idler Gear

0.0016-0.0044 inch (0,042-0,112 mm) Allowable Limit 0.0059 inch (0,15 mm) Cam Gear & Idler Gear 0.0016-0.0045 inch (0,042-0,115 mm) Allowable Limit 0.0059 inch (0,15 mm) Injection Pump Gear & Idler Gear 0.0016-0.0045 inch Allowable Limit Oil Pump Gear & Crankgear Allowable Limit

(0,042-0,115 mm) 0.0059 inch (0,15 mm) 0.0016-0.0043 inch (0,042-0,109 mm) 0.0059 inch (0,15 mm)

P-47266

Remove the fuel camshaft and fork lever assembly at the same time [Figure 70-100-51].

70-100-16


Crankshaft Gear Removal And Installation

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Fuel Camshaft Governor The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. Figure 70-100-52

Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Remove the idler gear. (See Idler Gear And Camshaft Removal And Installation on Page 70-100-13.) Figure 70-100-53

B-3686

1. Start Spring 2. Governor Spring 3. Governor Spring 4. Fork Lever 5. Fork Lever 6. Fork Lever Shaft 7. Fork Lever Holder 8. Governor Lever 9. Fuel Camshaft 10. Governor Ball Case 11. Steel Balls 12. Governor Sleeve 13. Steel Ball

Remove the crankshaft gear with a puller [Figure 70100-53]. Remove the crankshaft key.

PI-10008

Disassemble and assemble the governor and fuel camshaft as shown in figure [Figure 70-100-52]. Check all the parts for wear or damage and replace as needed.

70-100-17


Oil Pump Service


Figure 70-100-55

Oil Pump Removal And Installation Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Remove the crankshaft gear. Figure 70-100-54 1

B-3616

2

Measure the clearance between the lobes of the inner rotor and outer rotor [Figure 70-100-55]. Figure 70-100-56

B-3658

Remove the nut from the oil pump shaft. Use a puller to remove the oil pump gear (Item 1) [Figure 70-100-54]. Remove the oil pump mounting bolts. Remove the oil pump (Item 2) [Figure 70-100-54]. Installation: Tighten the oil pump mounting bolts to 6072 in.-lb. (6,9-8,1 N•m) torque. A-2732

Measure the clearance between the outer rotor and pump body [Figure 70-100-56]. If the clearance exceeds the allowable limit, replace the oil pump. Clearance Between Inner & Outer Rotor 0.0012-0.0055 inch (0,03-0,14 mm) Clearance Between Outer Rotor & Body 0.0043-0.0075 inch (0,11-0,19 mm)

70-100-18


Checking Engine Oil Pressure


Remove the oil pressure sender.

Oil Pump Service (Cont’d)

Figure 70-100-58

Figure 70-100-57

PI-10010 PI-10009

Put a piece of press gauge on the rotor face [Figure 70100-57]. Install the cover and tighten the bolts. Remove the cover carefully. Measure the width of the press gauge [Figure 70-100-57]. If the clearance exceeds the allowable limit replace the oil pump. End Clearance

0.0041-0.0059 inch (0,11-0,15 mm)

Install a pressure gauge [Figure 70-100-58]. Start the engine and run until it is at operating temperature. If the oil pressure is less than the allowable limit, check the following items: * Engine Oil Level Low * Oil Pump Defective * Oil Galley Plugged * Oil Strainer Plugged * Excessive Clearance at the Rod & Main Bearings * Oil Pump Relief Valve Stuck At Idle Speed Allowable Limit 7 PSI (0.50 Bar) At Rated Speed 43-64 PSI (2.94-4.41 Bar) Allowable Limit 36 PSI (2.45 Bar)

70-100-19



Piston And Connecting Rod Removal And Installation

Valve Tappets

Remove the cylinder head. (See Cylinder Head Removal And Installation on Page 70-100-1.)

Figure 70-100-59

Remove the top edge from the cylinder bore with a ridge reamer. Remove the oil pan. Figure 70-100-61 1

1

2 P-47267

Remove the valve tappets (Item 1) [Figure 70-100-59]. Figure 70-100-60 P-47269

Remove the oil pump strainer (Item 1) and O-ring (Item 2) [Figure 70-100-61] by tapping the edge of the strainer with a soft faced hammer. Turn the flywheel and put a pair of connecting rods at bottom dead center. Remove the connecting rod bolts. Installation: Tighten the connecting rod bolts to 33-36 ft.-lb. (44-49 N•m) torque. P-47268

Measure the O.D. of the tappet [Figure 70-100-60]. Measure the ID of the tappet bore [Figure 70-100-60]. If the clearance exceeds the allowable limit, replace the tappets. Tappet OD Tappet Bore ID Clearance Between Tappet and Tappet Bore Allowable limit

0.9433-0.9441 inch (23,96-23,98mm) 0.9449-0.9457 inch (24-24,02 mm)

0.0008-0.0024 inch (0,02-0,06 mm) 0.0028 inch (0,07 mm)

70-100-20


Figure 70-100-64

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Piston And Connecting Rod Removal And Installation (Cont’d)

4 1

3

Figure 70-100-62 2 1

P-47270

Remove the piston rings [Figure 70-100-64]. Remove the snap ring (Item 1) and piston pin (Item 2) [Figure 70-100-64].

PI-10013

Separate the piston (Item 3) from the connecting rod (Item 4) [Figure 70-100-64].

Remove the rod cap and bearing [Figure 70-100-62]. Use a hammer handle and push the piston/connecting rod assembly out of the cylinder bore [Figure 70-10062].

Figure 70-100-65 2

NOTE: Make sure the pistons are marked so they will be returned to the same cylinder bore. 3

Figure 70-100-63

1

PI-10015

1 Installation: When installing new rings, assemble the ring so the mark (Item 1) near the gap faces the top of the piston. When installing the oil ring, place the expander joint (Item 2) on the opposite side of the oil ring gap (Item 3) [Figure 70-100-65].

A-2903

Installation: Make sure the marks on the connecting rod and bearing are aligned when installing the bearing cap [Figure 70-100-63]. Repeat the procedure to remove the other piston/ connecting rod assemblies from the engine block.

70-100-21


Piston And Connecting Rod Servicing


Figure 70-100-67

Piston And Connecting Rod Removal And Installation (Cont’d) Figure 70-100-66 3

1 2

5

P-47272

4 Measure the I.D. of the piston pin bore in both horizontal and vertical directions [Figure 70-100-67].

P-47271

Installation: When reassembling, align the marks (Item 1) on the connecting rod and piston (Item 2). Heat the piston in clean engine oil to 176° F. (80° C.) and tap the piston pin into position. Place the piston rings so that there are gaps every 120° (Items 3, 4 & 5) [Figure 70100-66] with no gap facing the piston pin in the cylinder.

If the measurement exceeds the allowable limit, replace the piston.

70-100-22

Piston Bore I.D.

0.9843-0.9848 inch (25,0-25,013 mm)

Allowable Limit

0.9862 inch (25,05 mm)


Figure 70-100-69


1.38” (35 mm)

Piston And Connecting Rod Servicing (Cont’d)

1.063” (27 mm)

Figure 70-100-68

6.38” (162 mm) 1.378” (35 mm)

1

2

1.098-1.1004” (27,9-27,95 mm)

0.984-0.985” (25,0-25,01 mm) MC-1366

To replace the connecting rod small end bushing, make a driver tool as shown in figure [Figure 70-100-69]. P-47273

Figure 70-100-70 Measure the O.D. of the piston pin (Item 1) [Figure 70100-68]. Measure the I.D. of the connecting rod small end (Item 2) [Figure 70-100-68]. Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the bushing. If it still exceeds the specifications, replace the piston pin. Piston Pin O.D. Bushing I.D. Oil Clearance Between Piston Pin & Bushing Allowable Limit


PI-10016

Use a press and special driver tool to remove the small end bushing [Figure 70-100-70]. Installation: Clean the small end bushing and bore. Put oil on the bushing and press into the connecting rod until it is flush [Figure 70-100-70].

70-100-23


Figure 70-100-72

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Piston And Connecting Rod Servicing (Cont’d) Figure 70-100-71

PI-10017

Remove the carbon from the ring grooves. Measure the clearance between the ring and groove with a feeler gauge [Figure 70-100-72].

B-3622

Install a piston ring into the lower part of the cylinder bore. Measure the ring gap with a feeler gauge [Figure 70-100-71]. If the gap exceeds the allowable limit, replace the ring.

If the clearance exceeds the allowable limit, replace the ring. If the clearance still exceeds the allowable limit, replace the piston. Kubota V2203-M-DI Compression Rings

Kubota V2203-M-DI Top Ring Gap Oil Ring Gap Allowable Limit Second Ring Gap

0.0079-0.0138 inch (0,2-0,35 mm) 0.0079-0.0157 inch (0,20-0,40 mm) 0.0492 inch (1,25 mm) 0.0138-0.0197 inch (0.35-0,50 mm)

Allowable Limit Oil Ring Allowable Limit

Kubota V2003-M-DI-T (Turbo) Compression Rings Allowable Limit Oil Ring

Kubota V2003-M-DI-T (Turbo) Top Ring Gap Oil Ring Gap Allowable Limit Second Ring Gap

0.0020-0.0035 inch (0,05-0,09 mm) 0.0079 inch (0,2 mm) 0.0012-0.0028 inch (0,03-0,07 mm) 0.0059 inch (0,15 mm)

0.0079-0.0138 inch (0,2-0,35 mm) 0.0098-0.0177 inch (0,25-0,45 mm) 0.0492 inch (1,25 mm) 0.0157-0.0217 inch (0.40-0,55 mm)

Allowable Limit

70-100-24

0.0037-0.0050 inch (0,093-0,128 mm) 0.0079 inch (0,2 mm) 0.0008-0.0024 inch (0,02-0,06 mm) 0.0059 inch (0,15 mm)


Crankshaft And Bearings Removal And Installation

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Connecting Rod Alignment NOTE: The small end bushing is the basis of this check, check the bushing for wear before doing this check.

Remove the piston and connecting rod assemblies. (See Piston And Connecting Rod Removal And Installation on Page 70-100-20.) Figure 70-100-74 2

Install the piston pin into the connecting rod.

5

Install the connecting rod on an alignment tool. 4

Put the gauge over the piston pin and move it against the face plate.

1

Figure 70-100-73

3 P-47274

Mark and remove the inside screws (Item 1) first, then remove the outside screws (Item 2) [Figure 70-100-74]. NOTE: The inside bolts are different length than the outside bolts. Install two screws in the bearing case cover and remove the cover (Item 3) [Figure 70-100-74].

B-4067

If the gauge does not fit squarely against the face plate, measure the space between the gauge and face plate [Figure 70-100-73].

Remove the two gaskets (Item 4) and oil seal (Item 5) [Figure 70-100-74] from the cover. Figure 70-100-75

If the measurement exceeds the allowable limit, replace the connecting rod. Rod Alignment

0.002 inch (0,05 mm)

1 2

P-47275

Installation: Install the gaskets (Item 1) & (Item 2) [Figure 70-100-75] as shown.

70-100-25


Figure 70-100-78

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Crankshaft And Bearings Removal And Installation (Cont’d)

1

Figure 70-100-76 2

2

1 P-47278

Remove the main bearing case bolt (Item 1) [Figure 70100-78]. P-47276

Install the bearing case cover (Item 1) [Figure 70-10076] with the casting mark (Item 2) [Figure 70-100-76] in the upward position. Tighten the bolts to 17-20 ft.-lb. (23.5-27.5 N•m) torque.

Installation: Align the bearing case hole (Item 2) [Figure 70-100-78] with the hole in the block. Put oil on the bolt threads and tighten to 51-54 ft.-lb. (69-73 N•m) torque. Figure 70-100-79

Figure 70-100-77 1

P-47279

Remove the crankshaft/main bearing assembly from the engine block [Figure 70-100-79].

P-47277

Before removing the crankshaft/main bearings, check the end play. Install a dial indicator. Move the crankshaft [Figure 70-100-77] to the flywheel side, zero the dial indicator. Measure the end play by pulling the crankshaft toward the gear case side.

NOTE: Turn the crankshaft as needed to allow the crank pin journals to pass through the cut out (Item 1) [Figure 70-100-79] of the engine block. Mark the bearing case halves for correct installation.

If the measurement exceeds the allowable limit, replace the thrust washers [Figure 70-100-77]. End Play Allowable Limit

0.0059-0.0138 inch (0,15-0,35 mm) 0.0197 inch (0,5 mm) 70-100-26


Crankshaft And Bearings, Servicing


Figure 70-100-82

Crankshaft And Bearings Removal And Installation (Cont’d) Figure 70-100-80

A-2763

Put the crankshaft on V-blocks. Install a dial indicator on the center journal [Figure 70-100-82].

B-4092

Remove the two bearing case bolts [Figure 70-100-80]. Remove the bearing case and bearing. Installation: Tighten the bearing case bolts to 34-38 ft.lb. (46-51 N•m) torque. Figure 70-100-81

Turn the crankshaft at a slow rate to obtain the misalignment (one half of the alignment measurement). If the misalignment exceeds the allowable limit, replace the crankshaft. Alignment

0.0008 inch (0,02 mm)

Tighten the connecting rod bolts to 33-36 ft.-lb. (45-49 N•m) torque. Figure 70-100-83

120

PI-10021

Installation: When installing the main bearing case assemblies, face the mark FLYWHEEL to the flywheel side of the engine block [Figure 70-100-81]. The thrust washers oil grooves must face outward.

A-2727

Measure the crankpin bearing I.D. [Figure 70-100-83].

70-100-27



Figure 70-100-85 1

Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-84

PI-10022

Check the wear on the crankshaft sleeve (Item 1) [Figure 70-100-85]. A-2716

Measure the crankpin O.D. [Figure 70-100-84].

If the wear exceeds the allowable limit or the seal leaks oil, replace the sleeve. Wear of Sleeve

Calculate the oil clearance. Crankpin Bearing I.D. Crankpin O.D. Oil Clearance Allowable limit


0.0039 inch (0,1 mm)

The special tool set will be needed to replace the crankshaft sleeve. Remove the sleeve.

70-100-28


Figure 70-100-88

RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-86

2

2 1

3

B-3618

Measure the O.D. of the crankshaft journal [Figure 70100-88]. PI-10023

Calculate the oil clearance. Install the sleeve guide (Item 1) and stop (Item 2) [Figure 70-100-86].

If the clearance exceeds the allowable limit, replace the crankshaft bearing.

Heat the sleeve to approximately 300° F (150° C). Install the sleeve on the crankshaft using the special driver tool (Item 3) [Figure 70-100-86].

Bearing 1:

NOTE: The sleeve is installed with the larger chamfered surface to the front of the crankshaft (Item 1) [Figure 70-100-85 on Page 28].

Bearing I.D. Journal O.D. Oil Clearance Allowable Limit


Figure 70-100-87

B-3631

Measure the I.D. of the No. 1 crankshaft bearing [Figure 70-100-87].

70-100-29


Figure 70-100-91


1. Seam 2. Bearing 3. Engine Block 4. Bearing Recession

Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-89 Removal Tool

4

3

5.31” (135 mm) 0.8” (20 mm) 2.354-2.358” (59,80-59.90 mm)

2.83” (72 mm)

2

1

2 P-48778

0.8” (20 mm) 1.57” (40 mm)

0.4” (10 mm)

2.551-2.555 (64,80-64,90 mm) MC-1367

To remove the front bearing make the tool as shown in figure [Figure 70-100-89].

Installation Tool 5.12” (130 mm)

2.83”

0.8” (20 mm)

Bearing Number 1 Recession

2.551-2.555” (64,80-64.90 mm) 2.68” (68 mm)

0.8” (20 mm) 0.4” (9mm)

0.1654-0.1772 inch (4,2-4,5 mm)

Clean the crankshaft journal and bearing. Put a strip of press gauge on the center journal.

(72 mm)

1.57” (40 mm)

Installation: Clean the new bearing (Item 2) and bore, apply oil to the bearing and bore. Install the new bearing with the seam (Item 1) [Figure 70-100-91] towards the exhaust manifold side, using the installation driver tool. Check the depth (Item 4) of the bearing (Item 2) from the face of the engine block (Item 3) [Figure 70-100-91]. This will ensure proper bearing alignment with the crankshaft.

Figure 70-100-90

0.16” (4 mm)

Remove the front bearing with the special removal tool [Figure 70-100-89].

2.354-2.358” (59,80-59,90 mm)

Install the main bearing case halves and tighten the bolts. Remove the bearing case halves. NOTE: DO NOT turn the crankshaft with the press gauge installed. Incorrect measurements will be obtained.

MC-1365

To install the front bearing make the tool as shown in figure [Figure 70-100-90].

70-100-30


Cylinder Bore, Checking


Figure 70-100-93

Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-92

B-4066

Use a gauge to check the inside measurement of the cylinder bore [Figure 70-100-93].

PI-10025

Measure the flattened press gauge [Figure 70-100-92].

Figure 70-100-94

If the clearance exceeds the allowable limit, replace the No. 2 crankshaft bearing. Crankshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit

2.3591-2.3598 inch (59,92-59,94 mm) 2.3614-2.3632 inch (59,98-60,02 mm) 0.0016-0.0041 inch (0,04-0,12 mm) 0.0079 inch (0,2 mm) A-2717

Measure the six points as shown in figure [Figure 70100-94] to find the maximum wear. The factory specifications are: Kubota V2203-M-DI 3.4252-3.4261 inch (87,0-87,022 mm) The wear limit is: +0.0059 inch (+0,15 mm). Kubota V2003-M-DI-T (Turbo) 3.2677-3.2686 inch (83-83,02 mm). The wear limit is +0.0059 inch (+0,15 mm). If the cylinder bore is not within specifications, re-bore the cylinder for oversize piston.

70-100-31


Water Pump Disassembly And Assembly


Figure 70-100-96

Water Pump Removal And Installation

2

Drain the cooling system. 1

Remove the alternator belt. Remove the water pump bolts.

3 4

Figure 70-100-95

B-14424

Remove the flange (Item 1) [Figure 70-100-96]. Press the shaft (Item 2) and impeller (Item 3) [Figure 70100-96] out the impeller side of the water pump. Remove the impeller (Item 3) [Figure 70-100-96] from the shaft.

B-5318

Remove the seal (Item 4) [Figure 70-100-96].

Remove the water pump [Figure 70-100-95]. Installation: Always use a new gasket when installing the water pump.

Install a new seal (Item 4) [Figure 70-100-96] when assembling the water pump.

70-100-32


Figure 70-110-2

TURBOCHARGER Checking Inspect the turbine fins and the turbo housing for damage.

1

Spin turbine by hand. Turbine should spin freely. If the turbine is damaged replace the turbocharger.

2

Check the oil tubelines for leaks. Description P-48783

WARNING Turbochargers, operate at high speed and high temperatures. Keep fingers, tools and other objects away from the inlet and outlet ports. Avoid contact with hot surfaces. W-2257-1196

The oil flows from the fitting (Item 1) on the front of the engine to the turbocharger and returns to the engine block through the fitting (Item 2) [Figure 70-110-2] . The turbocharger serviceable.

internal

components

are

not

Figure 70-110-1

1

P16199

The turbocharger (Item 1) [Figure 70-110-1] is placed between the exhaust and intake manifolds. It is driven by hot exhaust gases and supplies air at more than atmospheric pressure to the intake. It is lubricated by oil from the main galley.

70-110-1


Figure 70-110-4

TURBOCHARGER (CONT'D) Removal And Installation Remove the muffler. (See Removal And Installation on Page 70-30-1.)

1

Figure 70-110-3

2

1 P-48598

Figure 70-110-5

P-48599

Remove the compressor outlet hose (Item 1) [Figure 70110-3] from the turbo.

1

Remove the air cleaner hose (Item 2) [Figure 70-110-3] from the turbocharger.

P16230

Remove the oil supply line fitting (Item 1) [Figure 70-1104] and the brass washer(s) (Item 1) [Figure 70-110-5] from the turbocharger. Installation: Tighten to 12-15 ft.-lb. (16,0-20,3 N•m) torque.

70-110-2


Figure 70-110-8

TURBOCHARGER (CONT'D) Removal And Installation (Cont'd) Figure 70-110-6

1

1

P-48780

Remove the mounting bolt (Item 1) [Figure 70-110-8] from the exhaust muffler flange.

P-48597

Installation: Tighten to 17-20 ft.-lb. (23,0-27,0 N•m) torque.

Figure 70-110-7

Figure 70-110-9 1

1 1 2 P-48785

Remove the mounting bolts (Item 1) [Figure 70-110-6] & [Figure 70-110-7] from the oil return line (Item 2) [Figure 70-110-6] & [Figure 70-110-7]. Installation: Tighten to 84-132 in.-lb. (9,5-15,0 N•m) torque.

P-48781

Remove the mounting bolt (Item 1) [Figure 70-110-9] from the exhaust muffler flange. Installation: Tighten to 17-20 ft.-lb. (23,0-27,0 N•m) torque.

70-110-3


TURBOCHARGER (CONT'D) Removal And Installation (Cont'd) Figure 70-110-10

1 1

P-48601

Remove the mounting nut and washer (Item 1) [Figure 70-110-10] from the turbocharger. Installation: Tighten to 17-20 ft.-lb. (23,0-27,0 N•m) torque. Figure 70-110-11

1

P16230

Remove the turbocharger assembly (Item 1) [Figure 70110-11] from the engine.

70-110-4


HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1 AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3 Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2 BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1 Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-3 Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-1 Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-2 Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-10 Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-11 Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1


DRIVE SYSTEM

COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1 EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-160-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1


HVAC

EXPANSION VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1 GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . Component Replacement And Refrigeration Leaks. . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . .

80-60-1 80-60-3 80-60-1 80-60-2

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1 Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1 Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2 Continued On Next Page

80-01


HEATING, VENTILATION, AIR CONDITIONING (CONT’D) HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Wire Connector Removal and Installation . . . . . . . . . . . .

80-210-1 80-210-2 80-210-1 80-210-4

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-220-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1 PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1 PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1 RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1 REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . Filter Elements Removal And Installation . . . . . . . . . . . . .

80-40-1 80-40-3 80-40-2 80-40-1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Procedure With A Manifold Gauge Set . . . . . . Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .

80-100-1 80-100-5 80-100-4 80-100-1

SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1 Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2 TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

80-02


80-10-1


AIR CONDITIONING SYSTEM FLOW Principals In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit. At these five points in the system the refrigerant goes through pressure and temperature changes. The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3. Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the refrigerant from a gas to a liquid. The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. where impurities such as moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3. The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, 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


AIR CONDITIONING SYSTEM FLOW (CONT'D) Chart

Thermostat

Cold Air Evaporator 5 Evaporator

4 Expansion Valve

Blower

6

1 Compressor

2 Condenser Sight Glass

Pressure Switch

Fan Dessicant 3

Receiver Drier

Status Of R134a_______________________________________________ High Pressure Gas

Low Pressure Liquid

High Pressure Liquid

Low Pressure Gas b-16691

80-10-3


80-10-4


Figure 80-20-3

COMPONENTS Identification

2

Figure 80-20-1

1 1

P-24219

P-24288

Compressor: The compressor (Item 1) [Figure 80-20-1] is the pump that circulates the refrigerant throughout the system. It raises the pressure of the refrigerant for heat transfer through the condenser and evaporator.

Receiver/Drier: The receiver/drier (Item 1) [Figure 80-203] 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. Figure 80-20-4

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 80-20-2

1

1 N-22206

Pressure Relief Valve: The pressure relief valve (Item 2) [Figure 80-20-3] is located on the receiver drier assembly. This small brass valve (Item 1) [Figure 80-204] is a safety feature that is designed to open and release the A/C charge if the pressure reaches 535 PSI.

P-48011

Condenser: The condenser (Item 1) [Figure 80-20-2] is the unit that receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it into a high temperature liquid.

80-20-1


Figure 80-20-7

COMPONENTS (CONT'D) Identification (Cont'd) Figure 80-20-5

3

1 2 N-22087

1 Evaporator Coil: The evaporator coil (Item 1) [Figure 8020-7] cools and dehumidifies the air before it enters the cab.

P-24227

Heater/Evaporator Unit: The heater/evaporator unit (Item 1) [Figure 80-20-5] is located behind the loader cab. The unit delivers the cold air for the A/C and warm air for heat into the cab. The unit contains the blower, heat & A/C coils , thermostat and expansion valve. Figure 80-20-6

Thermostat: The thermostat (Item 2) [Figure 80-20-7] controls the temperature of the evaporator coil. Heater Coil: The heater coil (Item 3) [Figure 80-20-7] supplies the warm air into the cab by passing air through the coil. Figure 80-20-8

1

1 P-21902 N-22100

Expansion Valve: The expansion valve (Item 1) [Figure 80-20-6] controls the amount of refrigerant entering the evaporator coil.

Heater/Evaporator Blower: The blower (Item 1) [Figure 80-20-8] is used to push air through the heater and evaporator coils and into the cab.

80-20-2


Figure 80-20-11

COMPONENTS (CONT'D) Identification (Cont'd)

1

Figure 80-20-9

1

2

3

4 P-24229

N-22261

Control Panel: The panel (Item 1) [Figure 80-20-9] has three separate components.

Pressure Switch: The pressure switch (Item 1) [Figure 80-20-11] will disengage the compressor clutch at high pressure readings over 384 PSI. (2647 kPa) on the high side, or at very low pressure of 28 PSI (193 kPa) or less on the high side, which indicates loss of refrigerant.

Fan Switch: This is a four position rotary switch (Item 2) [Figure 80-20-9]. When the fan switch is in the off position the A/C will not engage, but the heat valve will operate, as it is controlled by the ignition power. A/C Switch: The rocker switch (Item 3) [Figure 80-20-9] will be illuminated when the A/C is engaged. Potentiometer: The potentiometer (Item 4) [Figure 8020-9] 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. Figure 80-20-10

1

P-24232

Heater Valve: The heater valve (Item 1) [Figure 80-2010] is used to control the amount of engine coolant that flows to the heater coil. 80-20-3


80-20-4


SAFETY

WARNING

Safety Equipment Figure 80-30-1

In the event of a leakage, 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

R-134a inside a canister or in an A/C system is a liquid under pressure. When it escapes or releases into the air, ITS TEMPERATURE DROPS TO 21.6 F DEGREES "INSTANTLY". If it spills on your skin or in your eyes you should flood the area with cool water and SEEK MEDICAL ATTENTION FAST! It is a good idea to wear gloves [Figure 80-30-2] to prevent frost bite if you should get refrigerant on your hands. P16398

WARNING

Figure 80-30-2

HFC 134A refrigerant can be dangerous if not properly handled. Liquid 134A may cause blindness if it contacts the eyes and may cause serious frostbite if it contacts the skin. • Gaseous 134A becomes lethal (phosgene) gas when it contacts open flame or very hot substances. • NEVER SMOKE when there is the possibility of even small amounts of 134A in the air. Any servicing work that involves release or addition of 134A to the system must be done by a competent refrigeration dealer who has the proper equipment, knowledge, and experience to service refrigeration equipment.

P16399

W-2373-0500

In servicing A/C and heater systems you will be exposed to high pressures, temperatures and several chemical hazards. Moving belts and pulleys are normal shop hazards. In addition to exercising caution in your work, DO WEAR SAFETY GLASSES OR A FACE SHIELD [Figure 8030-1] when you are using R-134a or a leak detector, adjusting service valves or the manifold gage set connectors. Safety glasses or a transparent face shield are practical safety items and one or the other is absolutely required.

80-30-1


80-30-2


Figure 80-40-3

REGULAR MAINTENANCE Filter Elements Removal And Installation Figure 80-40-1

1

P-28820

1 Remove the filter (Item 1) [Figure 80-40-3] from the cover.

P-48012

Remove the two mount bolts (Item 1) [Figure 80-40-1] from the fresh air filter cover at the rear of the loader cab. Figure 80-40-2

The fresh air filter must be cleaned sometimes as often as twice a day, depending on the environment. The filter can be cleaned by removing and shaking it. A small amount of air pressure can be used to clean the filter. However the fresh air filter should be changed at least 24 times per year in normal conditions. In extremely dusty conditions the fresh air filter many need to be changed weekly. Figure 80-40-4

1

P-28819

Remove the filter cover and filter (Item 1) [Figure 80-402] from the loader.

2

1 P-48005

Remove the two retaining knobs (Item 1) [Figure 80-404] from the recirculating air filter cover, at the back of the cab. Remove the retaining cover (Item 2) [Figure 80-40-4] from the loader cab.

80-40-1


REGULAR MAINTENANCE (CONT’D)

Compressor Drive Belt Inspection

Filter Elements Removal And Installation (Cont’d)

Figure 80-40-7

Figure 80-40-5

P-48008

1

1 P-24288 P-48006

Remove the recirculating air filter (Item 1) [Figure 80-405] from the rear of the cab. Installation: Make sure the arrows on the filter are facing the front of the loader. (Inset) [Figure 80-40-5].

It is a good rule to regularly inspect (weekly) the compressor drive belt for tension and wear. Open the rear door. Remove the drive belt cover. Remove the compressor drive belt cover.

Figure 80-40-6

Check the tension on the compressor belt (Item 1) [Figure 80-40-7].

P-48007

The recirculating air filter is made of a paper filtering media with a rubber seal. A small amount of air can be used to clean the filter. It does not require cleaning as frequently as the fresh air intake filter [Figure 80-40-6].

80-40-2


Figure 80-40-10

REGULAR MAINTENANCE (CONT’D) Cleaning The Condenser Figure 80-40-8 1

1

P-48010

With water or air, the condenser (Item 1) [Figure 80-4010] can be cleaned.

P-48011

Open the rear door. Remove the rear grill on the loader. Check the condenser (Item 1) [Figure 80-40-8] for mud or dirt. Figure 80-40-9

2 1 P-24213A

P-48011

Lift the rear of the condenser and pull towards rear of machine until the front tabs (Item 1) slide out of mount (Item 2) [Figure 80-40-9]. With the condenser removed from the machine, the oil cooler can also be lifted.

80-40-3


80-40-4


Check the belt tension on the A/C compressor. ((See COMPRESSOR on Page 80-110-1.)

BASIC TROUBLESHOOTING Poor A/C Performance

Check the A/C condenser for dirt or mud, and clean if necessary. (See CONDENSER on Page 80-120-1.)

Figure 80-50-1

Check the A/C evaporator coil for dirt or mud, and clean if necessary. (See EVAPORATOR on Page 80-190-1.) Inspect the sight glass located on the receiver/drier for air bubbles. (See RECEIVER/DRIER on Page 80-130-1.) Check the engine coolant to see if it is bypassing the heater valve. (See HEATER VALVE on Page 80-210-1.)

1

WARNING N-22273


Figure 80-50-2

W-2059-0598

Cleaning The A/C Evaporator Coil & Heater Coil Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Figure 80-50-3 N-22411

Start the loader, engage the parking brake. Engage the A/C system with the blower fan on high. Run the loader at full RPM for approximately 15 minutes, with the loader cab door closed.

1

Check the temperature at the louvers (Item 1) [Figure 80-50-1] with a thermometer [Figure 80-50-2]. The louver temperature should be between 36-53°F. (2,2-11,6°C) depending on the amount of humidity in the air.

2 P-39463

If louver temperature is too high, (See SYSTEM TROUBLESHOOTING CHART on Page 80-70-1.) Check the blower fan for proper operation or noise, and replace if necessary. (See HEATER/AC FAN on Page 80-210-1.)

1

At the rear of the cab, Remove the six mounting screws (Item 1) [Figure 80-50-3]. Remove the access cover (Item 2) [Figure 80-50-3] from the loader.

80-50-1


BASIC TROUBLESHOOTING (CONT'D)

Compressor Drive Belt Inspection

Cleaning The A/C Evaporator Coil & Heater Coil (Cont'd)

Figure 80-50-6

Figure 80-50-4

1

1 P-48013

1 P-24288

Regularly inspect (weekly) the compressor drive belt for wear.

P-48014

The access cover is sealed to the heater unit with a foam gasket (Item 1) that keeps out dirt and debris. Check the gasket for rips and tears. Replace as needed.

Open the rear door.

The cover is held in place with screws that are held to the cover with plastic retainers (Inset) . These help hold the screws when installing the cover.

Remove the compressor belt cover.

Figure 80-50-5

Remove the drive belt cover.

Check the tension on the compressor belt (Item 1) [Figure 80-50-6].

2 1

P-39464

With air or water, clean the heater coil evaporator coil (Item 2) [Figure 80-50-5].

(Item 1) and

Replace the cover. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)

80-50-2


Figure 80-50-9

BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System Figure 80-50-7

1

2

1

P-24300


N-22284

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. Push the A/C switch (Item 1) to the ON position. Turn the blower fan switch (Item 2) [Figure 80-50-7] to the first On position.

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the loader harness (Item 1) [Figure 80-50-9] from the compressor clutch wire. Figure 80-50-10

The compressor clutch should make a click sound, which indicates the clutch is engaging. Figure 80-50-8 1

1

P-24314

With a multimeter, check the resistance to the compressor clutch (Item 1) [Figure 80-50-10]. P-21912

If there is no resistance value, replace the compressor clutch.(See COMPRESSOR on Page 80-110-1.)

If the compressor clutch does not engage, check the loader fuse (Item 1) [Figure 80-50-8] located on the control panel in the loader cab. Replace the fuse if burned out. NOTE: The decal inside the fuse cover, refers to the fuse as HEATER. This fuse controls the power for both the Heater and the A/C systems. 80-50-3


Figure 80-50-13

BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-11

1 1

P-24315

Using a multimeter check the loader wiring harness (Item 1) [Figure 80-50-13] for voltage.

P-24314

With a multimeter, check the voltage to the compressor clutch at the loader harness (Item 1) [Figure 80-50-11] The voltage reading should be around 12 volts. If there is no power at the clutch, check the wiring harness for broken wires.

The voltage should be around 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires. Figure 80-50-14

If there is power at the clutch, reconnect the wiring harness to the compressor clutch. Figure 80-50-12

2 1

P-24315

1

If there is voltage at the harness, check the resistance at the pressure switch (Item 1) [Figure 80-50-14]. If there is no resistance value, check for low refrigerant level. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.)

P-24299

Disconnect the loader harness (Item 1) from the pressure switch (Item 2) [Figure 80-50-12].

If a resistance value is observed, the pressure switch is good. Reconnect the loader harness to the pressure switch.

80-50-4


Figure 80-50-17


1 1

N-22259

If there is voltage at the wiring harness, check the thermostat (Item 1) [Figure 80-50-17] for resistance.

N-22258

Disconnect the thermostat wiring connector (Item 1) [Figure 80-50-15] from the loader wiring harness.

The resistance value of the thermostat should be 10 Ohms at 68° F (20° C). If there is no resistance value, replace the thermostat. (See THERMOSTAT on Page 80-170-1.)

Figure 80-50-16

If there is a resistance value, check the blower fan. Figure 80-50-18

2 1

N-22259

1 Check the loader harness (Item 1) [Figure 80-50-16] for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.

N-22130

Remove the mount bolt (Item 1) [Figure 80-50-18] from the left side cab access cover. Remove the access cover (Item 2) [Figure 80-50-18] from the loader.

80-50-5


Figure 80-50-21


1

1

N-22260

If there is voltage at the wiring harness, check the resistance to the blower fan at the blower fan wiring connector (Item 1) [Figure 80-50-21].

N-22129

Disconnect the blower fan wiring connector (Item 1) [Figure 80-50-19] from the loader wiring harness.

If there is no resistance value replace the blower fan. (See HEATER/AC FAN on Page 80-210-1.)

Figure 80-50-20

If there is a resistance value check the climate controls at the control panel inside the loader cab. Figure 80-50-22

1

1

1

N-22260

Check the loader harness (Item 1) [Figure 80-50-20] for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.

N-22261

Remove the three mount bolts (Item 1) [Figure 80-50-22] from the cab control panel.

80-50-6


Figure 80-50-25


C

H

B

M

L

N-22288

If there is voltage at the wiring harness, check the blower switch [Figure 80-50-25] for resistance.

N-22262

Remove the control panel and wiring harness from the cab [Figure 80-50-23].

With the switch in the OFF position, there should be zero resistance between all terminals. With the switch in the 1 position, there should be resistance between C terminal and the B terminal, between the C terminal and the L terminal, and also between the B terminal and the L terminal frame [Figure 80-50-25].

Figure 80-50-24

With the switch in the 2 position, there should be resistance between C terminal and the B terminal, between the C terminal and the M terminal, and also between the B terminal and the M terminal frame [Figure 80-50-25].

1

With the switch in the 3 position, there should be resistance between C terminal and the B terminal, between the C terminal and the H terminal, and also between the B terminal and the H terminal frame [Figure 80-50-25].

N-22265

Disconnect the loader wiring harness (Item 1) [Figure 80-50-24] from the blower switch. Check the loader harness for voltage. The voltage should be 12 volts.

If any of the above resistance tests fail, replace the blower switch. If the above resistance tests are good, check the A/C switch.

If there is no voltage at the wiring harness, check the harness for broken wires.

80-50-7



If a resistance value is found, check the potentiometer.

Checking The Electrical System (Cont'd)

Figure 80-50-28

Figure 80-50-26

1

1

N-22262

N-22264

At the loader cab, disconnect the loader harness (Item 1) [Figure 80-50-26] from the A/C switch. Check the harness for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.

The potentiometer will effect the A/C system and also effect the operation of the heater. If heater valve does not open, or close, or the A/C does not work, check the potentiometer. At the loader cab, disconnect the loader harness (Item 1) [Figure 80-50-28] from the potentiometer. Figure 80-50-29

Figure 80-50-27

1

1

2

N-22263

N-22289

If there is voltage at the wiring harness, check the A/C switch [Figure 80-50-27] for resistance.

Check the loader harness (Item 1) [Figure 80-50-29] for voltage. The voltage should be 12 volts.

With the switch in the OFF position there should be no resistance between any of the three terminals on the A/C switch.

If there is no voltage at the wiring harness, check the harness for broken wires.

With the switch in the ON position there should be resistance between terminal (Item 1) and terminal (Item 2) [Figure 80-50-27]. If no resistance value is found, replace the A/C switch.

80-50-8


Figure 80-50-32


C

A

1

N-22175

B To check the resistance of the white wire, turn the potentiometer control (Item 1) to the full A/C position [Figure 80-50-32].

N-22290

If there is voltage at the wiring harness, check the potentiometer [Figure 80-50-30] for resistance.

Figure 80-50-33

The resistance should be 10 K Ohm's between wire terminal A and wire terminal C frame [Figure 80-50-30]. If no resistance is found, replace the potentiometer. C

A

Figure 80-50-31

B N-22290

The resistance between the wire terminal A and wire terminal B frame [Figure 80-50-33] should be approximately 49 K Ohm's.

1

Check the resistance between the wire terminal C and wire terminal B frame [Figure 80-50-33] should be approximately 39 K Ohm's.

N-22201

The white wire B, (Item 1) [Figure 80-50-31], on the potentiometer, is a resistor wire.

80-50-9



Engine Coolant By-Passing The Heater Valve

Checking The Electrical System (Cont'd)

Figure 80-50-36

Figure 80-50-34

2

3 1

1 N-22284 N-22175

To check the resistance of the white wire, turn the potentiometer control (Item 1) [Figure 80-50-34] to the full Heater position. Figure 80-50-35

Raise the lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.) Push the A/C switch (Item 1) to the OFF position. Turn the fan switch (Item 2) to the High Speed position. Turn the temperature control (Item 3) [Figure 80-50-36] to the High A/C position, with the loader ignition switch OFF. Figure 80-50-37

1

C

A

B N-22290

Check the resistance between the wire terminal A and wire terminal B frame [Figure 80-50-35] should be approximately 39 K Ohm's. Check the resistance between the wire terminal C and wire terminal B frame [Figure 80-50-35] should be approximately 49 K Ohm's. If the resistance is not found, replace the potentiometer.

P-48009

Raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.) Start the loader and run at high idle, for ten minutes. Check the heater hose (Item 1) [Figure 80-50-37] for temperature. If the hose is hot, the heater valve is leaking by, and needs to be replaced.

80-50-10


Figure 80-50-39

BASIC TROUBLESHOOTING (CONT'D) Heater Valve Not Opening Or Closing Figure 80-50-38

1 P-48015

2

3 1

P-48009

N-22284

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Push the A/C switch (Item 1) to the OFF position. Turn the fan switch (Item 2) to position 1. Turn the temperature control (Item 3) [Figure 80-50-38] to the High A/C position, with the loader ignition switch OFF.

Place the remote start tool on the left fender of the loader, so the heater valve can be clearly seen. Watch the valve shaft (Item 1) [Figure 80-50-39], as the key of the remote start is turned to the ON position without starting the loader. The heater valve should rotate. If it does not rotate, check the potentiometer. (See HEATER VALVE on Page 80-220-1.) for proper function. Replace the heater valve. (See HEATER VALVE on Page 80-220-1.)

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.) Place the remote start tool on the left fender of the loader, so the heater valve can be clearly seen. Watch the valve shaft (Item 1) [Figure 80-50-39], as the key of the remote start tool is turned to the ON position without starting the loader. The heater valve should rotate. Place a mark on the loader shaft. Turn the key of the remote start tool to the OFF position and remove the remote start tool from fender. Lower operator cab. Turn the temperature control (Item 3) [Figure 80-50-38] to the High Heater position, with the loader ignition switch OFF. Raise the operator cab.

80-50-11


80-50-12


GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Figure 80-60-1

1

N-22243

The compressor (Item 1) [Figure 80-60-1] is factory filled with 150-170 cc's of PAG oil (Poly Alkelene Glycol). Unlike engine oil, it is not necessary to frequently check or change the compressor oil. It is necessary to check, replenish or replace the compressor oil in the following cases: 1. When the evaporator, condenser or receiver-drier is replaced. 2. When refrigerant has leaked from the system. 3. When refrigerant is suddenly released from the cooling cycle. 4. When any oil related problems occur in the cooling cycle. When one of the components (the evaporator, condenser or receiver-drier) is replaced, one ounce (30 cc) of PAG oil should be added for each component replaced. If the A/C compressor is changed, no oil should be added to the system, because the compressor comes factory filled with oil. NOTE: Only PAG oil should be used. Never mix R-12 and R-134a Oils.

80-60-1


GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D)

Run the compressor for at least 20 minutes at 800-1200 RPM.

Compressor Oil Check

Remove the compressor from the COMPRESSOR on Page 80-110-1.)

Figure 80-60-2

loader.

(See

Remove the oil drain plug (Item 1) [Figure 80-60-2] and drain the oil through the connectors and the oil drain hole [Figure 80-60-3]. Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lb. (13-15 N•m) torque. Figure 80-60-4 1

N-22245

Figure 80-60-3 1

N-22246

NOTE: After draining the oil through the drain hole and the connectors, extract the remaining oil through the discharge-side connector by rotating the drive pulley (Item 1) [Figure 80-604] several times by hand. P-16534A

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 CONDENSER on Page 80-1201.) Open the cab door and windows. Run the blower at maximum speed.

80-60-2


Component Replacement And Refrigeration Leaks

GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D)

Figure 80-60-6

Compressor Oil Check (Cont'd) Figure 80-60-5

1

1

P-24229

Whenever the A/C system is opened to the atmosphere or there has been a leak in the system, the receiver/drier (Item 1) [Figure 80-60-6] must be changed.

N-22245

Measure the drained oil in a measuring cylinder. Check the oil for contamination, dirt, metal shavings, or varnish color, discard the oil if contaminated.

Never leave hose fittings, compressor fittings or components uncapped while working on the A/C system.

NOTE: If metal shavings are found in the compressor oil, replace the complete compressor assembly. Add new compressor oil through the suction side connector (Item 1) [Figure 80-60-5]. Installation: Add 150 -170 cc's of PAG oil. NOTE: The suction port on the compressor is marked with an S and is the larger port on the compressor.

80-60-3


80-60-4


SYSTEM TROUBLESHOOTING CHART Blower motor does not operate

Possible Cause 1. Blown fuse. 2. Broken wiring or bad connection. 3. Fan motor malfunction.

Inspection Inspect the fuse/wiring. Check the fan motor ground and connectors.

Check the lead wires form the motor with a circuit tester. 4. Resistor malfunction. Check resistor using a circuit tester. 5. Fan motor malfunction. Check power into and out of the fan switch. Blower motor operates normally, but air flow is insufficient

Possible Cause

Solution Replace fuse/repair wiring. Repair the wiring or connector. Replace Motor. Replace Resistor. Replace Fan Switch.

Inspection

1. Evaporator inlet obstruction.

Check evaporator for plugging.

2. Air leak.

Check to make sure air hoses are properly hooked to Louvers, and air ducts. Check thermostat using a circuit tester.

3. Defective thermo. switch (frozen evaporator). Insufficient cooling although air flow and compressor operation are normal

Possible Cause

Solution Remove obstruction and clean evaporator fins with air or water. Repair of adjust. Replace thermostat.

Inspection

1. System low on refrigerant.

The high side pressure will be low and bubbles may be present in sight glass on receive drier.

2. Excessive refrigerant.

The high pressure side pressure will be high.

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.

The compressor does not operate at all, or operates improperly

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.

Magnetic clutch related 3. Low battery voltage. 4. Faulty coil. 5. Oil on the clutch surface.

Clutch slips. Clutch slips. Clutch slips.

6. Open oil.

Clutch does not engage and there is no reading when a circuit tester is connected between the coil and terminals. Clutch will not engage. Inspect the ground and connections. Test the conductance of the pressure switch, thermostat, Relay, etc.

7. Broken wiring or poor ground. 8. Wiring harness components.

80-70-1

Recharge the battery. Replace the magnetic clutch. Replace or clean the clutch surface. Replace clutch.

Repair. Check operation.


SYSTEM TROUBLESHOOTING CHART (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 than the low side pressure.

Possible Cause Low pressure side too high.

1. Expansion valve opens too far. 2. Dective compressor. Low pressure side Too low. 1. Low refrigerant charge. 2. Clogged or closed expansion valve. 3. Restriction between drier and expansion valve. 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.

Solution

Replace expansion valve.

The high and low pressure side gauge pressures equalize when the compressor is engaged.

Replace compressor.


Repair any leaks and recharge the refrigerant to the correct level. Clean or replace the expansion Valve. Flush system or replace hose.

The expansion valve’s inlet side is frosted. Moisture or other Contaminants can be the cause. Frost on the line between drier and expansion valve. A Negative low pressure reading may be shown.

Dirty or clogged condenser fins. Condenser fans not Operating. The high pressure side pressure will be high.

3. Excessive oil charge.

The high pressure side will be high.

4. Air in system.

Pressure is high on both high and low sides.

5. Restriction in drier, condenser or high pressure line. High pressure side Too low. 1. Low refirgerant charge.

High pressure side will be high, and low pressure side will be low.


80-70-2

Clean fins, and/or repair the fan. Use refrigerant recovery equipment to capture excess refrigerant. Charge to the correct refrigerant level. Evacuate system. Remove oil from condenser and compressor. Measure oil from compressor and add correct oil charge back into compressor. Flush system with nitrogen. Replace drier. Evacuate and recharge with Refrigerant. Evacuate and flush system replacing defective parts.

Repair any leaks and recharge the refrigerant to the correct level.


SYSTEM TROUBLESHOOTING CHART (CONT'D) Gauge Pressure Related Troubleshooting (Cont'd)

Possible Cause System pressures equal 1. Clutch not operating. 2. Compressor not pumping.

Inspection See magnetic clutch related topics above. Equal high and low pressures.

80-70-3

Solution

Replace compressor.


80-70-4


TEMPERATURE/PRESSURE Chart NORMAL EVAPORATOR RANGE

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

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.

80-80-1


80-80-2


AIR CONDITIONING SERVICE Chart

Service Company/Phone Number: Date: Machine Model: Machine Serial Number: Machine Hours: Pre Service Conditions Ambient Temperature: Louver Temperature: Cab Temperature At Head Position: Temperature Into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:

Machine Dealer: Customer: 15 Minutes

30 Minutes

Notes

15 Minutes

30 Minutes

Notes

Explain Services Required:

Post Service Conditions Ambient Temperature: Louver Temperature: Cab Temperature at Head Position: Temperature Into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:

80-90-1


80-90-2


Figure 80-100-3

SYSTEM CHARGING AND RECLAMATION Reclamation Procedure

1

Figure 80-100-1

1

2 N-23024

P-24208

Open the rear door and locate the low pressure port (Item 1), and high pressure port (Item 2) [Figure 80-1001]. Figure 80-100-2

NOTE: Before reclaiming a refrigeration system, it is recommended to identify the type of refrigerant that is in the A/C system and if it is pure enough to use. The tool MEL 1592, Refrigerant Identifier (Item 1) [Figure 80-100-3] will determine, the kind of refrigerant and any possible harmful or dangerous substances that may be present in the system. Thus preventing mixing of dangerous material with your reclaimed R-134a in your reclaimer, and further contamination to other A/C systems that are reclaimed and charged from your MEL 1581 Recovery/Recycling/Recharging Machine.

1

P-24230

NOTE: Do not use this port (Item 1) [Figure 80-100-2] for testing or charging.

WARNING In the event of a leakage, 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

NOTE: This test is run with the loader engine OFF, and the A/C switch in the OFF position. 80-100-1


Figure 80-100-5

SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Figure 80-100-4

1

N-22291

IMPORTANT: Only A/C trained technicians should perform the reclaiming and recharging.

P-24316

Remove the protective cap and connect the Refrigerant Identifier to the low pressure hose (Item 1) [Figure 80100-4]. Connect the Refrigerant Identifier to its power source. Follow the steps displayed on the refrigerant identifier screen. Allow two minutes for the refrigerant identifier to display the type of refrigerant and air content. An alarm will sound if potentially flammable hydrocarbons are present and will also indicate on the visual display. Disconnect the refrigerant identifier from the loader A/C. If the refrigerant is dangerous or flammable, it must be evacuated from the A/C system into a separate container and properly and safely disposed of. If R134a is found , evacuate the system.

WARNING HFC 134A refrigerant can be dangerous if not properly handled. Liquid 134A may cause blindness if it contacts the eyes and may cause serious frostbite if it contacts the skin. • Gaseous 134A becomes lethal (phosgene) gas when it contacts open flame or very hot substances. • NEVER SMOKE when there is the possibility of even small amounts of 134A in the air. Any servicing work that involves release or addition of 134A to the system must be done by a competent refrigeration dealer who has the proper equipment, knowledge, and experience to service refrigeration equipment. W-2373-0500

Use an approved recovery/charging unit [Figure 80-1005] to evacuate the system.

80-100-2


Figure 80-100-8

SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Figure 80-100-6

1 2

N-22381

P-24317

Connect the reclaimer to the loader A/C charge ports. Connect the Red hose (Item 1) [Figure 80-100-6] to the high pressure port and open the valve.

NOTE: The reclaimer unit, has a complete step by step set of instructions [Figure 80-100-8] to follow for reclimation and recharging of the A/ C system. A trained technician should follow these instructions as they may very slightly depending on the model and brand of reclaimer used.

Connect the Blue hose (Item 2) [Figure 80-100-6] to the low pressure port and open the valve. Figure 80-100-7

N-22292

Turn the reclaimer unit [Figure 80-100-7] to the ON position and follow the on screen instructions.

80-100-3


SYSTEM CHARGING AND RECLAMATION (CONT'D)

Connect the gauges to the loader A/C charge ports.

Charging Procedure With A Manifold Gauge Set

Connect the Red hose (Item 1) [Figure 80-100-10] to the high pressure port and open the valve. Connect the Blue hose (Item 2) [Figure 80-100-10] to the low pressure port and open the valve.

WARNING In the event of a leakage, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas.

Figure 80-100-11

W-2371-0500

Figure 80-100-9

1

P-24320

Connect the Yellow hose (Item 1) [Figure 80-100-11] to the vacuum pump. Figure 80-100-12

1 P-24318

Open the rear door. Check to see that the hand valves (Item 1) [Figure 80100-9] 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 Procedure on Page 80-100-1.)

1

Figure 80-100-10 P-24321

Start the vacuum pump and open ISO-valve (Item 1) [Figure 80-100-12] on the vacuum pump. Run the vacuum pump for at least 5-10 minutes to insure that a vacuum has been pulled on the system. 1

Close the ISO-valve (Item 1) [Figure 80-100-12] (which isolates the vacuum pump from the A/C system) and turn OFF the vacuum pump.

2

P-24319

80-100-4


Start the vacuum pump and open ISO-valve on the vacuum pump.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Charging Procedure

Be sure that both hand valves, and both charge port valves are open.

Figure 80-100-13

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.

1

Remove the vacuum pump and thermister vacuum gauge. Figure 80-100-15

P-24319

NOTE: Vacuum pressure indicated on the low pressure (Blue) gauge (Item 1) [Figure 80-10013]. Let stand for 5-10 min. and recheck the pressure for changes.

1 3

If the pressure drops, this may be an indication of a leak in the A/C system. Determine the problem with the A/C system and repair it.

2

Figure 80-100-14

P-24323

Place a refrigerant container with R134a (Item 1) on a charging scale (Item 2) [Figure 80-100-15] and zero out the scale. Connect the yellow hose (Item 3) [Figure 80-100-15] from the manifold gauge set to the valve on the refrigerant tank. 1 P-24322

A thermistor vacuum gauge (Item 1) [Figure 80-100-14] can be used to determine the critical vacuum level during evacuation. It is a solid state instrument that constantly monitors and visually indicates the vacuum level. The thermistor vacuum gauge is used with the vacuum pump [Figure 80-100-14].

80-100-5


SYSTEM CHARGING AND RECLAMATION (CONT'D)

The A/C system holds 2.0 lb. (0,91 kg) of refrigerant.

Charging Procedure (Cont'd)

Turn OFF the valve on the refrigerant container, and hand valves on the manifold gauge set.

Figure 80-100-16

Turn OFF the engine, and remove the A/C charging equipment from the loader. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.) 2 1

P-24324

Open the valve on the refrigerant container (Item 1) and open the low pressure hand valve (Blue) (Item 2) [Figure 80-100-16] on the manifold gauge set. Allow the vacuum to pull in the refrigerant until the pressure stabilizes. Figure 80-100-17

2

1

N-22284

Connect the remote start tool to the loader. (See Procedure on Page 10-60-1.) Press the A/C (Item 1) [Figure 80-100-17] switch to ON position. Turn fan switch (Item 2) [Figure 80-100-17] to HIGH position. Start loader engine, with the remote start switch, and run at medium speed. Watch the scale and run system until the predetermined amount of refrigerant is added to the A/C system. 80-100-6


COMPRESSOR

WARNING



Remove the compressor hoses (Item 3) [Figure 80-1102] from the compressor.

1 2

Installation: Tighten the compressor hoses to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the compressor hoses and the fittings with with the proper A/C caps and plugs. P-24325

Figure 80-110-3 Remove drive belt guard. Remove A/C belt guard (Item 1), by removing the mounting bolt and nut (Item 2) [Figure 80-110-1]. Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.)

1

Figure 80-110-2

P-24327

Remove the compressor mount bolt (Item 1) [Figure 80110-3]. 1

3

Remove the compressor from the loader.

2 P-24326

Remove the compressor adjustment bolt (Item 1) [Figure 80-110-2]. Installation: Tighten the compressor adjustment bolt to 34 ft.-lb. (46 N•m) torque. Remove the compressor belt (Item 2) [Figure 80-110-2]. Mark the compressor hoses for proper installation.

80-110-1


Figure 80-110-6

COMPRESSOR (CONT'D) Compressor Clutch Disassembly Figure 80-110-4

1.32”

1.32” 1.32” 1

1

2 N-22275

The armature plate puller, (Item 1) can be constructed by drilling three 10 mm holes in a flat circular plate, located 1.32 inches apart [Figure 80-110-6].

N-22244

Remove the center armature bolt (Item 1) [Figure 80110-4].

Attach the puller to the armature plate using three 8 mm bolts (Item 2) [Figure 80-110-6].

Installation: Tighten the armature bolt to 8-10 ft.-lb. (1214 N•m) torque.

Figure 80-110-7

Figure 80-110-5

1

2

N-22278

N-22277

To remove the armature plate (Item 1) [Figure 80-110-5] from the clutch face, you must make an armature plate puller.

Turn the bolts into the three 8 mm holes (Item 2) [Figure 80-110-5] on the armature plate as shown in [Figure 80110-7].

80-110-2


Figure 80-110-10

COMPRESSOR (CONT'D) Compressor Clutch Disassembly (Cont'd) Figure 80-110-8

1

1

N-22283

Remove the snap ring (Item 1) [Figure 80-110-10] from the pulley assembly.

N-22279

Attach a slide hammer puller (Item 1) [Figure 80-110-8] to the armature puller disk.

Figure 80-110-11

Remove the armature plate from the compressor clutch. Figure 80-110-9

1 N-22369

Install the pulley puller tool MEL 1595 on the compressor pulley [Figure 80-110-11]. N-22280

Remove the shims (Item 1) [Figure 80-110-9] from either the armature shaft or armature plate. Installation: Insure that the clutch has the correct clearance by adding the shims (Item 1) [Figure 80-1109]. The specified clearance for the clutch is 0.01-0.02 in. (0.3-0.6 mm). Adjusting shims are available in the following thicknesses: 0.0039 in. (0.1 mm) 0.0118 in. (0.3 mm) 0.0197 in. (0.5 mm)

80-110-3


Figure 80-110-14


1

N-22373

Slide the wire grommet (Item 1) [Figure 80-110-14] from the wire holder.

N-22370

Remove the pulley from the compressor [Figure 80-11012].

Figure 80-110-15

Figure 80-110-13

1

N-22374

Remove the coil lead wire (Item 1) [Figure 80-110-15] from the wire holder on the compressor.

N-22371

The pulley assembly and bearing [Figure 80-110-13] must be replaced as a complete unit.

80-110-4



1

1

N-22372

Remove the three coil mount bolts (Item 1) [Figure 80110-16] from the compressor. Installation: Tighten the mount bolts to 2.9-4.3 ft.-lb. (4-6 N•m) torque. Remove the coil from the compressor. Figure 80-110-17

N-22375

The compressor [Figure 80-110-17] must be replaced as a complete unit.

80-110-5


80-110-6


Figure 80-120-2

CONDENSER Removal And Installation Figure 80-120-1

LIFT HERE

1

P-48011

P-48011

Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.)

Lift the rear of the condenser [Figure 80-120-2], and pull toward the rear of the loader until the front tabs (Item 1) [Figure 80-120-4] slide out of bracket (Item 2) [Figure 80-120-4] Figure 80-120-3

Open the rear door of the loader. Open the rear grill on the loader. Mark the two A/C hoses (Item 1) [Figure 80-120-1] for proper installation.


P-48010

Remove the condenser from the loader [Figure 80-1203].

Disconnect the two hoses from the condenser (Item 1) [Figure 80-120-1]. Cap and plug the hoses and the condenser fittings with the proper A/C caps and plugs.

80-120-1


CONDENSER (CONT’D) Removal And Installation (Cont’d) Figure 80-120-4

2

1

P-24303

Installation: Make sure to insert tabs (Item 1), into the mounts (Item 2) [Figure 80-120-4], evenly for ease of installation.

80-120-2


Figure 80-130-2

RECEIVER/DRIER Removal And Installation

1

WARNING

2


3

W-2059-0598 P-24298

Figure 80-130-1

Note the flow direction on the drier (Item 1) [Figure 80130-2] for proper installation.

WARNING

1

In the event of a leakage, 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 P-24299

Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.))

Remove the two A/C hoses (Item 2) [Figure 80-130-2] from the receiver/drier. Cap and plug the hoses and the receiver/drier fittings with the proper A/C caps and plugs.


Loosen the hose clamps (Item 3) [Figure 80-130-2] that holds the receiver/drier to the mount.

Remove the refrigerant from the A/C system.(See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.)

Remove the receiver/drier from the loader.

Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper installation.

NOTE: When replacing a receiver/drier in an A/C system 1 fl. oz. (30 cc) of PAG oil must be added to the system when recharging.

Both fittings on the drier are the same size, so the hoses can be hooked up incorrectly.

80-130-1


RECEIVER/DRIER (CONT’D) Removal And Installation (Cont’d) Figure 80-130-3

1

P-24295

Remove the two mount bolts (Item 1) [Figure 80-130-3] from the receiver/drier mount bracket.

80-130-2


Figure 80-140-2

PRESSURE RELIEF VALVE Removal And Installation Figure 80-140-1

1

N-22206

The pressure relief valve [Figure 80-140-2] is designed to open and release the A/C charge if the pressure reaches 535 PSI (3689 kPa).

N-22205

The pressure relief valve (Item 1) [Figure 80-140-1] is located on the receiver drier assembly.

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). NOTE: If a Pressure Relief Valve is found open, check the A/C system for problems. Replace the complete receiver/drier unit.

80-140-1


80-140-2


PRESSURE SWITCH

WARNING



Remove the pressure switch (Item 1) [Figure 80-150-2] from the A/C high pressure hose. Remove the pressure switch from the loader.

1

Schraeder Valve Removal And Installation Figure 80-150-3 P-24299

Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) 1

Disconnect the loader wire harness (Item 1) [Figure 80150-1] from the pressure switch wire harness. NOTE: The pressure switch can be changed without evacuating the A/C system.

N-22166

Figure 80-150-2 The schraeder valve (Item 1) [Figure 80-150-3] is located in the A/C high pressure hose and is located under the pressure switch. Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

1

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) P-24298

Remove the pressure switch. With a tire valve core removal tool, remove the valve core from the hose. Replace with a new core.

80-150-1


80-150-2


Figure 80-160-3

EVAPORATOR/HEATER UNIT Removal And Installation Figure 80-160-1

1 1

N-22129

Disconnect the blower fan wiring connector (Item 1) [Figure 80-160-3] from the loader wiring harness.

N-22122


Figure 80-160-4

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Evacuate the A/C system.(See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) 1 At the rear of the cab, disconnect the thermostat wiring connector (Item 1) [Figure 80-160-1]. Figure 80-160-2 N-22119

Remove the two mounting nuts (Item 1) [Figure 80-1604].

2

1 N-22130

Remove the mount bolt (Item 1) [Figure 80-160-2] from the left side cab access cover. Remove the access cover (Item 2) [Figure 80-160-2] from the loader.

80-160-1


EVAPORATOR/HEATER UNIT (CONT'D)

Figure 80-160-7

Removal And Installation (Cont'd) Figure 80-160-5

1 1 N-22128

Remove the two A/C hoses (Item 1) [Figure 80-160-6] from the expansion valve.

N-22120

Remove the two mounting nuts (Item 1) [Figure 80-1605].

Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the hoses and the expansion valve fittings with the proper A/C caps and plugs.

Figure 80-160-6

Remove the heater hoses (Item 1) [Figure 80-160-7] from the heater coil. Installation: Tighten the Heater hoses to 22 ft.-lb. (29,8 N•m) torque. 1

Remove the evaporator/heater unit from the loader.

N-22126

Remove the Evaporator/Heater Unit from the rear of the cab. Place it on the fenders of the loader supported by 2X4's (blocking) [Figure 80-160-6].


80-160-2


EVAPORATOR/HEATER UNIT (CONT'D) Disassembly And Assembly Figure 80-160-8

1

1

1

N-22065

Remove the six mount bolts (Item 1) [Figure 80-160-8] from the Evaporator/Heater Unit rear cover. Remove the rear cover from the unit.

80-160-3


80-160-4


Figure 80-170-3

THERMOSTAT Removal And Installation Figure 80-170-1

2

1 N-22072

Remove the thermostat from the unit [Figure 80-170-3]. N-22069

Figure 80-170-4 A

NOTE: The thermostat can be changed without evacuating the A/C system, or removing the evaporator/heater unit from the loader.

B

Remove the rear cover from the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT on Page 80-1601.))

C 1

Remove the two thermostat mount bolts (Item 1), and remove the wiring harness and grommet (Item 2) [Figure 80-170-1] from the evaporator/heater housing. Figure 80-170-2

N-22072

The wire connector (Item 1) [Figure 80-170-4] can be changed. The wiring position and color in the connector is: A B C

1

Blue White Black

N-22071

Remove the thermostat probe (Item 1) [Figure 80-170-2] from the A/C evaporator coil.

80-170-1


80-170-2


Figure 80-180-2

EXPANSION VALVE Removal And Installation Figure 80-180-1

1 2 1

N-22073

Remove the two evaporator fittings (Item 1) [Figure 80180-2] from the expansion valve.

N-22150

NOTE: The expansion valve can be changed without removing the evaporator/heater unit from the loader. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)

Installation: Tighten the two evaporator fittings to 22 ft.lb. (29,8 N•m) torque. Remove the two mount bolts (Item 2) [Figure 80-180-2]. Remove the expansion valve from the loader. Figure 80-180-3

Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) 1

WARNING In the event of a leakage, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas.

N-22074

W-2371-0500

Remove the two A/C hoses (Item 1) [Figure 80-180-1] from the expansion valve.

Cap and plug the evaporator tubelines (Item 1) [Figure 80-180-3] and the expansion valve fittings with the proper A/C caps and plugs.

Installation: Tighten the two A/C hose fittings to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the hoses and the expansion valve fittings with the proper A/C caps and plugs.

80-180-1


EXPANSION VALVE (CONT'D) Removal And Installation (Cont'd) Figure 80-180-4

1 1

N-22074

Remove the two mount bolts (Item 1) [Figure 80-180-4] from the expansion valve mount. Remove the expansion valve mount from the unit. Figure 80-180-5

N-22085

The expansion valve [Figure 80-180-5] is replaced as a complete unit.

80-180-2


Remove the expansion valve mount bracket (Item 1) [Figure 80-190-2] from the unit.

EVAPORATOR Removal And Installation

Figure 80-190-3

Figure 80-190-1

2

1

1

N-22075 N-22073

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.)

Remove the two mount bolts (Item 1) from the mount plate (Item 2) [Figure 80-190-3]. Remove the mount plate from the unit. Figure 80-190-4

Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) Remove the evaporator/heater unit from the back of the cab. (See EVAPORATOR/HEATER UNIT on Page 80160-1.) Remove the expansion valve (Item 1) [Figure 80-190-1] from the unit. (See EXPANSION VALVE on Page 80180-1.) 1

Figure 80-190-2

N-22076

Remove the two retaining clips (Item 1) [Figure 80-1904] that connect the evaporator coil, to the heater coil. Remove the evaporator coil from the unit.

1

N-22074

80-190-1


EVAPORATOR (CONT'D) Removal And Installation (Cont'd) Figure 80-190-5

N-22078

Inspect the evaporator coil [Figure 80-190-5] for leaks, and replace as needed. Clean with low water or air pressure.

80-190-2


HEATER COIL

Remove the rear cover from the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT on Page 80-160-1.)

Removal And Installation With A/C

Remove the two mount bolts (Item 1) [Figure 80-200-2] from the heater coil at the expansion valve end of the unit.

Figure 80-200-1

Figure 80-200-3

1

1 N-22128

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the evaporator/heater unit from the back of the cab.(See EVAPORATOR/HEATER UNIT on Page 80160-1.)

N-22087

Remove the two retaining clips (Item 1) [Figure 80-2003] that connect the evaporator coil, to the heater coil. Figure 80-200-4

Mark the heater hoses (Item 1) [Figure 80-200-1] for proper installation.

1

1

Remove the two heater hoses from the heater coil. Cap the hoses and the heater coil with hydraulic caps and plugs to prevent oil loss from the system.

2

Installation: Tighten the two heater hose fittings to 22 ft.lb. (29,8 N•m) torque.

2

Figure 80-200-2 N-22089

1

Remove the three mount bolts (Item 1) [Figure 80-200-4] and remove the mount plate from the end of the unit. Remove the two mount bolts (Item 2) [Figure 80-200-4] that support the heater coil tubelines to the unit. Remove the heater coil from the unit.

1 N-22086

80-200-1


Mark the heater hoses (Item 1) [Figure 80-200-6] for proper installation.

HEATER COIL (CONT'D) Removal And Installation With A/C (Cont'd)

Remove the two heater hoses from the heater coil.

Figure 80-200-5

Cap the hoses and the heater coil with hydraulic caps and plugs to prevent oil loss from the system. Installation: Tighten the two heater hose fittings to 22 ft.lb. (29,8 N•m) torque. Figure 80-200-7

1

1 N-22090

2

The heater coil [Figure 80-200-5] can be cleaned with low air or water pressure.

2

If the heater coil needs replacement it must be replaced as complete unit. Removal And Installation Without A/C

N-22093

Remove the rear cover from the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT on Page 80-160-1.)

Figure 80-200-6

Remove the three mount bolts (Item 1) [Figure 80-200-7] and remove the mount plate from the end of the unit. Remove the two mount bolts (Item 2) [Figure 80-200-7] that support the heater coil tubelines to the unit. Figure 80-200-8

1

1 N-22128

Raise the lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the heater unit from the back of the cab. (See EVAPORATOR/HEATER UNIT on Page 80-160-1.)

N-22094

Remove the two mount bolts (Item 1) [Figure 80-200-8] from the heater coil. Remove the heater coil from the unit.

80-200-2


Figure 80-210-3

HEATER/AC FAN Removal And Installation Figure 80-210-1

1 1

N-22099

Remove the blower fan wiring harness and grommet (Item 1) [Figure 80-210-3] from the unit

N-22096


Figure 80-210-4

1

Raise the operator cab.(See Raising The Operator Cab on Page 10-30-1.) Remove the evaporator/heater unit from the back of the cab. (See EVAPORATOR/HEATER UNIT on Page 80160-1.) NOTE: The heater/AC fan assembly can be removed from the evaporator/heater unit without disconnecting the heater or A/C plumbing. The unit is removed here for photo clarity. Remove the grommet (Item 1) [Figure 80-210-1] from the side of the evaporator/heater unit.

N-22100

Remove the three mount bolts (Item 1) [Figure 80-210-4] from the blower fan housing.

Figure 80-210-2 Remove the blower fan housing from the evaporator/ heater unit.

1

N-22097

80-210-1


Figure 80-210-6

HEATER/AC FAN (CONT'D) Disassembly And Assembly Figure 80-210-5

2 1 2 1

1 N-22107

2

Check the blower housing (Item 1) and fan motor mount (Item 2) [Figure 80-210-6] for wear and replace as needed.

N-22102

Remove the eight mount bolts (Item 1) [Figure 80-210-5] from the blower wheel cover.

Figure 80-210-7

Remove the blower wheel cover from the fan housings.

1

Remove the four mount bolts (Item 2) [Figure 80-210-5] from the fan motor mount.

1

Remove the fan motor mount. Remove the fan motor assembly from the housing.

2 N-22108

Remove the outside rings (Item 1) and fan wheel covers (Item 2) [Figure 80-210-7] from the fan motor and blower wheels.

80-210-2


Figure 80-210-10

HEATER/AC FAN (CONT'D) Disassembly And Assembly (Cont'd) Figure 80-210-8

1 N-22112

Remove the outside blower wheel clamp (Item 1) [Figure 80-210-9] & [Figure 80-210-10] from the blower wheel.

N-22109

Inspect the end rings and fan wheel covers for wear and replace as needed [Figure 80-210-8].

Figure 80-210-11

Figure 80-210-9

1

1

N-22111

N-22110

Remove the inside blower wheel clamp (Item 1) [Figure 80-210-11] from the blower wheel.

80-210-3


HEATER/AC FAN (CONT'D)

Wire Connector Removal and Installation

Disassembly And Assembly (Cont'd)

Figure 80-210-13

Figure 80-210-12

1 2

1

N-22103 N-22116

Figure 80-210-14

Note: Before removing blower wheels, mark their orientation to ensure they are assembled back on the correct side and the fins are facing the same direction. Remove the blower wheel (Item 1) and inside ring (Item 2) [Figure 80-210-12] from the blower fan motor shaft.

1

Repeat the procedure for the other blower wheel.

N-22104

Remove the plastic wedge (Item 1) [Figure 80-210-13] & [Figure 80-210-14] from the center of the blower fan motor wiring connector.

80-210-4


HEATER/AC FAN (CONT'D) Wire Connector Removal and Installation (Cont'd) Figure 80-210-15

1

1

1

1

N-22105

With a pointed screw driver lightly press in on the tabs (Item 1) [Figure 80-210-15] and remove the individual wires from the connector. Figure 80-210-16

N-22106

The wiring code for the blower fan connectors [Figure 80-210-16]i: Number on Connector 1 2 3 4 5 6

Wire Color Orange Red Yellow Black Open Open

80-210-5


80-210-6


HEATER VALVE



Figure 80-220-2

Figure 80-220-1

1 2 3 1 3 N-22155 P-48009

Disconnect the loader wiring harness (Item 1) [Figure 80-220-1].

Remove the three mount bolts (Item 1) [Figure 80-220-2] from the heater valve actuator. Figure 80-220-3

Remove the two coolant hoses (Item 2) [Figure 80-2201] from the heater valve. NOTE: Cap the hoses and the heater valve to prevent contamination and coolant loss from the system. Remove the two heater valve mounting bolts (Item 3) [Figure 80-220-1].

2

1

Remove the heater valve from the loader.

N-22156

Remove the actuator (Item 1) and the three mounting spacers (Item 2) [Figure 80-220-3] from the heater valve mount plate.

80-220-1


Figure 80-220-6

HEATER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 80-220-4

1 1

N-22159

Remove the two mounting bolts (Item 1) [Figure 80-2206] from the heater valve.

N-22157

Remove the three mounting bolts (Item 1) [Figure 80220-4] from the heater valve mount plate.

Figure 80-220-7

Figure 80-220-5

1 1

N-22160

Remove the heater valve mount bracket (Item 1) [Figure 80-220-7] from the heater valve.

N-22158

Remove the mount plate (Item 1) [Figure 80-220-5] from the heater valve bracket.

Replace the parts as needed.

80-220-2


SPECIFICATIONS CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) . . . . SPEC-21-1 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI . . . . . . . . . . . . . . . SPEC-20-1 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2

SPEC-01


DRIVE SYSTEM


SPECIFICATIONS


SPECIFICATIONS (CONT’D) HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC-40-1 SPEC-40-2 SPEC-40-1 SPEC-40-3 SPEC-40-5 SPEC-40-2 SPEC-40-2

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS SPEC-50-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC-10-1 SPEC-10-4 SPEC-10-2 SPEC-10-4 SPEC-10-3 SPEC-10-2 SPEC-10-3 SPEC-10-1 SPEC-10-2 SPEC-10-4

TORQUE SPECIFICATIONS FOR BOLTS. . . . . . . . . . . . SPEC-30-1 Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-2 Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . SPEC-30-1

SPEC-02


LOADER SPECIFICATIONS Machine Dimensions • •

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses. Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

B-17328

TIRE DESCRIPTION 10-16.5 TIRES 31-15x15 TIRES

WIDTH (OVER TIRES) 66.0in. (1676mm) or 60.0in (1524mm) 72.0in. (1829mm)

WHEEL TREAD 54.5in. (1385mm) or 48.5in. (1232mm) 55.9in. (1420mm)

BUCKET WIDTH 62” 68” 74”

WIDTH (OVER BUCKET) 62.0in. (1575mm) 68.0in. (1727mm) 74.0in. (1880mm)

* 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. 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


LOADER SPECIFICATIONS (CONT’D) Performance Rated Operating Capacity (ISO)

S175

S185

1750 lb. (794kg)

1850 lb. (839kg)

Tipping Load (SAE Rating)

3900 lb. (1769 kg)

Operating Weight

5808 lb. ( 2635 kg)

SAE Breakout Force-Lift -Tilt

3400 lb. (15123 N)

3600 lb. (16013 N)

3240 lb. (14412 N)

3550 lb. (15791 N)

Axle Torque

4900 ft.- lb. (6644 N•m)

Travel Speed

0-7.3 MPH (11,7 km/hr.)

Controls Vehicle Steering Loader Hydraulics Lift and Tilt

Direction and Speed controlled by two hand levers. Controlled by separate foot pedals or optional hand controls.

Front Auxiliary

Controlled by electrical switch on RH steering lever.

Rear Auxiliary (Option)

Controlled by electrical switch on LH steering lever.

Engine Starting Aid Service Brake Secondary Brake Parking Brake

Hand lever throttle: Key-type starter switch and shutdown. Keyless start and shutdown with deluxe instrumentation. Glow Plugs Automatically activated by standard or deluxe instrumentation. Two independent hydrostatic systems controlled by two hand opertated steering levers. One of the hydrostatic transmissions. Mechanical Disc, switch in control panel.

Engine Make/Model

Kubota V2203-M-DI

Kubota V2003-M-DI-T

Fuel/Cooling

Diesel/Liquid

Diesel/Liquid

Horsepower (SAE Net)

46 HP (34kW)

56 HP (42kW)

2800 RPM

2800 RPM

103.5 ft.-lb. (140 N•m) @ 1700 RPM

120.8 ft.-lb. (164 N•m) @ 1825 RPM

Four

Four

134 cu.in. (2,2L)

122 cu.in. (2,0L)

Bore/Stroke

3.425/3.638 (87.0/92.4)

3.268/3.638 (83.0/92.4)

Lubrication

Pressure System W/Filter

Pressure System W/Filter

Closed Breathing

Open Breathing

Air Induction

Naturally aspirated

Turbocharged

Air Cleaner

Dry replaceable cartridge w/safety element

Dry replaceable cartridge w/safety element

Diesel-Compression

Diesel-Compression

Maximum Governed RPM

2800 RPM

2800 RPM

High Idle RPM

2860-3000

2860-3000

Low Idle RPM

1075-1225

1195-1245

SPEC-10-2


Maximum Governed RPM Torque (SAE Net) Number of Cylinders Displacement

Crankcase Ventilation

Ignition

LOADER SPECIFICATIONS (CONT’D) Hydraulic System S175

S185

Pump

Engine Driven, Gear Type

Pump Capacity Charge Pump Capcity (SJC) High Flow (Option)

16.9 GPM (64 L/min.) at High Idle 12.8 GPM (48,5 L/min.) at High Idle 26.4 GPM (99,9 L/min.) at High Idle

System Relief at Quick Couplers Filter

3300 PSI (206 Bar) Full flow replaceable, 3 micron synthetic media element

Hydraulic Cylinders

Doubleacting; Tilt cylinders have cushioning feature on dump

Bore Diameter: Lift Cylinder (2)

2.50 (63,5)

Tilt Cylinder (2)

2.75 (69,9)

Rod Diameter: Lift Cylinder (2)

1.50 (38,1)

Tilt Cylinder (2)

1.375 (34,9)

Stroke: Lift Cylinder (2)

23.67 (601,2)

Tilt Cylinder (2)

13.19 (335,0)

Control Valve

3-spool, open center type w/float detent on lift and electrically controlled auxiliary spool.

Fluid Lines

SAE standard tubelines, hoses & fittings

Fluid Type

BOBCAT FLUID, Hydraulic/Hydrostatic 6903117 - (Two - 2.5 gal. containers) 6903118 - (5 gal.) 6903119 - (55 gal.)

Hydraulic Function Time: Raise Lift Arms

3.49 Seconds

Lower Lift Arms

2.54 Seconds

Bucket Dump

2.28 Seconds

Bucket Rollback Electrical

1.78 Seconds

Alternator

Belt driven, 90 amp., open

Battery

12 volt, 600 cold cranking amps. @ 0°F. (-18°C); 115 minute reserve capacity at 25 amps.

Starter

12 volt, Gear reduction type, 3.62 HP (2,7Kw)

Instrumentation

Gauges: Hourmeter, Fuel, Engine Coolant Temperature. Warning lights: Fuel Level, Glow Plugs, System Voltage, Seat Belt, Engine Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure, Hydraulic Oil Temperature, Engine Air Filter & Hydraulic Filter. Other: Audible Alarm, BICS Function, Lights, Opt./Accessory Switches. Optional Deluxe Instrumentation: *Same gauges and warning lights as standard instrumentation. *Additional bar-type gauges for: Engine Oil Pressure, System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature. *Additional Features Incl.: Keyless Start, Clock, Job Clock, Help Screens, Diagnostic Capability, Automatic Shutdown Function.

SPEC-10-3


LOADER SPECIFICATIONS (CONT’D) Drive System S175 Main Drive Transmission Final Drive

S185 Hydrostatic 4 wheel drive

Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors. #80 HSOC endless roller chain & sprockets in sealed chaincase with oil lubrication.

Total Engine to Wheel Reduction

33:1

Axle Size

2.00 (50,8)

Wheel Bolts Capacities

(8) 9/16”

Cooling System W/Heater (Includes Recovery Bottle)

12 qts. (11,4 L)

Cooling System W/O Heater (Includes Recovery Bottle)

11 qts. (10,4 L)

Fuel

23.0 gals. (87,1 L)

Engine Oil W/Filter

9.5 qts. (9,0 L)

Hydraulic/Hydro. System W/Reservoir

8.5 gals. (32,2 L)

Chaincase Reservoir Tires

9 gals. (34,1 L)

Flotation

10-16.5, 8 Ply Rating

Ultra Grip

31 x 15.5-15, 8 Ply Rating

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


ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Fuel Injection Nozzles Opening Pressure Fuel Tightness Nozzle Seat

2702-2916 PSI (18600-20100 kPa) Dry Nozzle at 2418 PSI (16672 kPa) for 10 seconds

Fuel Injection Pump Injection Timing High Idle Low Idle

6.2-8.2 degrees B.T.D.C. 2860-3000 RPM 1195-1245 RPM

Cylinder Head Cylinder Head Surface Distortion Thickness of Gasket (Used) (New) Top Clearance (Piston to Head) Compression Allowable Limit Difference Between Cylinders

0.002 (0,05) Max. 0.0453-0.0492 (1,15-1,25) 0.0512-0.0551 (1,3-1,4) 0.0236-0.0276 (0,60-0,70) 427-469 PSI (2940-3240 kPa) 341 PSI (2350 kPa) 10%

Valves Valve Seat Width (Intake & Exhaust) Valve Seat Angle O.D. of Valve Stems I.D. of Valve Guides Clearance Between Valve Stem & Guide Allowable Limit Valve Clearance (Cold) Valve Recessing (Protrusion) (Recess)

0.084 (2,12) Intake 60 degrees, Exhaust 45 degrees 0.3134-0.3140 (7,96-7,98) 0.3156-0.3161 (8,015-8,03) 0.0016-0.0028 (0,04-0,07) 0.004 (0,1) 0.0071-0.0087 (0,18-0,22) 0.002 (0,05) 0.006 (0,15)

SPEC-20-1


ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Valve Springs Free Length Allowable Limit Fitted Length Compress to Fitted Length Allowable Limit

1.642-1.661 (41,7-42,2) 1.622 (41,2) 1.378 (35,0) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N)

Valve Timing Intake Valve (Open) (Close) Exhaust Valve (Open) (Close)

9 degrees B.T.D.C. 45 degrees A.T.D.C. 50 degrees B.T.D.C. 12 degrees A.T.D.C.

Rocker Arms O.D. of Rocker Arm Shaft I.D. of Rocker Arm Bushings Clearance Between Rocker Arm & Bushing Allowable Limit

0.5501-0.5506 (13,973-13,984) 0.5512-0.5519 (14,0-14,018) 0.0006-0.0018 (0,016-0,045) 0.0039 (0,10)

Camshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit Alignment Allowable Limit Cam Lobe Height Allowable Limit End Clearance Allowable Limit

1.5722-1.5728 (39,934-39,95) 1.5748-1.5758 (40,0-40,025) 0.002-0.0036 (0,05-0,091) 0.006 (0,15) 0.0004 (0,01) 1.3346 (33,90) 1.3327 (33,85) 0.0028-0.0087 (0,07-0,22) 0.012 (0,3)

Tappet Clearance Between Tappet & Guide Tappet O.D. Tappet Guide I.D.

0.0071-0.0087 (0,18-0,22) 0.9433-0.9441 (23,959-23,98) 0.9449-0.9457 (24,0-24,021)

SPEC-20-2


ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Cylinders Cylinder Bore I.D. Allowable Limit

3.4252-3.4261 (87,00-87,022) +0.0059 (+0,15)

Piston Rings Ring Gap (Top Ring) Limit Permitted Ring Gap (2nd Ring) Limit Permitted Ring Gap (Oil Ring) Limit Permitted Side Clearance of Ring Groove: Top Ring Second Ring Oil Ring

0.0079-0.0138 (0,20-0,35) 0.0492 (1,25) 0.0138-0.0197 (0,35-0,50) 0.0492 (1,25) 0.079-0.0157 (0,20-0,40) 0.0492 (1,25) 0.0037-0.0047 (0,093-0,12) 0.0037-0.0047 (0,094-0,12) 0.0008-0.002 (0,02-0,052)

Pistons Piston Pin Bore Limit Permitted

0.9843-0.9848 (25,0-25.013) 0.9862 (25,05)

Connecting Rod Piston Pin O.D. Small End Bushing I.D. Clearance Between Piston Pin & Small End Bushing Allowable Limit Connecting Rod Alignment Allowable Limit

0.9843-0.9847 (25,002-25,011) 0.9852-0.9858 (25,025-25,04) 0.0006-0.0015 (0,014-0,038) 0.0059 (0,15 mm) 0.002 (0,05)

Oil Pump Oil Pressure Rated RPM Limit Permitted Idle Speed Limit Permitted Clearance Between Inner Rotor & Outer Rotor Outer Rotor & Pump Body End Clearance Between Inner Rotor & Cover Limit Permitted

43-64 PSI (294-441 kPa) 36 PSI (248 kPa) 14 PSI (98 kPa) 7 PSI (49 kPa) 0.0012-0.0055 (0,03-0,14) 0.0043-0.0075 (0,11-0,19) 0.0041-0.0059 (0,105-0,15) 0.0079 (0,20)

SPEC-20-3


ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Crankshaft Crankshaft Alignment Limit Permitted Oil Clearance Between Journal & Bearing #1 Limit Permitted Journal O.D. #1 Bearing I.D. #1 Oil Clearance Between Journal & Bearing #2 Limit Permitted Journal O.D. #2 Bearing I.D. #2 Oil Clearance Between Crank Pin & Bearing Limit Permitted Crank Pin O.D. Crank Pin Bearing I.D. Crankshaft Side Clearance Limit Permitted

0.00079 (0,02) 0.0016-0.0046 (0,04-0,118) 0.0079 (0,2) 2.3591-2.3598 (59,921-59,940) 2.3614-2.3637 (59,98-60,039) 0.0016-0.0041 (0,04-0,104) 0.0079 (0,2) 2.3591-2.3598 (59,921-59,940) 2.3614-2.3632 (59,98-60,025) 0.0010-0.0034 (0,025-0,087) 0.0079 (0,2) 1.8488-1.8494 (46,96-46,97) 1.8504-1.8522 (47,0-47,046) 0.0059-0.0138 (0,15-0,35) 0.0197 (0,5)

Timing Gear Timing Gear Backlash: Crank Gear-Idle Gear Idle Gear-Cam Gear Idle Gear-Injection Pump Gear Crank Gear-Oil Pump Gear Limit Permitted Clearance Between Idle Gear Shaft & Idle Gear Bushing Limit Permitted Idle Gear Side Clearance Idle Gear

0.0016-0.0044 (0,042-0,112) 0.0016-0.0045 (0,042-0,115) 0.0016-0.0045 (0,042-0,115) 0.0016-0.0043 (0,042-0,109) 0.006 (0,15) 0.001-0.0026 (0,025-0,066) 0.004 (0,10) 0.005-0.019 (0,12-0,48)

Thermostat Valve Opening Temperature Valve Fully Open

176.9-182.3°F (80.5-83.5°C) 203°F (95°C)

SPEC-20-4


ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Fuel Injection Nozzles Opening Pressure Fuel Tightness Nozzle Seat

2702-2916 PSI (18.6-20.1 MPa) Dry Nozzle at 2418 PSI (16.67 MPA)

Fuel Injection Pump Injection Timing High Idle Low Idle Cylinder Bore I.D. of Bore Allowable Limit

8.5-10 degrees B.T.D.C. 2860-3000 RPM 1075-1225 RPM 3.2677-3.2686 (83,0-83,022) +0.0059 (+0,15)

Cylinder Head Cylinder Head Surface Distortion Top Clearance (Piston to Head) Compression Allowable Limit Difference Between Cylinders

0.002 (0,05) Max. 0.0236-0.0276 (0,60-0,70) 427-469 PSI (2944,1 - 3233,6 kPa) 341 PSI (2351,1 kPa) 10% or less

Valves Valve Seat Width (Intake & Exhaust) Valve Seat Angle O.D. of Valve Stems I.D. of Valve Guides Clearance Between Valve Stem & Guide Allowable Limit Valve Clearance (Cold) Valve Recessing (Protrusion) (Recess)

0.0835 (2,12) Intake 60 degrees, exhaust 45 degrees 0.3134-0.3140 (7,96-7,98) 0.3156-0.3161 (8,015-8,03) 0.0016-0.0028 (0,04-0,07) 0.0039 (0,1) 0.0071-0.0087 (0,18-0,22) 0.002 (0,05) 0.0059 (0,15)

SPEC-21-1


ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Valve Springs Free Length Allowable Limit Fitted Length Compress to Fitted Length Allowable Limit Tilt Allowable Limit

1.6417-1.6614 (41,7-42,2) 1.622 (41,2) 1.378 (35,0) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N) 0.039 (1,0)

Valve Timing Intake Valve (Open) (Close) Exhaust Valve (Open) (Close)

9 degrees B.T.D.C. 45 degrees A.B.D.C. 50 degrees B.B.D.C. 12 degrees A.T.D.C.

Rocker Arms O.D. of Rocker Arm Shaft I.D. of Rocker Arm Bushings Clearnace Between Rocker Arm & Bushing Allowable Limit

0.5501-0.5506 (13,973-13,984) 0.5512-0.5519 (14,0-14,018) 0.0006-0.0018 (0,016-0,045) 0.0039 (0,1)

Camshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit Alignment Allowable Limit Cam Lobe Height (Intake) Allowable Limit (Intake) Cam Lobe Height (Exhaust) Allowable Limit (Exhaust) Side Clearance Allowable Limit

1.5722-1.5728 (39.934-39,95) 1.5748-1.5758 (40,0-40,025) 0.002-0.0036 (0,05-0,091) 0.0059 (0,15) 0.0004 (0,01) 1.3346 (33,90) 1.3327 (33,85) 1.3346 (33,90) 1.3327 (33,85) 0.0028-0.0087 (0,07-0,22) 0.0118 (0,3)

Tappet Clearance Between Tappet & Guide Allowable Limit Tappet O.D. Tappet Guide I.D.

0.0008-0.0024 (0,02-0,062) 0.0028 (0,07) 0.9433-0.9441 (23,959-23,98) 0.9449-0.9457 (24,0-24,021)

SPEC-21-2


ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Cylinder Liner Cylinder Bore I.D. Allowable Limit Oversized Cylinder Liner (Bore) I.D. Allowable Limit

3.2677-3.2686 (83,0-83,022) +0.0059 (+0,15) 3.2776-3.2784 (83,25-83,27) +0.0059 (+0,15)

Piston Rings Ring Gap (Top Ring) Allowable Limit Ring Gap (2nd Ring) Allowable Limit Ring Gap (Oil Ring) Allowable Limit Side Clearance of Ring Groove: Second Ring Allowable Limit Oil Ring Allowable Limit

0.0079-0.0138 (0,2-0,35) 0.0492 (1,25) 0.0157-0.0217 (0,4-0,55) 0.0492 (1,25) 0.0098-0.0177 (0,25-0,45) 0.0492 (1,25) 0.0037-0.0050 (0,093-0,128) 0.20 (0,0079) 0.0008-0.0021 (0,02-0,060) 0.0059 (0,15)

Pistons Piston Pin Bore Allowable Limit

0.9843-0.9848 (25,0-25,013) 0.9862 (25,05)

Connecting Rod Piston Pin O.D. Small End Bushing I.D. Clearance Between Piston Pin & Small End Bushing Allowable Limit Connecting Rod Alignment Allowable Limit

0.9843-0.9847 (25,002-25,011) 0.9852-0.9858 (25,025-25,04) 0.0006-0.0015 (0,014-0,038) 0.0059 (0,15) 0.002 (0,05)

Oil Pump Oil Pressure Rated RPM Allowable Limit Idle Speed Allowable Limit Clearance Between Inner Rotor & Outer Rotor Clearance Between Outer Rotor & Pump Body End Clearance Between Inner Rotor & Cover

43-64 PSI (294-441 kPa) 36 PSI (245 kPa) 7 PSI (49 kPa) 0.0012-0.0055 (0,03-0,14) 0.0043-0.0075 (0,11-0,19) 0.0041-0.0059 (0,105-0,15)

SPEC-21-3


ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Crankshaft Crankshaft Alignment Limit Permitted Oil Clearance Between Journal & Bearing #1 Limit Permitted Journal O.D. #1 Bearing I.D. #1 Oil Clearance Between Journal & Bearing #2 Limit Permitted Journal O.D. #2 Bearing I.D. #2 Oil Clearance Between Crank Pin & Bearing Limit Permitted Crank Pin O.D. Crank Pin Bearing I.D. Crankshaft Side Clearance Limit Permitted

0.00079 (0,02) 0.0016-0.0046 (0,04-0,118) 0.0079 (0,2) 2.3591-2.3598 (59,921-59,940) 2.3614-2.3637 (59,98-60,039) 0.0016-0.0041 (0,04-0,104) 0.0079 (0,2) 2.3591-2.3598 (59,921-59,940) 2.3614-2.3632 (59,98-60,025) 0.0010-0.0034 (0,025-0,087) 0.0079 (0,2) 1.8488-1.8494 (46,96-46,97) 1.8504-1.8522 (47,0-47,046) 0.0059-0.0138 (0,15-0,35) 0.0197 (0,5)

Timing Gear Timing Gear Backlash: Crank Gear-Idle Gear Allowable Limit Idle Gear-Cam Gear Allowable Limit Idle Gear-Injection Pump Gear Allowable Limit Crank Gear-Oil Pump Gear Allowable Limit Clearance Between Idle Gear Shaft & Idle Gear Bushing: Idle Gear Allowable Limit Idle Gear Bushing I.D. Allowable Limit Idle Gear Shaft O.D. Idle Gear Side Clearance Idle Gear Allowable Limit

0.0016-0.0044 (0,0415-0,1122) 0.0059 (0,15) 0.0016-0.0045 (0,0415-0,1154) 0.0059 (0,15) 0.0016-0.0045 (0,0415-0,1154) 0.0059 (0,15) 0.0016-0.0043 (0,0415-0,109) 0.0059 (0,15) 0.001-0.0026 (0,025-0,066) 0.0039 (0,10) 1.4961-1.4970 (38,0-38,025) 0.0039 (0,10) 1.4944-1.4951 (37,959-37,975) 0.0079-0.020 (0,2-0,51) 0.0315 (0,8)

Thermostat Valve Opening Temperature Valve Fully Open

176.9-182.3°F (80.5-83.5°C) 203°F (95°C)

SPEC-21-4


TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating are specified by the letter H following the part number.

INCH. LBS. (N•m) FOOT LBS. (N•m)

Thread size .250 .3125 .375 .4375 .500 .5625 .625 .750 .875 1.000 1.125 1.250 1.375 1.500 1.625 1.750 1.875 2.000

sae grade 5 80-90 (9,0-10,2) 180-200 (20,3-22,6) 25-28 (34-38) 40-45 (54-61) 65-70 (88-95) 90-100 (122-136) 125-140 (170-190) 220-245 (300-330) 330-360 (450-490) 475-525 (645-710) 650-720 (880-975) 900-1000 (1200-1360) 1200-1350 (1630-1830) 1500-1650 (2040-2240) 2000-2800 (2720-2980) 2500-2750 (3390-3730) 3150-3500 (4270-4750) 3800-4200 (5150-5700)

sae grade 8 110-120 (12,4-13,6) 215-240 (24,2-27-1) 35-40 (47-54) 60-65 (81-88) 90-100 (122-136) 125-140 (170-190) 175-190 (240-260) 300-330 (410-450) 475-525 (645-710) 725-800 (985-1085) 1050-1175 (1425-1600) 1475-1625 (2000-2200) 2000-2200 (2720-2980) 2600-2850 (3530-3870) 3450-3800 (4680-5150) 4300-4800 (5830-6500) 5500-6100 (7450-8300) 6500-7200 (8800-9800)

SPEC-30-1


TORQUE SPECIFICATIONS FOR BOLTS (CONT'D) Torque For General Metric Bolts THREAD SIZE (DIA. X PITCH)

MATERIAL HEAD MARK 4

M 5 x 0.8 M 6 x 1.0 M 8 x 1.25 M 10 x 1.25 M 12 x 1.25 M 14 x 1.25

6-9 ft.-lb. (8-12 N•m) 13-18 ft.-lb. (18-24 N•m) 22-30 ft.-lb. (30-41 N•m) 36-50 ft.-lb. (49-68 N•m)

HEAD MARK 7

3-4 ft.-lb. (4-5 N•m) 6-7 ft.-lb. (8-9 N•m) 11-16 ft.-lb. (15-22 N•m) 22-30 ft.-lb. (30-41 N•m) 40-54 ft.-lb. (54-73 N•m) 58-80 ft.-lb. (79-108 N•m)

SPEC-30-2

HEAD MARK 10

6-9 ft.-lb. (8-12 N•m) 18-25 ft.-lb. (24-34 N•m) 36-50 ft.-lb. (49-68 N•m) 69-87 ft.-lb. (94-118 N•m) 116-137 ft.-lb. (157-186 N•m)


Figure SPEC-40-2

HYDRAULIC CONNECTION SPECIFICATIONS

O-ring Face Seal Tightening Torque

O-ring Face Seal Connection

x Tubeline Outside Diameter

x x x Thread Size

* TORQUE Ft.-lb. (N•m)

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)

I-2003-0888

7/8”

1-3/16” - 12

98 (133)

1”

1-7/16” - 12

118 (160)

1-1/4”

1-11/16” - 12

154 (209)

1-1/2”

2” - 12

163 (221)

IMPORTANT

Figure SPEC-40-1

B-7575

When the fitting is tightened, you can feel when the fitting is tight to eliminate leakage caused by under or over torqued fittings. Use vaseline petroleum jelly to hold the O-ring in position until the fittings are assembled [Figure SPEC-40-1].

SPEC-40-1


Flare Fitting

HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)

Figure SPEC-40-4

Straight Thread O-ring Fitting Figure SPEC-40-3

1 Nut Washer

Nut Washer

2

O-ring O-ring

TS-1619

Use the following procedure to tighten the flare fitting:

A-1852

Lubricate the O-ring before installing the fitting. Loosen the jam nut and install the fitting. Tighten the jam nut until the washer is tight against the surface [Figure SPEC-403]. Tubelines And Hoses Replace any tubelines that are bent or flattened. They will restrict flow, which will slow hydraulic action and cause heat.

Tighten the nut until it makes contact with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [Figure SPEC-40-4] Use the chart [Figure SPEC-40-5 on Page 3] to find the correct tightness needed (Item 2) [Figure SPEC-40-4]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.

Replace hoses which show signs of wear, damage or weather cracked rubber. Always use two wrenches when loosening and tightening hose or tubeline fittings.

SPEC-40-2


Figure SPEC-40-7


Hex Flat Tightening Method

Flare Fitting (Cont’d) Figure SPEC-40-5

1

Flare Fitting Tightening Torque Tubeline Outside Diameter

x x Thread Size

TORQUE Ft.-lb. (N•m)

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”

1-5/16” - 12

118 (160)

1-1/4”

1-5/8” - 12

154 (209)

1-1/2”

1-7/8” - 12

163 (221)

2”

2-1/2” - 12

252 (342)

2

TS-1619

Tighten the nut until it contacts with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [Figure SPEC-40-7]. Use the chart [Figure SPEC-40-8 on Page 4] to find the correct tightness needed (Item 2) [Figure SPEC-40-7]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.

O-ring Flare Fitting Figure SPEC-40-6 Primary Seal

O-ring Flare

Secondary Seal P13009

The flare is the primary seal, the O-ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [Figure SPEC-40-6]. If necessary, the O-ring-flare fitting can be used without an O-ring. Use the following procedure to tighten the O-ring flare fitting.

SPEC-40-3



Figure SPEC-40-9

O-ring Flare Fitting (Cont’d) Copper Bonnet Orifice

Figure SPEC-40-8 O-ring Flare Fitting Tightening Torque x Tubeline Outside Diameter

x x x Thread Size

* TORQUE Ft.-lb. (N•m)

1/4”

7/1” - 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”

1-5/16” - 12

118 (160)

1-1/4”

1-5/8” - 12

154 (209)

1-1/2”

1-7/8” - 12

163 (221)

2”

2-1/2” - 12

252 (342)

1

P13572

NOTE: O-ring flare fittings are not recommended in all applications. Use the standard flare fittings in these applications. Do not use a O-ring flare fitting when a copper bonnet orifice is used. When tightened the connection at the bonnet may distort the flare face and prevent it from sealing.

* If a torque wrench is used to tighten a new fitting to a used hose/tubeline.

Use a standard flare fitting (Item 1) [Figure SPEC-40-9] as shown.

* If a toque wrench is used to tighten a used fittng to a new hose/tubeline.

When a O-ring flare fitting is used as a straight thread port adapter the O-ring flare face is not used to seal. The O-ring may come off the fitting and enter the system.

* If a torque wrench is used to tighten a new fitting to a new hose/tubeline.

Figure SPEC-40-10

** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline. 2

** If using the hex flate tighening method to tighten a new fitting to a used hose/tubeline. *** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.

1

P13573

NOTE: Always remove the O-ring (Item 1) [Figure SPEC-40-10] from the flare face as shown. An O-ring (Item 2) [Figure SPEC-40-10] is added to the flat boss of the fitting to seal the connection in this application.

SPEC-40-4


Figure SPEC-40-12

HYDRAULIC CONNECTION SPECIFICATIONS (CONT'D)

Port Seal and O-ring Boss Tightening Torque

Port Seal Fitting Figure SPEC-40-11

Nut Seals To Fitting

Nut Seals To Port

x x Thread Size

TORQUE Ft.-lb. (N•m)

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)

Use the following procedure to tighten the port seal fitting: Secondary O-ring Seal

P-13008

Port seal and nut, washer and O-ring (O-ring Boss) fittings use the same tightening torque valve chart.

The nut is the primary seal, the O-ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [Figure SPEC-40-11].

If a torque wrench cannot be used, use the following method.

The hex portion of the nut does not contact the surface of the component when the nut is tight.

Tighten the nut until it just makes metal to metal contact, you can feel the resistance. Tighten the nut with a wrench no more than one hex flat maximum. Do not over tighten the port seal fitting. NOTE: If a torque wrench cannot be used, use the hex flat tightening method as an approximate guideline. NOTE: Port seal fittings are not recommended in all applications. Use O-ring boss fittings in these applications.

SPEC-40-5


SPEC-40-6


HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS

WARNING

Specifications Use Bobcat hydraulic/hydrostatic transmission fluid (P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.), (P/N 6903119 - 55 Gal.). Hydraulic Fluid Chart

During cold weather (32°F [0°C] and below), do not operate machine until the engine has run for at least five minutes at less than half throttle. This warm-up period is necessary for foot pedal operation and safe stopping. Do not operate controls during warm-up period. When temperatures are below -20°F (-30°C), the hydrostatic oil must be heated or kept warm. The hydrostatic system will not get enough oil at low temperatures. Park the machine in an area where the temperature will be above 0°F (-18°C) if possible. W-2027-1285

DO NOT use automatic transmission fluids in the loader or permanent damage to the transmission will result.

WARNING 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-2072-0496

When temperatures below zero degree F (-18°C) are common, the loader must be kept in a warm building. Extra warm-up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by TRANS light ON) can cause transmission damage in less than 60 seconds.

SPEC-50-1


SPEC-50-2


CONVERSIONS Decimal And Millimeter Equivalents

U.S. To Metric Conversion

SPEC-60-1


SPEC-60-2


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SERVICE MANUAL REVISION NOTICE Revision No: Date: Product: Model: Manual No:

Insert This Sheet With The Below Listed Manual For Future Reference.

S175, S185-1 8 January, 2004 Bobcat Loader S175, S185 6902732 (11-03)

The following pages are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below: TAKE OUT

PUT IN

REVISION DESCRIPTION

10-170-1 thru 10-170-2

10-170-1 thru 10-170-2

Revised Text

50-100-1 thru 50-100-14

50-100-1 thru 50-100-14

Revised Text

50-101-1 thru 50-101-20

Added CONTROL PANEL (ADJUSTABLE PINTLES)

Printed in U.S.A.

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PARTS MANAGER SERVICE MANAGER X SALES MANAGER


S175, S185-2 20 April, 2004 Bobcat Loader S175, S185 6902732 (11-03)


PUT IN


10-70-1 thru 10-70-2

10-70-1 thru 10-70-2

Revised Text

10-110-1 thru 10-110-2

10-110-1 thru 10-110-2

Revised Text

10-130-1 thru 10-130-2

10-130-1 thru 10-130-2

Revised Text

10-150-1 thru 10-150-2

10-150-1 thru 10-150-2

Revised Text

10-170-1 thru 10-170-2

10-170-1 thru 10-170-2

Revised Text

20-01 thru 20-04

20-01 thru 20-04

Revised Text

HYD./HYDO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED NOVEMBER 2002) V-0444 title & legend

HYD./HYDO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2002) V-0444 title & legend

Revised Text

HYD./HYDO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED NOVEMBER 2002) V-0445 title & legend

HYD./HYDO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2002) V-0445 title & legend

Revised Text

TAKE OUT

PUT IN

REVISION DECRIPTION

20-21-1 thru 20-21-10

20-21-1 thru 20-21-10

Revised Text

20-40-1 thru 20-40-32

20-40-1 thru 20-40-32

Revised Text

20-41-1 thru 20-41-24

20-41-1 thru 20-41-24

Revised Text

20-42-1 thru 20-42-34

20-60-1 thru 20-60-12

20-60-1 thru 20-60-12

Added Hyd. Control Valve (1 piece casting) (Foot Control) Added Hyd. Control Valve (1 piece casting) (Advanced Hand Control) (ACS) Revised Text

20-61-1 thru 20-61-16

20-61-1 thru 20-61-16

Revised Text

20-100-1 thru 20-100-8

20-100-1 thru 20-100-8

Revised Text

50-01 thru 50-02 50-30-1 thru 50-30-2 50-31-1 hru 50-31-6 50-100-1 thru 50-100-14 50-101-1 thru 50-101-20

50-01 thru 50-02 50-30-1 thru 50-30-2 50-31-1 hru 50-31-6 50-100-1 thru 50-100-14 50-101-1 thru 50-101-20

Revised Text Revised Text Revised Text Revised Text Revised Text

60-30-1 thru 60-30-10 60-40-1 thru 60-40-10 60-80-1 thru 60-80-6 60-120-1 thru 60-120-20

60-30-1 thru 60-30-10 60-40-1 thru 60-40-10 60-80-1 thru 60-80-6 60-120-1 thru 60-120-20

Revised Text Revised Text Revised Text Revised Text

70-01 thru 70-02 70-70-1 thru 70-70-14 70-100-1 thru 70-100-32

70-01 thru 70-02 70-70-1 thru 70-70-18 70-100-1 thru 70-100-32

Revised Text Revised Text Revised Text

80-50-1 thru 80-50-12 80-70-1 thru 80-70-4

80-50-1 thru 80-50-12 80-70-1 thru 80-70-4

Revised Text Revised Text

SPEC-10-1 thru SPEC-10-4

SPEC-10-1 thru SPEC-10-4

Revised Text

20-43-1 thru 20-43-30

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S175, S185-3 10 May, 2004 Bobcat Loader S175, S185 6902732 (11-03)


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10-90-1 thru 10-90-4

10-90-1 thru 10-90-4

Revised Text

10-120-1 thru 10-120-4

10-120-1 thru 10-120-4

Revised Text

20-01 thru 20-04

20-01 thru 20-04

Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2004) V-0444 tilte & legend

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0444 tilte & legend

Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2004) V-0444

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0444

Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2004) V-0445 tilte & legend

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0445 tilte & legend

Revised Text

Printed in U.S.A.

TAKE OUT HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED APRIL 2004) V-0445

20-40-1 thru 20-40-32 20-41-1 thru 20-41-24 20-42-1 thru 20-42-34 20-43-1 thru 20-43-30 WIRING SCHEMATICS OPTIONS S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED NOVEMBER 2003) V-0442 60-10-1 thru 60-10-6 60-40-1 thru 60-40-10 SPEC-21-1 thru SPEC-21-6

PUT IN HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0445

REVISION DESCRIPTION Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0565 tilte & legend

Added

HYD./HYDRO. SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0565

Added

HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0566 tilte & Legend

Added

HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0566

Added

20-40-1 thru 20-40-32 20-41-1 thru 20-41-24 20-42-1 thru 20-42-34 20-43-1 thru 20-43-30 WIRING SCHEMATICS OPTIONS S175 (S/N 525211001 AND ABOVE) (S/N 525311001 AND ABOVE) S185 (S/N 525011001 AND ABOVE) (S/N 525111001 AND ABOVE) (PRINTED MAY 2004) V-0442 60-10-1 thru 60-10-6 60-40-1 thru 60-40-10 SPEC-21-1 thru SPEC-21-6

Revised Text Revised Text Revised Text Revised Text Revised


ROUTE TO ATTENTION




S175, S185-4 14 April, 2005 Bobcat Loader S175, S185 6902732 (11-03)

The following Sections are a revision to the above Service Manual. Take out existing Sections and put in the new Sections as listed below: TAKE OUT

PUT IN


Section 10-50

Section 10-50

Revised Text

Section 10-110

Section 10-110

Revised Text

Section 10-130

Section 10-130

Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0444

HYD./HYDRO. SCHEMATIC S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED APRIL 2005) V-0444

Revised Text

HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED MAY 2004) V-0445

HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525211001 -525214999) (S/N 525311001 - 525314999) S185 (S/N 525011001 - 525014999) (S/N 525111001 - 525114999) (PRINTED APRIL 2005) V-0445

Revised Text

HYD./HYDRO. SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0565

HYD./HYDRO. SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED APRIL 2005) V-0565

Revised Text

Printed in U.S.A.

TAKE OUT HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED MAY 2004) V-0566

PUT IN


HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED APRIL 2005) V-0566

Revised Text

Section 20-21 Section 20-30 Section 20-40 Section 20-41 Section 20-110


Revised Text Revised Text Revised Text Revised Text Revised Text

30-01, 30-02 Section 30-20 Section 30-30

30-01, 30-02 Section 30-20 Section 30-30


40-01, 40-02 Section 40-30

40-01, 40-02 Section 40-30


Section 50-40 Section 50-41 Section 50-101

Section 50-40 Section 50-41 Section 50-101


Section 60-120

Section 60-120

Revised Text

Section 70-70 Section 70-100



Section SPEC-10 Section SPEC-20 Section SPEC-21 Section SPEC-50

Section SPEC-10 Section SPEC-20 Section SPEC-21 Section SPEC-50

Revised Text Revised Text Revised Text Revised Text

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S175, S185-5 5 July 2005 Bobcat Loader S175, S185 6902732 (11-03)

The following Sections are a revision to the above Service Manual. Take out existing Sections and put in the new Sections as listed below: TAKE OUT

PUT IN


Maintenance Safety ALPHABETICAL INDEX

Maintenance Safety ALPHABETICAL INDEX

Foreword i-x Section 10-120

Foreword i-x Section 10-120

20-01

20-01

HYD/HYDRO SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED APRIL 2005) V-0565

HYD/HYDRO SCHEMATIC S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0565

Revised

HYD/HYDRO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED APRIL 2005) V-0566

HYD/HYDRO SCHEMATIC WITH HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0566

Revised

HYD/HYDRO SCHEMATIC WITH SJC OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V 0715

Added

Revised Revised Text Updated Safety pages Revised Text Revised Text

Printed in U.S.A.

TAKE OUT

PUT IN


Added HYD/HYDRO SCHEMATIC WITH SJC AND HIGH FLOW OPTION S175 (S/N 525215000 AND ABOVE) (S/N 525315000 AND ABOVE) S185 (S/N 525015000 AND ABOVE) (S/N 525115000 AND ABOVE) (PRINTED JULY 2005) V-0716 Section 20-62 Section 20-63

Added Hydraulic Pump (SJC) Added Hydraulic Pump (High Flow) (SJC) Revised Text

Section 20-70

Section 20-70

30-01 Section 30-20

30-01 Section 30-20 Section 30-21 Section 30-22

Section 30-30


Revised Text Revised Text Added Hydrostatic Motor Carrier Added Hydrostatic Motor Carrier (SJC) Revised Text Added Hydrostatic Pump (SJC)

50-01

50-01 Section 50-102 Section 50-112

Revised Text Added Control Panel (SJC) Added Control Handle (SJC)

60-01

60-01

ALL WIRING SCHEMATICS (PRINTED NOVEMBER 2003)

ALL WIRING SCHEMATICS (PRINTED JULY 2005)

Section 60-50


Section 60-80


Section SPEC-10

Section SPEC-10

Revised Text Revised Revised Text Added Controller (Selectable Joystick Control) (SJC) Revised Text Added Electrical/Hydraulic Controls Reference (Selectable Joystick Control) (SJC) Added Service PC (Laptop Comuter) Added Calibration Added Speed Sensor Revised Text

ROUTE TO ATTENTION




S175, S185-6 23 March 2006 Bobcat Loader S175, S185 6902732 (11-03)

S175, S185 Service Manual (P/N 6902732) Dated (2-06) contains updated service information which replaces the previous S175, S185 Service Manual (P/N 6902732) Dated (11-03).

Printed in U.S.A.

pdf-bobcat-s175-s185-service-repair-manual-sn-525011001-525111001-525211001-525311001-and-above

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