Beruflich Dokumente
Kultur Dokumente
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6987160 (12-09) Printed in U.S.A. Bobcat Company 2009
Page 2 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-5
1-6
Page 8 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
SAFETY &
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
FW SSL-1008 SM
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
Page 10 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
be made before the machine
is returned to service.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM
1-9
S630 Service Manual
FW SSL-1008 SM
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
Warning, be alert! Your safety is involved! that the machine is in safe operating condition.
Carefully read the message that follows.
The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operators and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions An Operators Handbook fastened to the operator
can cause injury or death. cab. Its brief instructions are convenient to the
W-2003-0903
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.
IMPORTANT
The AEM Safety Manual delivered with the machine
Page 12 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
SI SSL-1008 SM
SI SSL-1008 SM
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Page 14 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
SI SSL-1008 SM
Fire Extinguishers
Page 15 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
SI SSL-1008 SM
Figure 1
P-90466
1
P-85646A
Page 16 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
located on the outside of the loader frame.
Figure 2
Module 2 - Production
Sequence (Series)
Figure 4
B-16315
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
[2] BUCKET
STEP
BUCKET
STEPS
Page 18 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILL
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
TAIL LIGHT [4] TIRES NA1027
DOOR NA1028
Page 20 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1
Procedure
Figure 10-10-1
P-85985
Lift the front of the loader and put jack stands under the
B-7023A axle tubes [Figure 10-10-2].
WARNING Lift the rear of the loader and install jack stands [Figure
10-10-3].
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
Installing
1
2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 3
support device can allow the lift arms or attachment
to fall and cause injury or death.
Figure 10-20-2
Page 25 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic 1
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm P-85293
support. Replace if damaged.
D-1009-0409
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure
Remove attachment from the loader. (See Removal And 10-20-2] to the lift arm support device so there will be no
Installation on Page 50-40-1.) OR (See Removal And interference with the support device engagement.
Installation on Page 50-41-1.)
Sit in the operators seat, fasten the seat belt and lower
the seat bar. Start the engine.
1
2
P-85295A P-85296A
P-85298
Raise the lift arms until the lift arm support device drops
onto the lift cylinder rod (Item 1) [Figure 10-20-3] Raise the lift arms a small amount. The spring will lift the
support device off the lift cylinder rod [Figure 10-20-5].
Lower the lift arms slowly until the support device is held Lower the lift arms. Stop the engine.
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar, disconnect the seat belt and make
Raise the seat bar, disconnect the seat belt and make sure the lift and tilt functions are deactivated.
sure the lift and tilt functions are deactivated.
Disconnect the spring from the bracket.
Install pin (Item 2) [Figure 10-20-3] into the rear of the lift
Page 26 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
arm support device below the cylinder rod. Figure 10-20-6
Removing
1
Remove the pin from the lift arm support device.
Figure 10-20-4
2
1
P-85462A
Description
Level I
Level II
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
Raising
WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.) STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-1
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3
P-85463A
Page 28 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 10-30-2
P-90512A P-90511A
Figure 10-30-5
N-20120 P-85461
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-8
1
2
P-68116
P-68115
Page 30 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] Available for special applications to restrict material from
will be OFF when the door is closed, the key switch is entering cab openings. Kit includes 1/2 inch thick
turned to RUN or the RUN button is pressed, the seat bar polycarbonate front door and polycarbonate rear window
is lowered and the PRESS TO OPERATE LOADER [Figure 10-30-8].
button is pressed.
Polycarbonate top window (standard item) must be
Figure 10-30-7 installed for special applications to restrict material from
entering cab openings.
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P-85616A
W-2058-0807
Figure 10-40-1
P-85466B
P-85465B
P-85466
P-85717A P-85599A
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.
Procedure
Figure 10-60-1
P16117
1
Figure 10-60-3
2
2
1
1
P-85728
The service tool harness control (Item 1) is used to Connect the service tool harness to the ACD connector
connect the remote start tool (Item 2) [Figure 10-60-3] to and the loader harness connector.
the electrical system on the loader.
NOTE: To monitor, diagnose or load new software
Figure 10-60-4 the Service PC must be connected to the
Remote Start Tool.
Page 36 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85729
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
Figure 10-60-8
1
1
P-85728
Figure 10-60-11
P-85729
Figure 10-60-9
1
Page 38 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85726
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the remote start tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.
WARNING 2
3 1
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 P16118
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899 The traction lock switch (Item 1) [Figure 10-60-13] is
used to turn traction lock ON or OFF. Push the switch to
the override position. The switch will illuminate to indicate
Figure 10-60-12
traction lock OVERRIDE, in this position the wheels are
able to turn.
P16116
WARNING
The remote start tool (Item 1) [Figure 10-60-12] has
three rocker switches. AVOID INJURY OR DEATH
Use traction lock override switch for service
work with seat bar raised.
Traction lock is engaged when light is OFF.
Lift and block the loader. Check that wheels are
clear.
Traction lock is disengaged when light is ON.
See Service Manual for more instruction.
W-2785-0209
Figure 10-60-14
P-85311
Page 40 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Description
Kit Includes:
1
6689778 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS Service Tool Harness
Figure 10-61-1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-2] has five buttons.
Page 42 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678
The traction lock button (Item 5) [Figure 10-61-2] is used
to turn traction lock ON or OFF. Push the button and the
The remote start tool (Item 1) [Figure 10-61-1] is button will illuminate indicating the traction lock is
required when the service technician is checking the disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics. The auxiliary button (Item 6) [Figure 10-61-2] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.
Figure 10-61-3
1
1
P-85725
2
The loader service tool harness (Item 1) [Figure 10-61-3] When the remote start procedure is completed, replace
is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].
Figure 10-61-4
Page 43 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85729
Figure 10-61-6
2 1
1
2
P-76450
Page 44 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
WARNING
AVOID INJURY OR DEATH
Lift and block the machine.
Check that wheels or tracks are clear.
Cab ignition must be in the STOP position to
start the engine with the Service Tool (if
applicable).
See machine Service Manual for more
instructions.
W-2792-0409
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 P-85729
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. Loaders without an attachment control harness, remove
W-2357-0899 the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
The tool listed will be needed to do the following
procedure:
NOTE: When using a Remote Start Tool (Service tool)
harness on loaders not equipped with an
6689779: Remote Start Tool (Service Tool) Kit
attachment control device, the Remote Start
Tool (Service Tool) harness attachment
Figure 10-61-8
control device connector must be capped.
Figure 10-61-10
Page 45 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure 10- P-85725
61-8] is required when the operator cab is in the raised
position for service and the service technician needs to
turn on the loader or start the engine. Example: adjusting Loaders with an attachment control harness (7 pin or 14
the steering linkage. pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
Lift and block the loader. 10-61-10].
Raise the lift arms (if required by the procedure) and When the remote start procedure is completed, replace
install an approved lift arm support device. the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
Raise the operator cab (if required by the procedure). harness.
Figure 10-61-11
5 3
2
1 6 4
P-76439
Page 46 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when checking pressures and flow rate.
WARNING
AVOID INJURY OR DEATH
Lift and block the machine.
Check that wheels or tracks are clear.
Cab ignition must be in the STOP position to
start the engine with the Service Tool (if
applicable).
See machine Service Manual for more
instructions.
W-2792-0409
Figure 10-61-13
1 2
P-85311
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE [1]
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, air Check condition. Replace as needed.
conditioning, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. [2] [3]
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. [4]
Coolant Replace the coolant Every 2 years
[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Perform at first 500 hours, then as scheduled.
[5] Or every 12 months.
Figure 10-80-1
3 1 2
P-76460G
P-90528A
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Page 51 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90523A
Install the dust cover and secure the latches [Figure 10-
80-2].
Inner Filter
1 2
Page 52 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90524A
P-85502
Install new inner filter element. Push all the way in until it
contacts the base of the housing.
Check the cooling system every day to prevent over- Figure 10-90-1
heating, loss of performance or engine damage.
WARNING
AVOID INJURY OR DEATH 2 2
Wear safety glasses to prevent eye injury when any
3
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-0907
P-85824A
Cleaning
Use low air pressure or water pressure to clean the top of
Open the rear door. (See REAR DOOR (TAILGATE) on the air conditioning condenser (Item 1) [Figure 10-90-1].
Page 50-70-1.)
The area between the air conditioning condenser and the
Remove the rear grill. (See REAR GRILL on Page 50-60- oil cooler will require occasional cleaning. Remove the
1.) bolts (Item 2) and the brackets (Item 3) [Figure 10-90-1].
Figure 10-90-2
Page 53 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85799A
Cleaning (Contd) Unhook the two rubber straps (Item 2) [Figure 10-90-3].
Figure 10-90-3
1 1
2
2
P-90502
P-90501
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into place to support the oil cooler. Use low air pressure
Use low air pressure or water pressure to clean the top of or water pressure to clean the top of the radiator (Item 3)
the oil cooler (Item 1) [Figure 10-90-3]. [Figure 10-90-4].
Page 54 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Check the cooling system for leaks.
Checking Level For the service interval for replacing the engine
coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door and raise the rear grill.
Open the rear door and remove the rear grill.
Figure 10-90-5
Remove the coolant fill cap (Item 1) [Figure 10-90-5].
Figure 10-90-6
1
2 1
P-90529A
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE F (C) NO. 2 NO. 1 corrosion and plugging of fuel system components.
+15 (-9) 100% 0% Use of biodiesel blend fuel may result in premature
Down to -20 (-29) 50% 50% failure of fuel system components, such as plugged
Below -20 (-29) 0% 100% fuel filters and deteriorated fuel lines.
WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks NO
1 SMOKING [Figure 10-100-2].
WARNING
Page 58 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85367 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water
WARNING
Figure 10-100-3
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
2 W-2072-0807
Figure 10-100-4
1
P-85508
Replacing Element
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and P-85507
hand tighten.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air
housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 1) [Figure
10-100-4] until fuel flows from the vent with no air
WARNING bubbles.
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Removing And Replacing Oil And Filter Install the cover and the cover mounting bolts [Figure
10-110-3]. Tighten all bolts.
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-110-5
Figure 10-110-3 2
P-85506
2
Open the rear door, remove the oil filter (Item 3) [Figure
10-110-5] and clean the filter housing surface.
3 P-90497A
P-90499A
Use genuine Bobcat filter only.
The oil drain hose is located behind a cover under the Put oil on the new filter gasket, install the filter and hand
right rear corner of the loader (Inset) [Figure 10-110-3]. tighten.
Page 62 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove two cover mounting bolts (Item 1) [Figure 10- Remove the oil fill cap (Item 1) [Figure 10-110-5].
110-3].
Put oil in the engine. For the correct quantity (See
Loosen one cover mounting bolt (Item 2) and slide the Capacities on Page SPEC-10-4.) Do not overfill.
cover (Item 3) [Figure 10-110-3] to the rear of the loader.
Start the engine and let it run for several minutes. Stop
Figure 10-110-4 the engine and check for leaks at the filter.
WARNING
1 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
P-90498A
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Remove the oil drain cap (Item 1) [Figure 10-110-4] from W-2103-0508
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
Park the loader on a level surface, lower the lift arms and HYDRAULIC / HYDROSTATIC FLUID
place the attachment flat on the ground or tilt the Bob- RECOMMENDED ISO VISCOSITY GRADE (VG)
Tach fully back if no attachment is installed. AND VISCOSITY INDEX (VI)
Figure 10-120-1
Figure 10-120-2
WARNING
AVOID INJURY OR DEATH
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.
W-2103-0508
P-90504
Remove the rear grill. (See REAR GRILL on Page 50-60- P-90502
1.)
Figure 10-120-4 Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into place to support the oil cooler. This
will aid in draining the hydraulic fluid.
1
Figure 10-120-6
Page 64 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90505A
Figure 10-120-7
1
P-90506
Pinch off and disconnect the hose (Item 1) [Figure 10- Install hydraulic fill screen and add the correct fluid to the
120-7] from the cooling fan motor. Route the hose out the reservoir until the fluid level is within the operating range
side of the loader and drain the fluid into a container. of the sight gauge. (See Capacities on Page SPEC-10-
4.) and (See Checking And Adding Fluid on Page 10-
Connect the hose to the cooling fan motor when the fluid 120-1.)
stops draining.
Install the hydraulic fill cap.
Recycle or dispose of used fluid in an environmentally
safe manner.
Page 65 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps.
1 WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
P-90500 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
The filter housing is located behind the hydraulic fluid
not use your bare hand. Wear safety goggles. If fluid
reservoir.
Page 66 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Clean the top of the filter housing. W-2072-0807
Figure 10-120-10 Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
P-85478
Figure 10-120-11
1
P-85489A
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.
1
Put clean oil on the seal of the new filter element. Install
P-85470 the element on the filter base. Install and tighten the filter
housing to 35 - 40 ft.-lb. (47 - 54 Nm) torque.
Figure 10-120-12
Removing And Replacing Hydraulic Charge Filter See the SERVICE SCHEDULE for the correct
(Contd) replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Figure 10-120-14
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid 1
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Page 68 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Install the rear grill.
Figure 10-130-1
P-85745
1
Figure 10-130-3
P-85744
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.
P-85742
Add oil through the check plug hole until the oil flows from
the hole.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Figure 10-140-1 If the wedge does not contact the lower edge of the hole
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
P-85513A
WARNING
Page 71 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 10-140-2
2 B-17460
P-85320A
WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208
Figure 10-141-2
B-17460
1
Lubrication Locations
4
1
Page 75 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85481
P-85484
P-85482
Figure 10-150-5
7
P-85487
Figure 10-150-6
Page 76 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
6
P-85719
Mounting
Rotating WARNING
Check the tires regularly for wear, damage and pressure.
AVOID INJURY OR DEATH
Do not inflate tires above specified pressure. Failure
Figure 10-160-2
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
NA1023A
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].
Cleaning Procedure
WARNING
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrestor muffler. (See SERVICE
When the engine is running during service, the
SCHEDULE on Page 10-70-1.)
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Do not operate the loader with a defective exhaust
death.
system. W-2006-0284
Consult local laws and regulations for spark arrestor fumes. If the engine is stationary, vent the exhaust
requirements outside. Exhaust fumes contain odorless, invisible
I-2022-0807 gases which can kill without warning.
W-2050-0807
Figure 10-170-1
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
P-85509 Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
Remove the plug (Item 1) [Figure 10-170-1] from the cause injury or death.
bottom of the muffler. W-2068-1285
Figure 10-180-1
P-85488
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].
Park the loader in a dry protected shelter. Be sure all shields and guards are in place.
Lower the lift arms all the way and put the bucket flat Lubricate the loader.
on the ground.
Check tire inflation and remove blocks from under
Put blocks under the frame to remove weight from the frame.
tires.
Remove cover from exhaust pipe opening.
Put grease on any exposed cylinder rods.
Start the engine and let run for a few minutes while
Put fuel stabilizer in the fuel tank and run the engine observing the instrument panels and systems for
a few minutes to circulate the stabilizer to the pump correct operation.
and fuel injectors.
Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the
Page 83 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 10-200-3
P-85737A P-85735A
P-90525A
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
External Access
Figure 10-210-1
P-85459A
Front Door
P-85724
This machine may be equipped with a front door.
The rear window can be removed from outside the loader NOTE: Use this procedure to remove the front door
using a T40 TORX driver. Turn both screws (Item 1) only under emergency conditions. Damage to
[Figure 10-210-1] in until the latches disengage from the machine may occur.
window frame. Pull the top of the window away from the
cab and lift up to remove. Figure 10-210-4
Page 87 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Rear Window
P-90725
Push the rear window out of the rear of the operator cab.
Figure 10-210-5
1
1
P-90685
P-85781A
1
Page 88 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 10-210-6
2
3
P-90686A
Install the gas spring socket on the ball stud fitting. Install
Rotate and pull the clip (Item 1) out of the gas spring the clip into the hole in the gas spring socket. Rotate the
socket. Pull the gas spring socket (Item 3) straight off the clip to lock into place [Figure 10-210-6].
ball stud fitting (Item 2) [Figure 10-210-6].
Connect electrical connector (Item 2) and washer fluid
Remove the door hinges from the loader. hose (Item 1) [Figure 10-210-5].
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Page 90 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
Page 92 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
S630 (S/N A3NT11001 AND ABOVE)
Printable Version Click Here
13 PILOTED ACTIVATED DIRECTIONAL 30 CHECK VALVE - With 200 PSI (13,8 bar)
CONTROL VALVE - TILT CONTROL
Spring
14 PILOTED ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - LIFT CONTROL
DRIVE MOTOR
OUT
Male
L HYDRAULIC CONTROL VALVE
31 29
30 12
Female
9
10
10
Auxiliary Spool
32
TILT
CYLINDERS
A B
8
11
Tilt Spool
35
38 8 13
27
11
M4 M
3
14
D C
Lift Spool
36 36
Charge
Inlet 8 LIFT
CYLINDERS
37 36 20 18
11 16 16
B A 17 15 ?
IN 2
M M1 7
2 6
36
1
T 19
35
VARIABLE SPEED HYDRAULIC
Oil Cooler 3 RESERVOIR (VENTED)
FAN MOTOR W/ INTEGRATED FILTER 2
34 5
1
33 25 23
4
26 PUMP
SUPPLY
WORKING
B A CIRCUIT
HYDRAULIC FILTER
PILOT
PRESSURE
24 21 DRAIN /
32 RETURN
P DR 22
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
30
29 31 WITH NO OPTIONS
S630 (S/N A3NT11001 & ABOVE)
L
DRIVE MOTOR
DRAIN / RETURN MANIFOLD
(PRINTED APRIL 2009)
Page 94 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off 7172255
PRINTED IN U.S.A.
Page 95 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
S630 (S/N A3NT11001 AND ABOVE)
Printable Version Click Here
56 54 Male
12
55
Female
HIGH FLOW VALVE (OPTIONAL)
BUCKET POSITIONING VALVE (OPTIONAL)
68 OUT D
HYDRAULIC CONTROL VALVE 29 30
69
X 31
67 28
?
57
W
REAR AUXILIARY COUPLERS (OPTIONAL)
9
C
A
58 59 10
FEMALE MALE 27
60 10 ?
Auxiliary Spool
Z
Base
? Rod ?
6
A B
48
B TILT
50 CYLINDERS
8
49 11
HYDROSTATIC PUMP
46
? ? BICS CONTROL VALVE
51 Tilt Spool
75
47
8 13
70
M4
45 11
M
3
LIFT
D C CYLINDERS
44 14
P - in P - out T
REAR AUXILIARY
52 VALVE (OPTIONAL)
52
Lift Spool
Charge
Inlet BOB-TACH CYLINDER 8
(OPTIONAL) RIDE CONTROL
53 18 (OPTIONAL)
20
BOBTACH VALVE 11 16 16
B A 74 17 15
(OPTIONAL) ?
37 IN
M M1 74 38 7
2
2 36 6
71
DUAL STAGE
ACCUMULATOR
52 52 1
39
19
51 35
? ?
73 72
34 40 PP
DR Oil Cooler RESERVOIR (VENTED)
T 3 2
5
P1 P2 1
42 33 32 4
62 C DRAIN /
P 24 21 RETURN
D 58 59
W
P DR 22
62 61
?
57
A X
A1
55
HYDRAULIC/HYDROSTATIC SCHEMATIC
54 56 WITH ALL OPTIONS
S630 (S/N A3NT11001 & ABOVE)
L DRAIN / RETURN MANIFOLD
TWO SPEED DRIVE MOTOR (OPTIONAL)
(PRINTED APRIL 2009)
Page 96 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7172255
PRINTED IN U.S.A.
Page 97 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
S630 (S/N A3NT11001 AND ABOVE)
Printable Version Click Here
Male
TWO SPEED DRIVE MOTOR (OPTIONAL) 12
39 L OUT Male
10
41 10
A B
6
8 TILT CYLINDERS
31 37 11
36 35
X
34 15
8
X
11
16 LIFT CYLINDERS
13
M 36
M
A B
M
32 32
Charge 8
33 G Inlet
20
A B
M 14 19
M 36 11 18 18 17 ?
IN 2
32 7 6
?
32
X
VARIABLE SPEED HYDRAULIC
34 FAN MOTOR W/ INTEGRATED FILTER
1
X ?
36
35 27
25 RESERVOIR (VENTED) 21
T OIL COOLER 3 2
28 5
31
R
1
29
4
23
30 26 PUMP
SUPPLY
P DR WORKING
24 HYDRAULIC FILTER CIRCUIT
PILOT
PRESSURE
B A DRAIN /
RETURN
41
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
22
SJC WITH NO OPTION
40
38 S630 (S/N A3NT11001 & ABOVE)
39
L DRAIN/RETURN
MANIFOLD
DRIVE MOTOR (PRINTED APRIL 2009)
Page 98 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7170813
PRINTED IN U.S.A.
Page 99 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
S630 (S/N A3NT11001 AND ABOVE)
Printable Version Click Here
Male
TWO SPEED DRIVE MOTOR (OPTIONAL)
12
62 L
Male
63 61
12
Female
HIGH FLOW VALVE (OPTIONAL)
74
BUCKET POSITIONING VALVE
75 OUT (OPTIONAL) D
31 32
HYDRAULIC CONTROL VALVE (SPOOL
X VALVE) 33
30
?
65 64
W
76 9
C
A
66 REAR QUICK COUPLERS
10
67 10 ?
FEMALE MALE
Z
A B
?
51
?
6
29
B
8 TILT CYLINDERS
53
54 60 11
52
R
49
TANDEM
? ?
BICS CONTROL VALVE
T
HYDROSTATIC
59 58
X
50
57 15
8
X
48 11
16 LIFT CYLINDERS
47 13
M 59 P in P out T
M REAR AUXILIARY
A B VALVE (OPTIONAL)
M
55 55
Charge 8
56 G Inlet
BOBTACH CYLINDER (OPTIONAL)
20
A B 22
M 14 19
40 POWER BOBTACH
M 59 11 18
VALVE (OPTIONAL) 18 17 ?
39 IN 2
55 38 40 41 7
? 6
55
X
57
1
X ?
42
59 37 ? ?
58
36 43 PP
DR
OIL COOLER 3 RESERVOIR (VENTED) 21
T 2
5 77
54 P1 P2 78
R
1
45 35 34
4
T HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTION
44
61
63 S630 (S/N A3NT11001 & ABOVE)
62
L
TWO SPEED DRIVE MOTOR (OPTIONAL) (PRINTED APRIL 2009)
Page 100 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7170813
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
Page 102 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).
NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the opening (fully or restricted) or the closing of one or
more flow paths (represented by several squares).
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
BACK
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
Page 104 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
LOCK VALVE - hydraulic pressure is
applied to open the valve to allow the
hydraulic cylinder to move.
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
Check for correct function after adjustments, repairs
most common. Many of the recommended procedures
or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel
adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal is in neutral position 4, 9, 10, 11
Bypass valve stuck 12
Bypass valve stem bent or broke 13
Testing
1
Figure 20-20-1
1
P-85546
Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.
Figure 20-20-3
P-85550
Figure 20-20-4
Page 108 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85549
P-85548
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-6] from the pivot pin at the base end of the lift cylinder.
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-4] from the pin on the rod end of the lift cylinder. Installation: Tighten the retainer bolt and nut to 35 - 40
ft.-lb. (48 - 54 Nm) torque.
Installation: Tighten the retainer bolt and nut to 35 - 40
ft.-lb. (48 - 54 Nm) torque.
Figure 20-20-7
1
P-85555
WARNING
Page 109 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Parts Identification
1. Case 9. Spacer
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. O-ring 13. Seal
6. Nut 14. Plug
7. Seal 15. O-ring
8. O-ring 16. Tubeline
7 4
14 15
TS-1060a
Page 110 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
TS-1060a
13
1 16
3
11
10
12
14 15
TS-1060b PE3950S
Disassembly
2
Use the following tools to disassemble the cylinder:
Figure 20-20-11
1
Page 111 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48033
4
3 P-48039
2
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-9].
Disassembly (Cont'd)
Figure 20-20-12
P-48040
Figure 20-20-13
Page 112 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-48042
Assembly
Figure 20-20-14
P-48038
Figure 20-20-16
P7424 1
Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-20-16].
fits the piston [Figure 20-20-14].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-20-16] must be installed
on the piston. toward the inside of the cylinder.
Assembly (Cont'd)
Figure 20-20-17 1
2 3
P-48036
Install the head (Item 1), spacer (Item 2) piston (Item 3),
Install the rod seal in the head [Figure 20-20-17]. and nut (Item 4) [Figure 20-20-19].
Figure 20-20-18 Tighten the nut (Item 4) [Figure 20-20-19] to 1100 ft.-lb.
(1491 Nm) torque.
Figure 20-20-20
2
Page 114 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48035
1) toward the outside of the head (Item 2) [Figure 20-20-
18].
Put the base end of the hydraulic cylinder in a vise.
Testing
Figure 20-21-1
1
2
P-85552
Engage the parking brake. Lower the seat bar. Start the
Remove the attachment. Roll the Bob-Tach fully back. engine and press the PTOL button.
Stop the engine. Raise the seat bar.
Operate the controls that rolls the Bob-Tach forward.
Hydraulic fluid escaping under pressure can have Repeat procedure to check the other tilt cylinder.
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-21-3
2
1
1
P-85562
Page 116 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Tighten the retainer nut to 35 - 40 ft.-lb. (48 -
54 Nm) torque.
Figure 20-21-4
P-85648
Figure 20-21-7
P-85564
Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-7].
Page 117 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-21-8
P-85567
1
Check pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9
Page 118 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Parts Identification
1. Tube
2. Piston
3. Head
4. Rod
5. Bushing
6. Nut
7. O-ring
8. Seal TS-1688b
9. O-ring 17
10. Washer
11. O-ring
12. Seal 12
13. Seal
14. Plug
15. O-ring 9
16. Tubeline 1
17. Grease Fitting 15
18. Seal 10
16 14
11
15 6
3
Page 119 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
14
2 13
4
8
18
18
17
TS-1688a PE3951S
TS-1060a
Disassembly
3
Use the following tools to disassemble the cylinder: 2
1
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].
2
Page 120 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85651
Figure 20-21-12
P-85647
Disassembly (Cont'd)
Figure 20-21-14
1
2
P-48040
Figure 20-21-17
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.
Figure 20-21-15
1
Page 121 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48042
Assembly
1
Use the following tools to assemble the cylinder:
Figure 20-21-18
P-48073
Figure 20-21-20
P7424 1
Page 122 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-21-20].
fits the piston [Figure 20-21-18].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-21-20] must be installed
on the piston. toward the inside of the cylinder.
Assembly (Cont'd)
Figure 20-21-21 1
2
P-48071
Install the head (Item 1), piston (Item 2) and nut (Item 3)
Install the rod seal in the head [Figure 20-21-21]. [Figure 20-21-23].
Figure 20-21-22 Tighten the nut (Item 3) [Figure 20-21-23] to 1100 ft.-lb.
(1491 Nm) torque.
Figure 20-21-24
2
Page 123 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item P-48088 P-48089
1) toward the outside of the head (Item 2) [Figure 20-21-
22].
Mark the end of the shaft and nut [Figure 20-21-24].
Tighten the nut an additional 135 degrees or 2-1/4 flats
[Figure 20-21-24].
Assembly (Cont'd)
Figure 20-21-25
P-85647
Figure 20-21-26
Page 124 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-85650
Testing
WARNING 1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention P-85570
from a physician familiar with this injury.
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
Figure 20-22-1
P-85568
Engage the parking brake. Lower the seat bar. Start the
engine.
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Page 126 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-22-5
1
1
P-85569
Parts Identification
1. Tube 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
2
3
4
5
Page 127 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7
8
9
10
11
12
13
PE3954S
Disassembly 3 2 1
Figure 20-22-6
P16295
Figure 20-22-9
Use the following tools to disassemble the cylinder:
Page 128 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Put the base end of the cylinder in a vise.
5
Use a spanner wrench to loosen the head [Figure 20-22- 3
6].
2
4 3 1 Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.
Assembly
3 1
2
Figure 20-22-10
P16295
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Assembly (Contd)
Figure 20-22-13
2
3
P7422
3
2 4
1
Page 130 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P7425
P16294
Assembly (Cont'd)
Figure 20-22-17
P-85647
Description
Testing
1
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-85571
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the
When the engine is running during service, the hydraulic tester to the bottom (female) quick coupler on
steering levers must be in neutral and the parking the loader.
brake engaged. Failure to do so can cause injury or
death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-0284 hydraulic tester to the top (male) quick coupler on the
loader.
Figure 20-30-2
WARNING
Page 134 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
1
The tools listed will be needed to do the following
procedure:
P-85572
Figure 20-30-4
Right
Page 135 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Steering
1 Lever
Control
P-26697
Adjusting
Figure 20-30-5
1
2
P-85573
Page 136 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or
out until the pressure is correct. Turning screw in will
increase pressure.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-37689
NOTE: This procedure is for standard loaders, Clean the main relief valve in clean solvent. Use air
loaders equipped with ACS option and pressure to dry the valve.
loaders equipped with SJC option. The main
relief valve is located in the same place on all Install new O-rings and back-up washers. Install the main
of the loaders. relief valve and tighten [Figure 20-30-7].
1
2
P-85573
Description
Figure 20-40-1
P-90327
The lift and tilt functions in the hydraulic control valve are
Page 139 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
WARNING
Page 140 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
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 2
P-90187
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-40-2] off to the side.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Figure 20-40-3
2
1
P-90270
Figure 20-40-4 1
P-90271
2
Figure 20-40-7
1 1
2 2
1 1
P-90274
Figure 20-40-10
Remove the tubeline clamp (Item 1) [Figure 20-40-7].
Figure 20-40-8
Page 142 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-90275
Figure 20-40-11
1
P-90280
Figure 20-40-14
Disconnect the hose (Item 1) [Figure 20-40-11] that
routes from the bottom of the control valve to the outlet
2
fitting of the hydraulic pump.
Figure 20-40-12
Page 143 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90279
Support the control valve and remove the two bolts (Item Installation: Torque the two frame bolts (Item 2) [Figure
1) [Figure 20-40-12]. 20-40-14] to 300 - 330 ft.-lb. (406 - 447 Nm).
Remove the control valve from the loader. Remove the control valve bracket from the loader.
Identification Chart
Figure 20-40-15
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307
Page 144 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve 4000 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End) J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve 4000 PSI J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve 3500 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
4000 PSI (Optional)
3
1 P-90309
Figure 20-40-17
Page 145 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90310
Figure 20-40-19
IMPORTANT
When repairing hydrostatic and hydraulic systems,
2 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
P-90311
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-19].
Page 146 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NOTE: The tilt and auxiliary load check valves are
interchangeable.
Figure 20-40-20
3
4
P-90312
Figure 20-40-21
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-40-23].
At the back side of the control valve, remove the lift Figure 20-40-24
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
Page 147 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3 1
4
P-90315
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 Nm)
20-40-22]. torque.
Figure 20-40-25
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-27] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1) Figure 20-40-28
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
Page 148 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-90319
Replace the O-ring (Item 1) [Figure 20-40-26] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 Nm)
installation. torque.
Figure 20-40-29
P-90318A
Figure 20-40-30
1
Page 149 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51640
2
P-90318 Installation: Always use new O-rings (Item 1) [Figure
20-40-32]. Tighten to 38 - 45 ft.-lb. (52 - 61 Nm) torque.
Figure 20-40-33
1
P-51461
Figure 20-40-34
Page 150 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51462
Figure 20-40-37
P-51506
Figure 20-40-38
Page 151 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
P-51701
Figure 20-40-39
1 1
1 1
P-51699A
1
Figure 20-40-42
P-51697
1
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-39] from the
end cap/spool lock block.
4
Figure 20-40-40
Page 152 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
P-51701
Figure 20-40-43
P-90321
Figure 20-40-46
P-51511A
Page 153 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
Remove the O-ring (Item 1) [Figure 20-40-43]. 2
P-51512
Figure 20-40-47
1 P-51516
Page 154 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
in.-lb. (10,2 - 11,3 Nm) torque.
2 1
3
IMPORTANT
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and
assembly.
I-2012-0284
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-49].
Figure 20-40-50
P-8988
Figure 20-40-53
Remove the lift spool assembly and seal (Item 1) [Figure
20-40-50] from the control valve. 2
Figure 20-40-51
1
Page 155 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-18915
Figure 20-40-54
N-19009
Page 156 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
(Item 2) [Figure 20-40-54].
Figure 20-40-55
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-19004
N-18961
N-18918 NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Remove the stud from the end of the spool [Figure 20- this O-ring. Always replace the O-ring and
40-58]. recheck the lift spool before the control valve
is replaced.
Figure 20-40-59
Figure 20-40-61
Page 157 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-18920
N-18963
Removal of the plastic plug:
Install the plastic plug and O-ring in the spool [Figure 20-
Make a center point in the plug using a 1/16 in. drill.
40-61].
Drill a hole all the way through the plug using a 7/64 in.
tap drill
O-ring
1 3
2
N-18958
Plastic
Plug
0.60 in. Apply grease on all the detent component surfaces
(15,2 mm)
before assembly [Figure 20-40-64].
Page 158 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-65].
Clamp the collar (Item 1) [Figure 20-40-63] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
Figure 20-40-66
N-19005
Figure 20-40-69
2
N-18917
Figure 20-40-70
2
P-51515
Page 160 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
N-19008
P-51514
Figure 20-40-74
1
1
P-51512
Figure 20-40-75
1
Page 161 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51511A
Figure 20-40-78
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 16.02 - 19.58 ohm.
Page 162 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -
11,3 Nm) torque.
Figure 20-40-79
P-90320
Remove the lift and tilt end cap/spool lock block. (See
End Cap Block Removal And Installation on Page 20-40- 2
14.)
Figure 20-40-81
P-90323
Figure 20-40-82
P-51544
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-87].
N-18942
Figure 20-40-88
Put the linkage end of the spool in the vice [Figure 20-
40-85]. 2
1
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
Page 164 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-51545 N-18943
N-19014
Figure 20-40-89
1
1
2 3 2
P-51547
1
Remove the spool centering block (Item 3) [Figure 20-
40-89] from the control valve.
Figure 20-40-90
P-51549A
P-51546A
Figure 20-40-93
1
2
P-51550
Figure 20-40-94
Page 166 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-51551
Figure 20-40-95
1
2
P-85528
Figure 20-40-96
P-85556
Figure 20-40-97 1
1
2
P-85528
Page 168 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-40-98
N-18694
Figure 20-40-101 1
1
1
1
2
2
1
2
2 P-51564
Figure 20-40-104
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-101] is for the lift
circuit.
Figure 20-40-102
Page 169 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51705
Figure 20-40-105 1
1
1
2
1
2
2
1 2
P-51564
Page 170 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-40-106
P-90324
Figure 20-40-108
1
P-51707
Figure 20-40-109
Page 171 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Check the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 38 - 45
109]. ft.-lb. (52 - 61 Nm) torque.
Figure 20-40-112
1
P-68869
Figure 20-40-115
Remove the tubeline (Item 1) [Figure 20-40-112].
Figure 20-40-113
Page 172 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90326
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
P-90337
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
The hydraulic control valve is located inside the main D-1009-0409
frame on the right hand side, below the operators cab.
operated using electronic control handles / levers that the lift arms are secured by an approved lift arm
send an electronic signal to the electronic actuators to support device. Failure to use an approved lift arm
move the lift and tilt spools in the control valve. support device can allow the lift arms or attachment
to fall and cause injury or death.
The auxiliary function is operated by pilot pressure. W-2059-0598
There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.
IMPORTANT
The hydraulic control valve also contains a main relief
valve which is adjustable. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10- 1
20-1.)
Figure 20-41-2
Page 174 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3
2
P-90187
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-41-2] off to the side.
Figure 20-41-4
1
3
2
P-90271
Figure 20-41-7
Disconnect the wire harness connectors (Item 1) [Figure
20-41-4] from the control valve.
1
hydraulic pump.
Figure 20-41-5
P-90272
2
1
Remove the tubeline clamp (Item 1) [Figure 20-41-7].
P-90270
P-90275
1
Disconnect the hose (Item 1) [Figure 20-41-10] that
routes from the control valve to the junction block at the
P-90273 rear of the machine.
Page 176 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-41-9] Disconnect the hose (Item 1) [Figure 20-41-11] that
that route from the control valve to the junction block at routes from the bottom of the control valve to the outlet
the rear of the loader. fitting of the hydraulic pump.
Figure 20-41-12
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
1
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 20-41-13
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-12].
P-90330
Figure 20-41-14
1
2
1
P-54568
Page 178 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-15
P-54566
Figure 20-41-17
P-54339
P-54337 Remove the actuator and linkage pin from the valve.
Figure 20-41-20
Remove the two mount bolts (Item 1) [Figure 20-41-17]
from the tilt actuator.
Figure 20-41-18
P-54340
Pull the actuator away from the control valve [Figure 20-
41-18].
Figure 20-41-21
1 1
P-54343
Page 180 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-22
P-54340
Pull the actuator away from the control valve [Figure 20-
41-22].
Figure 20-41-25
4 3
1
3
P-90329
Identification Chart
Figure 20-41-26
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307
Page 182 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve 4000 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End) J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve 4000 PSI J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve 3500 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
4000 PSI (Optional)
Figure 20-41-27
P-90308
1
Page 183 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90310
P-90279
Figure 20-41-31
2
P-90311
3
P-90309 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
Remove and install new O-rings (Item 1) and back-up At the front side of the control valve locate the auxiliary
ring (Item 2) [Figure 20-41-31]. section load check valve (Item 2) [Figure 20-41-32].
Check the free movement load check valve and spring NOTE: The tilt and auxiliary load check valves are
(Item 3) [Figure 20-41-31]. interchangeable.
Page 184 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-33
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 3
damage the system. 4
I-2003-0888
P-90312
Figure 20-41-34
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-41-36].
At the back side of the control valve, remove the lift Figure 20-41-37
section anti-cavitation valve (Item 1) [Figure 20-41-34].
Figure 20-41-35
Page 185 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3 1
4
P-90315
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 Nm)
20-41-35]. torque.
Figure 20-41-38
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-40] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1) Figure 20-41-41
[Figure 20-41-38] from the base end of the tilt section.
Figure 20-41-39
Page 186 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-90319
Replace the O-ring (Item 1) [Figure 20-41-39] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 Nm)
installation. torque.
Figure 20-41-42
P-90318A
Figure 20-41-43
1
Page 187 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51640
Figure 20-41-46
1
P-51461
Figure 20-41-47
Page 188 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-51462
Remove the lift and tilt actuators from the control valve. MEL 1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-5.) Remove the end cap block from the control valve.
1 2
P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-41-50] from Remove the O-ring (Item 1) [Figure 20-41-52].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly with
Remove the two end cap block mount screws (Item 2)
Page 189 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-51
P-68047
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
P-90339 20-41-53] from the lift spool.
Figure 20-41-54
1
1
P-68045
1
Figure 20-41-55
Page 190 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-68046
P-68044
N-190146
4 1
1
P-51776
P-51773
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-61].
Install the spring tool (Item 1) [Figure 20-41-59] over the
centering spring.
N-18920
P-74184
Removal of the plastic plug:
Make a center point in the plug using a 1/16 in. drill. Install the plastic plug and O-ring in the spool [Figure 20-
41-64].
Drill a hole all the way through the plug using a 7/64 in.
tap drill. Figure 20-41-65
Turn a 6-32 tap (Item 1) [Figure 20-41-62] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
Page 192 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
break the tap. 2
1
Figure 20-41-63 1
2
P-68046 P-51775
1
Remove the spool seal(s) (Item 1) and the back-up
washer (Item 2) [Figure 20-41-65].
P-74183
Figure 20-41-66
1 1
2
2
P-68047
3
3
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-41-68] on the lift spool.
P-68044
Figure 20-41-69
Install the lift spool assembly (Item 1) [Figure 20-41-66]
in the spool bore.
1
Install the end cap (Item 2) [Figure 20-41-66].
Figure 20-41-67
P-68042
P-68048
2
2
1
P-68040
P-68049
Install the end cap block (Item 1) and the two mount bolts Remove the spacer (Item 1) and O-ring (Item 2) [Figure
(Item 2) [Figure 20-41-70]. 20-41-71] from the tilt spool.
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 - Figure 20-41-72
11,3 Nm) torque.
Page 194 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
Install the lift and tilt actuators to the control valve.
P-90321
Figure 20-41-73 1
N-18942
1
Put the linkage end of the spool in the vice [Figure 20-
41-75].
P-90342
Install the spring tool (Item 1) [Figure 20-41-75] over the
centering spring.
Remove the spool centering block (Item 1) [Figure 20-
41-73] from the control valve. Figure 20-41-76
Installation: Replace the O-ring (Item 2) [Figure 20-41-
73] and lubricate lightly with oil / grease before
installation of the end cap block.
1
Page 195 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-74
1
N-19014
Remove the tilt spool, centering spring, back-up washer Remove spring tool from the spring assembly.
and spool seal (Item 1) [Figure 20-41-74].
Figure 20-41-77
2 1
3
2
4
1
P-90321
Page 196 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-80
2
P-51545 N-18943
Figure 20-41-81
2
2
P-68077
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-83] from the auxiliary spool.
P-68054
Figure 20-41-84
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-81] from the auxiliary spool.
Figure 20-41-82
Page 197 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1 P-68078
P-68076
Figure 20-41-85
1
2
P-90337
Page 198 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-41-86
P-85556
Figure 20-41-87 1
P-90346
Figure 20-41-88
N-18694
Figure 20-41-91
1
2 P-51792
Page 200 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
1
2
2
2
P-51564
P-90321
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-94] from the valve, and replace with new.
Remove the lift lock valve (Item 1) [Figure 20-41-92]
from the back of the control valve.
Figure 20-41-95
1
P-51794
Figure 20-41-98
Remove the fitting (Item 1) [Figure 20-41-95] from the
valve.
Figure 20-41-96
Page 201 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-90344
Figure 20-41-99
1
P-68869
Figure 20-41-102
Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100
Page 202 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90326
Description
Testing
Figure 20-50-1
1
Page 203 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85290B P-85290A
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms
slowly lower.
1
DANGER 3
P-90328 P-85670
AVOID DEATH
Disconnecting or loosening any hydraulic Hold the lift arm bypass control knob (Item 1) [Figure 20-
tubeline, hose, fitting, component or a part failure 50-2] and loosen the jam nut on the lift arm bypass valve
can cause lift arms to drop. shaft.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm Remove the lift arm bypass control knob (Item 1).
support. Replace if damaged. Remove the jam nut (Item 2) from the valve shaft [Figure
D-1009-0409 20-50-2].
Page 204 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
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-85671
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.
Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50
Reverse the removal procedure to install the lift arm Nm) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.
Page 205 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 3700 PSI (255 bar).
supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
A seal kit is available to service the hydraulic pump. If should be approximately 23 - 24 GPM. Start turning the
any of the main components of the pump are damaged, restrictor clockwise, causing more restriction on the flow.
the entire pump must be replaced. The GPM should drop off slightly until the pressure
reaches approximately 3100 PSI. At approximately 3100
Pump Test At Quick Couplers PSI the flow should start decreasing rapidly until the
pressure reaches 3450 - 3500 PSI. At 3450 - 3500 PSI
The tools listed will be needed to do the following the flow should be at zero GPM. Turn the restrictor (Item
procedure: 2) [Figure 20-60-1] counterclockwise to free flow. Shut
the auxiliary hydraulics off.
TWX-RFIK200-S-6 54 GPM Flow Meter
MEL10006 - Fitting Kit If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Figure 20-60-1 Section) on Page 20-60-2.)
Page 207 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 P-90171
1
1
WARNING 2
P-90178 P-90176
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 Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-2
1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING
Page 208 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-2] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-1]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-60-2] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-1] on the control valve.
6689779 on Page 10-61-1.)
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*.
WARNING
P-85897A
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 Disconnect the inlet hose (Item 1) [Figure 20-60-3].
fall or move and cause injury or death.
W-2017-0286
Figure 20-60-4
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING 1 2
Page 210 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
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
P-90580
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-4] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-3]
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-4] from the tester to the inlet fitting on the fan (Item
Tester, to prevent any contamination to the 1) [Figure 20-60-3].
Hydrostatic Pumps.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment 1
to fall and cause injury or death. 1
W-2059-0598
1
P-90180
Page 212 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
unless supported by an approved lift arm
1
support. Replace if damaged.
D-1009-0409
2
IMPORTANT
3
When repairing hydrostatic and hydraulic systems,
P-90509
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 Disconnect and cap the outlet hoses (Item 1) [Figure 20-
damage the system. 60-6] from the hydraulic pump.
I-2003-0888
Remove the two mounting bolts (Item 2) [Figure 20-60-
Lift and block the rear of the loader. (See Procedure on 6] from the hydraulic pump.
Page 10-10-1.)
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb.
Raise the lift arms and install an approved lift arm support (75 - 85 Nm) torque.
device. (See Installing on Page 10-20-1.)
Remove the hydraulic pump (Item 3) [Figure 20-60-6]
Raise the operator cab. (See Raising on Page 10-30-2.) from the loader.
Removal And Installation (Contd) NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Figure 20-60-7
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-60-8
Momentary Switch
P-43940 P-43938A
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
16
Parts Identification
2
11
1
5
HYDRAULIC PUMP (CONT'D)
6
12
2
13
3
14
4
5
5
2
20-60-8
6
7
8
15
9
5
2
17
10
P-66540
18
10. Auxiliary Pump End Section Assembly: Tighten the eight pump housing bolts (Item
19) [Figure 20-60-9] to 37 ft.-lb. (50 Nm) torque.
11. Spline Shaft
NOTE: Position the wear plate (Item 5) [Figure 20-60-
12. Drive Gear (Charge Pump) 9] inlets and traps as shown with the bronze
Page 215 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 P-90171
1
1
WARNING 2
P-90178 P-90176
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 Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING
Page 218 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
6689779 on Page 10-61-1.)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the MEL1563 or 6689779 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6 54 GPM Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
RPM*.
Figure 20-61-5
Page 220 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
P-90580
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-90186
IMPORTANT
Page 221 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90183
A low percentage may indicate a failed pump.
Disconnect the high flow pump OUTLET hose (Item 1) *Refer to Hydraulic Schematics Legend for system relief
from the high flow check valve INLET fitting (Item 2) pressure and full RPM.
[Figure 20-61-7].
Figure 20-61-8
Page 222 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
P-90580
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*.
1
Page 223 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90577 1
P-45445
If the pump reaches 3700 PSI and there is flow stop the
engine. The relief screw must be turned
counterclockwise 1/4 turn and retested with the
procedure above.
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Remove right rear wheel. (See Wheel Nuts on Page 10- P-45444
160-1.)
Figure 20-61-12 Locate the high flow relief valve through rear door along
the right side of the engine.
Figure 20-61-14
Page 224 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-90577
3
Remove the mounting bolts (Item 1) [Figure 20-61-12]
from the access cover and remove the cover from the 2
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and washer (Item 2) [Figure 20-61-14].
Figure 20-61-15
P-45461
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 1) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid. Installation: Tighten the solenoid valve to 35 - 40 ft.-lb.
(47 - 54 Nm).
Figure 20-61-16
Figure 20-61-18
1
Page 225 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-45460
P-45462
Installation: Tighten the solenoid nut to 48 - 72 in.-lb. (5 - Inspect the O-ring and back-up washer (Item 2) [Figure
8 Nm) 20-61-18] and replace as needed.
1
1
P-90184
Page 226 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all P-90185
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Removal And Installation (Contd) NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Figure 20-61-21
Fill the system with hydraulic fluid. (See Removing And
1 Replacing Hydraulic Fluid on Page 10-120-2.)
2
Figure 20-61-23
Momentary Switch
2
3
P-90509A
Remove the hydraulic pump (Item 3) [Figure 20-61-21] The starter bypass tool consists of two wires, each with a
from the loader. clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Figure 20-61-22
Connect the starter bypass tool to the starter solenoid
battery terminal and S terminal. Crank the engine for 15
seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
1
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
P-43940 P-43938A of cylinder stroke.
Parts Identification
Figure 20-61-24
21
1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Pre-load Seal
8. Load Seal
22 9. Spline Connector
24 10. Pin
11. Gear Set
1 12. Gear Housing
10 13. Gear Housing
2
14. Gear Set
3
11 15. Gear Housing
8 9
7 16. Gear Set
23 4 17. Center Housing
10
17 12 18. Center Housing
19. Front Housing
Page 228 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
4 20. Shaft Seal
3
21. High Flow Relief
22. Seal
10 23. Nut
3 24. Coil
9 14
8
7
4
10 13
18
4
3
10
4
8
7
4 15
16
19
20
10
MS1456S
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
Description
2
The hydraulic / hydrostatic filters help to remove 2
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
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 20-70-2
P-90011
Figure 20-70-3
Page 232 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1 P-90537
Description
Figure 20-80-1
P-90013
Figure 20-80-3
P-90506
Page 234 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Wash the screen in clean solvent and air dry, before
replacing.
Description
1
The oil cooler is used to cool the loaders hydraulic and 2
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
3
The oil cooler is located underneath the rear grill between
the A/C condenser (if so equipped) and the radiator.
P-90589
IMPORTANT Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-2] and
When repairing hydrostatic and hydraulic systems,
pull hose out.
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Cap or plug all hoses and fittings.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-90-3
4 4
Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-1.) 2
5
Page 235 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-90-1 3
1 2 2
P-90501
3
Undo the rubber straps (Item 1) [Figure 20-90-3]
Cap or plug all hoses and fittings. 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.
The Bucket Position Valve is an option that allows the Cover the fuel tank inlet.
operator to hold the attachment at the same angle from
Figure 20-100-2
the ground to maximum lift height without using the tilt
function.
DANGER
1 P-90197
Figure 20-100-1
3 1
2
N-18191
2
P-90187
Inspect the solenoid stem and replace the O-rings (Item
1) and the back-up washer (Item 2) [Figure 20-100-3].
Solenoid Testing
DANGER
1 P-90197
Page 238 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
support. Replace if damaged.
D-1009-0409
1
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-100-4
2
3
4 3
P-90188
1
Disconnect and cap the tilt base inlet hose (Item 1), the
tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.
2
P-90187
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-100-4] off to the side.
Figure 20-100-7
P-90190A
2
1
Remove the mounting screws (Item 1) [Figure 20-100-
P-90189A 9].
Figure 20-100-8
Page 239 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.
Figure 20-100-10
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Check for wear,
check the O-ring and replace as needed.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 56 - 64 ft.-lb. (75,9 - 86,8
stem (Item 3) [Figure 20-100-10]. Nm) torque.
Page 240 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Nm) torque. 2 3
Figure 20-100-11
P-90193
Description
Solenoid Testing
Figure 20-110-1
Page 241 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P9137
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
Disconnecting or loosening any hydraulic 110-3]
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Figure 20-110-4
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
1
Put jackstands under the rear corners of the loader.
Raise the lift arms and install an approved lift arm support
Page 242 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
device. (See Installing on Page 10-20-1.)
Figure 20-110-2
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-4] from the main harness.
P-90583
Figure 20-110-5
1
1
P-48751
P-90581
Figure 20-110-7
1
Page 243 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48752
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
1
Figure 20-110-8
P-48755
Figure 20-110-11
1
2
2
Page 244 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-48755
Figure 20-110-9
P-48757
P-48756
Figure 20-110-12
P-48759
1
Figure 20-110-15
P-48753
Figure 20-110-13
1
3
Page 245 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2 2
P-48760
Assembly: Put oil on O-ring and back-up washers. Remove the spacer (Item 2) and solenoid valve coils
Tighten to 20 - 25 ft.-lb. (27 - 34 Nm) torque. (Item 3) [Figure 20-110-15].
Figure 20-110-16
1
2 2
1 1
P-48763
Page 246 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 20-110-17
P-48762
Figure 20-110-19
P-48765
1 2
P-48764 1
P-48766
Figure 20-110-23
1
1
P-48758
Remove the plug (Item 1) [Figure 20-110-23]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
Assembly: Tighten the plug to 10 ft.-lb. (13,6 Nm) parts in clean solvent. Use air pressure for drying them.
torque. Install new O-rings and back-up washers.
Page 248 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-48786
Description
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
Page 249 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-120-1
2 4
3
3
3
P-90969
Page 250 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Drain the hydraulic reservoir. (See Removing And 2] from block.
Replacing Hydraulic Fluid on Page 10-120-2.)
Installation: Tighten the mounting bolts to 35 - 40 ft.-lb.
Disconnect and cap the two electrical solenoid (48 - 54 Nm) torque.
connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness. Remove the power Bob-Tach block.
Figure 20-120-3
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-4].
IMPORTANT 1
Figure 20-120-6
1
1
P-48122
Installation: Oil the check valve and O-rings and tighten Figure 20-120-9
the check valve to 20 - 25 ft.-lb. (27,1 - 34 Nm) torque.
Figure 20-120-7
Page 252 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
1
P-48384
3
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-9]
(Item 2) [Figure 20-120-7]. to 12 - 14 ft.-lb. (16,3 - 19 Nm) torque.
Figure 20-120-10 2
2
1
P-48106A
Figure 20-120-11
Page 253 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
2
P-48386
Figure 20-120-14
1
P-48174
1
Page 254 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3
2 2
1 1
P-48138
P-48173
IMPORTANT P-90002
2
Figure 20-130-1
Page 255 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90003
P-85281
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-1].
4
4 1
4
4 2
2
P-34665
3
Page 256 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
[Figure 20-130-2], [Figure 20-130-4] and [Figure 20-
130-4].
Page 258 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
Check for correct function after adjustments, repairs
most common. Many of the recommended procedures
or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel
adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
Description
Page 260 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Description
DANGER
1
2
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure P-90510
can cause lift arms to drop.
Keep out of this area when lift arms are raised Remove the motor cover.
unless supported by an approved lift arm
support. Replace if damaged. Mark the hoses for correct installation.
D-1009-0409
Disconnect the case drain hose (Item 1) [Figure 30-20-
1].
Figure 30-20-2
Page 262 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment 1
to fall and cause injury or death. 2
W-2059-0598 1 1
1
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all P-90495
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Remove the ten mounting bolts (Item 1) [Figure 30-20-
damage the system.
I-2003-0888
2].
Figure 30-20-3
P5405
Parts Identification
4
5
4 6
8 7
9
10
11
12
Page 264 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
13
23
25
15
28
29 14
16
22 16
24 21
20
19
18
26
17
27
30
B-17125
2
IMPORTANT 1
Figure 30-20-4
Apply low air pressure to each port in the cylinder block
1 to remove the roller (Item 1) and piston/ring assembly
(Item 2) [Figure 30-20-5].
Figure 30-20-6 2
N-17864
Page 266 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
4
2
N-17868
Remove the cam ring (Item 1) [Figure 30-20-7] from the Assembly: Install the stop pin (Item 1) [Figure 30-20-8]
motor housing. and tighten to 7 - 9 ft.-lb. (10 - 12 Nm) torque.
Inspect the cam ring for surface scratches or wear. Assembly: Install the distributor (Item 2) [Figure 30-20-
9] into the housing.
Assembly: Install the cam ring (Item 1) [Figure 30-20-7]
and align the mounting bolt holes. Assembly: Align the distributor hole (Item 3) [Figure 30-
20-9] with the stop pin. When aligned correctly, the
distributor can be depressed slightly.
Figure 30-20-10 5
1 2 3 4
1
N-17872
Remove and replace the two seals and back-up O-rings Assembly: Remove and replace the O-ring (Item 5)
(Item 1) [Figure 30-20-10] on the distributor. [Figure 30-20-12].
Inspect the distributor and springs (Item 2) [Figure 30- Assembly: Tighten the plug to 9 - 11 ft.-lb. (12 - 15 Nm)
20-10] for damage or surface scratches. torque.
2 3 4 2 1
1
N-17871
Description
DANGER
Page 269 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
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 30-21-1
1
P-90257
Page 270 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-21-2
1
P-90257
1
Figure 30-21-5
P-90496
Figure 30-21-6
N-22535
Parts Identification
Ref. Description
15
14
1. Roller
2. Piston 13
3. Ring 13
4. Clamp 12
5. Ring 11
6. Block
7. Cam 9
10
8. Quad Ring 8
9. Distributor
10. Spring
11. Seal/O-ring 1 7
12. Seal/O-ring
13. Seal/O-ring 2
14. Seal/O-ring
15. Seal/O-ring
16. Poppet 3
17. Spool 6
18. Spring 5
19. O-ring
20. Plug 4 4 36
21. Pin 34
22. Plug 5 35
23. Housing 33
24. Spring
25. Spool 32
26. Washer 2728
27. O-ring
Page 272 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
28. Plug 24 31
26
29. Quad Ring 25 30
30. Bushing 24 29
31. Shaft 22
32. Dowel
33. Housing 23
34. Bolt 16
35. Shim 37
36. Brake Disc 17 38
37. O-ring 18 39 51
38. Snap Ring 19 40 50
39. Washer 41
40. Spring 49
20
41. Spool 42
42. Bolt 48
43. Seal 21 47
44. O-ring
45. Clamp 46
46. Piston
47. O-ring 45
48 Spring 44
49. Gasket 43
50. Cover
51. Bolt
MS1467S
Disassembly
Figure 30-21-7
1
2
N-22492
N-22493
1
Disassembly (Cont'd)
1
Figure 30-21-11
P-69985
Figure 30-21-14
Remove the five mounting bolts (Item 1) [Figure 30-21-
11] from the brake housing.
1
Remove the brake housing (Item 2) [Figure 30-21-11]
from the rear housing. 2
Figure 30-21-12
Page 274 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-69978
Disassembly (Cont'd)
Figure 30-21-15
1
P-73057
2
4
3 Remove the flushing spool assembly (Item 1) [Figure 30-
21-17] from the housing.
N-22501
Figure 30-21-18
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-15]. 1
2 4 3
NOTE: The spool (Item 1) [Figure 30-21-15] is marked
with either an A or B. The spool must be
replaced with a spool with the same mark.
Page 275 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-21-16
N-22504
P-69979
Disassembly (Cont'd)
Figure 30-21-19
1
2
1 3
N-22507
Figure 30-21-22
Remove the plug (Item 1) [Figure 30-21-19] from the
housing.
Figure 30-21-20
Page 276 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-73058
Disassembly (Cont'd)
Figure 30-21-23
N-22511
Figure 30-21-26
1
Page 277 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-22509
P-73059
Remove the cylinder block (Item 1) [Figure 30-21-24]
from the housing.
Remove the shaft from the distributor [Figure 30-21-26].
Remove the O-ring (Item 2) [Figure 30-21-24] from the
housing. NOTE: The end of the shaft with the snap ring (Item 1)
[Figure 30-21-26] must be toward the brake
housing during assembly.
Disassembly (Cont'd) 1
Figure 30-21-27
N-22523
Figure 30-21-28
Page 278 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
2 N-22519
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-21-30].
N-22521
Assembly 1
Figure 30-21-31
N-22525
Figure 30-21-32
P-73060
Assembly (Cont'd) 1
Figure 30-21-35
N-22509
Page 280 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-69983
P-73061
Figure 30-21-39 2
P-69986
Figure 30-21-40
1
P-73064
Clamp the disc pack in a vise and measure the height End the disc pack with an outer disc.
[Figure 30-21-40]. The height must be 1.22 in. (31.1
mm).
Assembly (Cont'd)
Figure 30-21-43
1
2
N-22493
Page 282 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Install a new o-ring (Item 3) [Figure 30-21-43] in the
seal.
Figure 30-21-44
N-22492
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-44].
Assembly (Cont'd)
Figure 30-21-47
N-22490
Description
DANGER
1
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
P5467A
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised Remove the six mounting bolts (Item 1) [Figure 30-30-1]
unless supported by an approved lift arm from the carrier.
support. Replace if damaged.
D-1009-0409 Installation: Tighten the mounting bolts to 340 - 360 ft.-
lb. (461 - 488 Nm) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
WARNING Figure 30-30-2
Page 286 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Parts Identification
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring
2
3
Page 287 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7
8
TS-1227B
Disassembly
Figure 30-30-3
P-76544
Figure 30-30-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-30-3] in the housing.
Figure 30-30-4
Page 288 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P5766
Figure 30-30-7
P5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange, MEL1431 - Seal Driver Tool
use the hydraulic press to remove the bearing from the
shaft [Figure 30-30-7]. Install the first seal (Item 1) [Figure 30-30-9] into the
housing with the seal lip facing away from you.
Figure 30-30-8
Use the tool (Item 2) [Figure 30-30-9] as shown in the
figure.
Page 289 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-30-10
2
1
2
P5763
Use the press and apply pressure to the end of the spline
1
shaft to reduce preload and clearance.
P5767
Figure 30-30-12
Page 290 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P5769
Description
Figure 30-31-1
DANGER
1
1
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
P5467A
can cause lift arms to drop.
Keep out of this area when lift arms are raised
Remove the six mounting bolts (Item 1) [Figure 30-31-1]
unless supported by an approved lift arm
from the carrier.
support. Replace if damaged.
D-1009-0409 Installation: Tighten the mounting bolts to 340 - 360 ft.-
lb. (461 - 488 Nm) torque.
Figure 30-31-2
WARNING
Page 292 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) P5489A
Parts Identification
Ref. Description
1. Snap Ring
2. Bearing
3. Race
4. Seal
5. Housing
6. Speed Washer
7. Shaft
8. Cover
7
5
6 8
2 3
4 3
2
Page 293 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
PE3328SA
Disassembly
Figure 30-31-3
P-28155
Figure 30-31-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-31-3] in the housing.
Figure 30-31-4
Page 294 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P5766
Disassembly (Contd)
Figure 30-31-7
P-28158
Figure 30-31-10
NOTE: The bearing (Item 1) [Figure 30-31-7] and the
wheel speed washer (Item 2) [Figure 30-31-7],
must both be replaced, due to damage to the
wheel speed washer from removing the
bearing.
Figure 30-31-8
1
Page 295 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-76464
P-28157
Figure 30-31-11
2
1
P5764
P-28164
The tool listed will be needed to the following procedure:
Remove the two seals (Item 1) [Figure 30-31-11] from MEL1431 - Seal Driver Tool
the housing.
Install the first seal (Item 1) [Figure 30-31-12] into the
Check the bearing cup (Item 2) [Figure 30-31-11] (both housing with the seal lip facing away from you.
sides) and replace as needed.
Use the tool (Item 2) [Figure 30-31-12] as shown in the
figure.
Page 296 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-31-13
P5762
Assembly (Cont'd)
Figure 30-31-14
1 2
P-76542
sprocket.
Assembly (Cont'd)
2
Figure 30-31-16
P-76539
Page 298 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NOTE: The wheel speed washer should be tight on
the shaft. After the bearing is seated. Install the snap ring on the
shaft and reposition the motor carrier to allow back press
operation.
Use the press and apply pressure to the end of the spline
shaft to reduce preload and clearance.
Figure 30-40-2
1
Page 299 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3
2
P-43197
Testing (Contd)
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
W-2059-0598 3
P-90301
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].
Place the loader on jackstands. (See Procedure on Page
10-10-1.) Install the hose (Item 2) [Figure 30-40-4], that was
disconnected from the motor, to the T fitting.
Raise the operator cab. (See Raising on Page 10-30-2.)
Install the hose (Item 3) [Figure 30-40-4], that is
Figure 30-40-3 attached to the pressure gauge, to the T fitting.
Page 300 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
REMOTE START TOOL (SERVICE TOOL) KIT -
6689779 on Page 10-61-1.)
Figure 30-40-5
P-90302
Adjusting
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. N-17231
I-2003-0888
Figure 30-40-8
Page 302 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-43856
1
Adjusting (Contd)
SJC Machines
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. P-64435
I-2003-0888
P-64431
Description
P-90222
Remove the pump pulley and key from the pump drive
Figure 30-50-1 shaft.
Figure 30-50-3
Page 306 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-50-1] on the
hydrostatic pump drive shaft.
Remove the two mounting bolts and nuts (Item 1)
Installation: Tighten the nut to 190 - 240 ft.-lb. (258 - 325 [Figure 30-50-3].
Nm) torque
Installation: Tighten the mounting bolts and nuts to 65 -
70 ft.-lb. (88 - 95 Nm) torque.
Removal And Installation (Contd) Follow the hydraulic pump startup procedure. (See
Hydrostatic Pump Startup on Page 30-50-3.)
Figure 30-50-4
P-90224
Figure 30-50-5
1
2
P-66670
Page 308 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
forward drive loop. be replaced as a complete unit.
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block
19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Page 309 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing / High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10
18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
Page 310 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B
Disassembly
Figure 30-50-7
3
1
1 3
2
N-19571
Remove the four mounting bolts (Item 1) [Figure 30-50- Remove the two small O-rings (Item 3) [Figure 30-50-9].
7].
Figure 30-50-10
Figure 30-50-8
1 1
Page 311 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-19550
N-19570
Disassembly (Cont'd)
2
1
Figure 30-50-11
N-17194
2
Check the valve plate locating pin (Item 1) [Figure 30-50-
N-19551 13] for wear and replace if needed.
Figure 30-50-12
1
1
Page 312 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-17197
Disassembly (Cont'd)
3 3
Figure 30-50-15
1 1
3 2
3
2
N-17200
N-17199
N-17201
Disassembly (Cont'd)
Figure 30-50-19
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-21] from
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
Remove the driveshaft key (Item 1) the snap ring (Item 2) Figure 30-50-22
and the support washer (Item 3) [Figure 30-50-19] from
the drive shaft end of the pump.
Figure 30-50-20
Page 314 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-17241
Disassembly (Contd)
Figure 30-50-23
N-17244
Figure 30-50-26
Check the pump shaft (Item 1) [Figure 30-50-23] for
wear and replace if needed.
Figure 30-50-24
1
Page 315 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-17245
1 1
Check the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-50-26] for wear and replace as needed.
Disassembly (Contd)
Figure 30-50-27
1
2
1 N-17250
1
Figure 30-50-30
Inspect the dust seal on the pintle shaft.
Figure 30-50-28
Page 316 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-17248
N-17247
Disassembly (Contd)
1
Figure 30-50-31
N-17252
2
Figure 30-50-32
Page 317 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-50-32] from
the swash plate shaft.
Assembly
Figure 30-50-34
1
1
2
N-17249
Figure 30-50-37
Install the lower bearing (Item 1) [Figure 30-50-34] on
the swash plate.
Figure 30-50-35
Page 318 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-17248
Assembly (Contd)
Figure 30-50-38
1 N-17245
Figure 30-50-41
N-17247
Figure 30-50-39
Page 319 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-17244
N-17246
Assembly (Contd)
Figure 30-50-42
N-17241
Figure 30-50-45
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-50-42].
Figure 30-50-43
Page 320 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
50-45].
Assembly (Contd)
Figure 30-50-46
1
1
1
1 2 3
N-17198
Figure 30-50-47
Page 321 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
N-17197
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-50-49].
Assembly (Contd)
Figure 30-50-50
1
1
2
N-17193
Replace the needle bearing (Item 1) and valve plate The notch (Item 1) [Figure 30-50-52] on the valve plate
locating pin (Item 2) [Figure 30-50-50] in the charge must engage the locating pin.
pump.
Figure 30-50-53
Figure 30-50-51
Page 322 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
N-19551
N-17196
Assembly (Contd)
Figure 30-50-54
1 1
N-19570
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-50-54] to 35 - 45 ft.-
lb. (47 - 61 Nm) torque. 1
Figure 30-50-55
Page 323 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
3 P-43858
N-19571
Figure 30-51-1
Page 325 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90206
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
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
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
IMPORTANT
fall or move and cause injury or death.
When repairing hydrostatic and hydraulic systems,
Page 326 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
W-2017-0286
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Raise the operator cab. (See Raising on Page 10-30-2.)
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-51-2 I-2003-0888
Figure 30-51-4
1
1
1
P-90207
1
1 2
3 1
P-90210
P-90210
Remove the controller gaskets (Item 2) [Figure 30-51-5] NOTE: When a hydraulic controller is replaced, the
from the pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Installation: Page 30-51-25.)
Page 327 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-51-6
2 2
P-90209
P-90222
Page 328 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
P-90221
P-90223
Removal And Installation (Contd) Before putting a hydrostatic pump back into operation,
the hydrostatic pump should be filled with hydrostatic
Figure 30-51-11 fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
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.
Parts Identification
3 1
1. O-ring 5 4
2. Bolt
3. End Housing 7
4. O-ring 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. O-ring 11 9 2
13. Position Sensor 12
14. Washer 13
15. Bolt 14
15
16
22 17
21 19
23 24
20 18
26
Page 330 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
18
25 27
19
29 26
P-90240
Figure 30-51-13
1
1
P-64437
Figure 30-51-14
4
3
2 1
P-64436
Figure 30-51-16 3 4
2 5
1
1 P-64435
The charge relief valve (Item 1) [Figure 30-51-16] is Inspect the sealing ring (Item 3) [Figure 30-51-18] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or
foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 52 ft.-lb. (70 shims (Item 5) [Figure 30-51-18].
Nm) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-51-18] = 43.5
Page 332 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-51-17 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Figure 30-51-19
2
P-90228
P-90226
Figure 30-51-20
3 3
2 2
1 1
3
3
P-90227
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-20] from both sides.
Figure 30-51-22
3
1
1
1
P-64445
P-90217
Left End Housing
Figure 30-51-23
Page 334 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
P-64447
Figure 30-51-26
P-64466
Pull the end housings from the case housing [Figure 30- Figure 30-51-29
51-26].
Figure 30-51-27
1 1 2
2
Page 335 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-64463
Figure 30-51-30
RIGHT SIDE
P-64454
Figure 30-51-31
LEFT SIDE
Page 336 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-64501
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-32]
P-64455 and [Figure 30-51-33] in the case housing with the notch
(Item 1) [Figure 30-51-34] and [Figure 30-51-35] that
does not go through the valve plate.
Figure 30-51-33
Align the shoulder of the roller bearing (Item 2) [Figure
LEFT SIDE 30-51-32] and [Figure 30-51-33] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-34] and [Figure
30-51-35].
1
2
P-64502
Figure 30-51-34
RIGHT SIDE
1
2
P-64456
Figure 30-51-36
1
P-64469
Figure 30-51-37
1
Page 338 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-64475
P-64471
Figure 30-51-43
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-40] in the
1
slippers, are not plugged.
Figure 30-51-41
1
Page 339 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-64472
P-64479
Figure 30-51-47
1
Page 340 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-45] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-47].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-45] are not bent or damaged.
1 P-64483
2 1
P-64482
Figure 30-51-52
LEFT SIDE
1
P-76742
Figure 30-51-55
Figure 30-51-53
RIGHT SIDE 1
Page 342 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-52] and a rubber mallet.
[Figure 30-51-53] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Figure 30-51-56
1 1
P-90232
Figure 30-51-59
B25013
1
The Servo Piston Assembly [Figure 30-51-56] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-57
P-90231
P-64490
Figure 30-51-60
P-64466
Figure 30-51-61
Page 344 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item
2) [Figure 30-51-63] from the pump housing.
Figure 30-51-64 1
2
P-64496
Figure 30-51-67
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-51-64].
Figure 30-51-65
Page 345 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-67] from the
P-64495 servo piston.
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-68 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
P-64498
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-68] from the servo piston. Raise the lift arms, and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Inspect mechanism for broken parts.
Raise the operator cab. (See Raising on Page 10-30-2.)
Replace O-ring (Item 2) [Figure 30-51-68]
Connect the remote start tool. (See REMOTE START
Figure 30-51-69 TOOL KIT-MEL1563 on Page 10-60-1.)
Page 346 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Disconnect the swash plate angle sensors in the
electrical harness. This prevents unwanted swash plate
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
2 find an accessible connector to disconnect.
P-64502
Figure 30-51-70
1
P-64438
Figure 30-51-71
1 1
Page 347 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1 1
P-90243
Figure 30-51-74
1 1
P-90238
Start the loader using the remote start tool and run at idle.
WARNING
Page 348 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-75
P-90238
P-90238
2
WARNING
Put jackstands under the front axles and rear corners
1
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
P-90238
fall or move and cause injury or death.
W-2017-0286
While holding the adjustment screw (Item 1) in position, Raise the lift arms, and install an approved lift arm
tighten the lock nut (Item 2) [Figure 30-51-78] to 22 ft.-lb. support device. (See Installing on Page 10-20-1.)
(30 Nm) torque.
Raise the operator cab. (See Raising on Page 10-30-2.)
Shut loader OFF.
Connect the remote start tool. (See REMOTE START
Remove the hydraulic hose from the X1 and X2 ports on TOOL KIT-MEL1563 on Page 10-60-1.) or (See
the pump. Install the plugs and tighten to 18 ft.-lb. (25 REMOTE START TOOL (SERVICE TOOL) KIT -
Page 349 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 30-51-79
P-64975
Figure 30-51-80
Page 350 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-90236
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
Figure 30-51-83
P-90236
Figure 30-51-84
Page 351 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
P-90236
Turn the adjustment screw (Item 1) [Figure 30-51-84] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 18 ft.-lb. (25
Nm) torque.
Belt Adjustment Stop the engine and open the rear door.
The drive belt does not need adjustment. The belt has a Remove the battery. (See Removal And Installation on
spring loaded idler which constantly maintains the correct Page 60-20-1.)
belt tension.
Figure 30-60-1
P-85518
Figure 30-60-2
Page 353 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90467
1
1
2
P-90468A
P-90470
2
Page 354 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove the drive belt from the hydrostatic pump pulley mounting bolts and slide the drive belt shield toward the
and flywheel pulley. Inspect the pulleys for wear. front of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-60-5].
Install new drive belt.
Figure 30-60-6
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-3] and allow the idler to contact the drive
belt.
Figure 30-60-4
1
P-85518
Move the breaker bar to adjust the stop arm until a gap of Close the rear door.
0.125 in. (3.2 mm) (Item 1) [Figure 30-60-4] is achieved.
Stop Adjustment
Figure 30-60-7
P-90470
Figure 30-60-8
Page 355 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90471
Move the breaker bar to adjust the stop arm until a gap of
0.125 in. (3,2 mm) (Item 1) [Figure 30-60-8] is achieved.
1 2
2 3
P-90306
Page 356 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
the slot provided in the stop arm as shown and push Remove the two bolts (Item 1) and the adjustment plate
breaker bar down to release tension on drive belt. (Item 2) [Figure 30-60-11].
Figure 30-60-10
1
2
1
P-90304
Figure 30-60-13
P-90303
Description
Figure 30-70-1
P-90507
DANGER
2
2
P-90328 P-90437
AVOID DEATH
Disconnecting or loosening any hydraulic Remove the steering shock (Item 1) [Figure 30-70-2].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Mark all hydraulic hoses for proper installation.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm Disconnect the five hydraulic hoses (Item 2) [Figure 30-
support. Replace if damaged. 70-2] from the brake / two speed valve block.
D-1009-0409
Figure 30-70-3
WARNING
Page 360 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING P-90425
Put jackstands under the front axles and rear corners Disconnect the three hydraulic hoses (Item 1) [Figure
of the frame before running the engine for service. 30-70-3] from the brake / two speed block.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 30-70-4
P-90444
Figure 30-70-5
Page 361 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90446
Figure 30-70-6 1
1
N-22580
Figure 30-70-9
Mark all hydraulic hoses and fittings for proper
installation. 1
Figure 30-70-7 4
Page 362 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
3
1
2
P-90550
Figure 30-70-10
P-90552
Figure 30-70-13
Use a test meter and test the solenoid coils (Item 1)
[Figure 30-70-10] for resistance.
Figure 30-70-11
Page 363 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-22584
P-90551
Figure 30-70-14
1
1 P-90547
Figure 30-70-15
Page 364 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90554
Description
IMPORTANT 1
Figure 30-80-1
1
Page 365 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90484
Remove and plug all hoses from the drain manifold (Item
1) [Figure 30-80-1].
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3
Page 367 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 40-10-1
N-19081A
Page 369 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 40-10-3
P-85491
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
WARNING 1
N-19105
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 Inspect the traction lock guides (Item 1) [Figure 40-10-3]
support device can allow the lift arms or attachment and the brake disc for damage or wear and replace as
to fall and cause injury or death. necessary. (See Inspecting on Page 60-120-3.)
W-2059-0598
Figure 40-10-4
N-19082A
Figure 40-10-5
Page 370 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-19083A
Description
Figure 40-11-1
P-85413
Description
Page 373 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NA1285
The two speed brake is part of the two speed drive motor.
Page 374 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove the hub from the axle.
2
Figure 40-20-3
1
2
P4850
Remove the two wheel studs (Item 2) [Figure 40-20-1] Remove the key (Item 1) [Figure 40-20-3] from the axle.
across from each other.
Figure 40-20-4
P4817
Figure 40-20-5
Page 375 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P4814
DANGER 1
P-68196
Page 376 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
AVOID DEATH Installation: Tighten the axle sprocket bolt to 515 - 535
Disconnecting or loosening any hydraulic ft.-lb. (699 - 726 Nm) torque.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
unless supported by an approved lift arm
support. Replace if damaged. Figure 40-20-7
D-1009-0409
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support P-4158A
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-10- Install a Port-a-Power ram between the two sprockets
1.) [Figure 40-20-7].
P-4171
P5406A
Press the splined end of the axle free from the bearing
Push the axle out until the ram is at the end of the stroke. [Figure 40-20-10].
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
[Figure 40-20-8].
Figure 40-20-9
P-4170
Figure 40-20-13
Bearing Cup
Tool
P-4175
Recess
Installation: Put the spline end of the axle shaft into the
MC-2164
bearing and press the bearing onto the axle.
Page 378 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Put a piece of tubing over the axle (Item 1) [Figure 40-
20-11] that contacts inner race of the bearing only.
Figure 40-20-12
P4812
P5468A
Figure 40-20-17
P4816
P4811
Figure 40-20-18
P4813
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
Page 380 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
is seated inside the axle tube [Figure 40-20-18].
Figure 40-20-19
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised Front Drive
Rear Drive Chain
unless supported by an approved lift arm
Chain
support. Replace if damaged.
D-1009-0409
P-68194
Never work on a machine with the lift arms up unless Remove the motor carrier. (See Removal And Installation
the lift arms are secured by an approved lift arm on Page 30-30-2.)
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 40-20-20
B-13504A
Page 382 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-20].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-20]. Tighten the
threaded rod of the chain link tool to 250 ft.-lb. (339 Nm)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307
Description
3 3
The chaincase contains the drive components.
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
Page 384 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
D-1009-0409
2
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Figure 40-30-2
1
4
P-90048
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
1
Raise the loader operator cab. (See Raising on Page 10-
30-2.)
DANGER 1
P-90056
P-90328 Remove the hydraulic tube clamp bolt and nut (Item 2)
[Figure 40-30-4].
AVOID DEATH
Disconnecting or loosening any hydraulic Remove chain case cover (Item 4) [Figure 40-30-4].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. NOTE: There are tabs (Item 5) [Figure 40-30-4] on the
Keep out of this area when lift arms are raised side of the cover to help pry the covers off.
unless supported by an approved lift arm
support. Replace if damaged. Installation: Apply polyurethane sealer to mating
Page 385 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
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
Page 388 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-3
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Page 390 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-10-1
1
P-90021
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Page 391 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-10-2
P-85652
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023
4 4
5 5
9 8
3 6
3 6 2
2 10 7
Page 392 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] & [Figure 50-10-5]. bar pivot assembly [Figure 50-10-6] & [Figure 50-10-7].
5
4 8
3
2
1
P-90028
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] & [Figure 50-10- Bushing (Item 2)
9] out of the clevis. Spring (Item 3)
Bushing (Item 4)
Assembly: Apply Loctite #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite
Page 393 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or 1
death.
W-2113-0288
Figure 50-20-3
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
Page 395 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-20-1 1
3
1
P-85652
Remove the rue ring (Item 1), the pin (Item 2), and the
gas spring (Item 3) [Figure 50-20-3] from the loader.
P-85662
Lift the cab with the hoist to release the pressure on the
gas spring(s).
Figure 50-20-4
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
3 operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
1 W-2760-0309
1
Remove the clevis (Item 1) from both ends, and the outer NOTE: Use the hoist connected to the operator cab
housing (Item 2) from the gas spring (Item 3) [Figure 50- grab handles to lower or (raise) the operator
20-4]. cab when the gas spring(s) are disconnected.
Page 396 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WARNING
AVOID INJURY 1
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
P-85663
Figure 50-20-6
P-85658
Figure 50-20-7
Page 397 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85662
Using a strap and a hoist remove the cab from the loader.
Figure 50-30-1
P-90355
P-85776
Remove the nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Repeat for other half of seat belt and guide
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the two slide rail mounting bolts (Item 1) [Figure
Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3
P-85770
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.
Figure 50-31-5
Page 402 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85772
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50-31- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
7]. the seat back to the upright position.
1 1
P-85775
Shock Removal And Installation Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Page 404 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-85784
1 3
1
P-85788
Figure 50-31-14
Page 405 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85787
Description 1
1
Page 407 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85554
Figure 50-40-3
1 P-31405
Figure 50-40-6
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
Page 408 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 35 - 40 ft.-lb. (48 - 54
Nm) torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 330 ft.-lb. (446 Figure 50-40-10
Nm) torque.
Figure 50-40-8
Page 409 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-85665
1
P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
Figure 50-40-11
1 3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.
Page 410 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-40-12
P-85667
Figure 50-40-14
2 1
P-85669
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. 2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].
Figure 50-41-2
1 1
P-31402
Figure 50-41-5
Remove the retainer bolt and nut (Item 1) [Figure 50-41-
2] from the rod end pivot pin.
Figure 50-41-3
Page 414 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649
Figure 50-41-6
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
P-31405 the Bob-Tach pivot pin (both sides).
1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 7/8 in. (0,875 mm) punch (Item 1) [Figure 50-41-
Tach pivot pin retaining bolt (both sides). 9] and a hammer, drive the pivot pin out of the lift arm
and Bob-Tach (both sides).
Figure 50-41-10
1 1 2
P-85665
Figure 50-41-13
Remove the washers and bolts (Item 1) [Figure 50-41-
10] from the cylinder (both ends).
Page 416 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-41-11
P-85666
Figure 50-41-14
2 1
P-85669
Remove the wedge (Item 1) [Figure 50-41-14] out the Use a seal pick to remove seal (Item 1) [Figure 50-41-
bottom of the Bob-Tach. 16] from the Bob-Tach.
Always replace bent or broken wedges. Remove and replace bushing (Item 2) [Figure 50-41-16]
with a driver tool and hammer.
Figure 50-41-15
Page 417 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-15] are damaged, put the
assembly in a vise.
Figure 50-50-1
P-85692
1
P-85682
Page 419 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
At the right side upright disconnect and cap the two tilt
cylinder hoses (Item 1) [Figure 50-50-1].
P-85693
Figure 50-50-5
1
1
P-85686
Page 420 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-85687 P-85685
Install a floor jack (Item 1) [Figure 50-50-6] under the Remove the retaining bolt and nut (Item 1) and the pin
front of the lift arms, and raise the lift arms 2 - 3 inches. (Item 2) [Figure 50-50-8] (both sides).
Figure 50-60-1
1 P-85602
Align the tabs of the two side covers into the slots in the
P-85496 loader frame and lower [Figure 50-60-3].
Figure 50-60-4
Flip up the lockable handle (Item 1) [Figure 50-60-1] and
turn the handle a quarter turn counter-clockwise. Lift and
pull the rear grill to remove it from the loader.
Figure 50-60-2
Page 421 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-85604
Align the edge of the rear grill under the loader frame and
slide rear grill in while lowering [Figure 50-60-4].
P-85600A P-85601A
Turn the lockable handle a quarter turn clockwise and
fold the handle down.
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].
Figure 50-70-1 1
3
2
P-85695
1
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].
Remove both rear lights (Item 2) [Figure 50-70-1] from
Installation: Tighten the mounting bolts and nuts to 25 -
the door. (See Rear Removal And Installation on Page
28 ft.-lb. (34 - 38 Nm) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
Page 423 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-90584
Figure 50-70-6
1
1
P-85698A
Figure 50-70-5
Page 424 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2
3 Align the striker assembly in the center of the mounting
holes.
Figure 50-70-7
1
1
P-85701
Figure 50-70-8
Page 425 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85700
Figure 50-80-1
P-85707
1 Figure 50-80-4
1 4
P-85714
2 3
Remove the three mount bolts (Item 1) [Figure 50-80-1]
Page 427 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-80-2
1
P-85708
P-85713
Figure 50-80-5
1
1
1 1
P-85711
At the right side of the loader, remove the two main frame
P-85710 mount bolts and nuts (Item 1) [Figure 50-80-7].
Figure 50-80-6
Page 428 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1 1
P-85712
2
P-85709 At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-8].
Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount bolts to 400 -
(Item 2) [Figure 50-80-6]. 430 ft.-lb. (542 - 583 Nm) torque.
Lift the fuel tank and remove it from the loader frame.
Figure 50-80-9
1
1
P-85707
P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
Disconnect the wire harness connector (Item 1) [Figure
50-80-9] from the fuel level sender. Figure 50-80-12
Figure 50-80-10
1
Page 429 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85715
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
WARNING P-85675
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Check the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-90-2
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Figure 50-90-3
1
1
2
P-85679
Page 432 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
2
1
P-85681
P-85680
1
1
2
P-85675 P-85676
Remove the bolt (Item 1) [Figure 50-90-7] and nut from Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
the pedal linkage. from the pedal mounting bracket.
Figure 50-90-8
1
Page 433 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
P-85675
P-85675A
Loosen the bolt (Item 1) [Figure 50-90-1] and nut on the
pedal linkage.
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage. Check the bushing in the pedal for wear and replace as
needed.
Remove the linkage (Item 2) [Figure 50-90-8].
Tilt the pedal back and forth until an acceptable neutral
Pedal (Adjusting) angle is achieved on the pedal.
After installing the pedal, adjust the pedal angle so that Tighten the two nuts (Item 2) and pivot bolt (Item 1)
there is clearance under the rear of the pedal. The valve [Figure 50-90-1] on the pedal assembly to standard
spool must travel full stroke without the pedal hitting the torque.
floor panel.
Figure 50-90-2
1
1
P-85859 P-85860
Page 434 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-90-3
1 1
P-85858
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Check the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 50-91-2
W-2059-0598
Raise the lift arms and install an approved lift arm support
device.(See Installing on Page 10-20-1.)
Page 435 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
DANGER 1
P-85676
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-91-5
1 1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.
Figure 50-91-4
P-85676
Page 436 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-91-6
1
P-90981
2
Remove the linkage (Item 1) [Figure 50-91-4] and the
rubber boot.
Figure 50-91-7
1
1
P-85859 P-85860
Page 437 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-91-8
1 1
P-85858
Description
Figure 50-100-1
Page 439 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or creep.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, creep
linkage bars are adjustable in length for full travel 2. Set full travel at steering linkage bars
adjustment. 3. Set drift at drift adjustment bolts
2
DANGER
1
P-85846
P-90328
WARNING
Page 440 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm P-85847
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. Disconnect the control harness connectors (Item 1) and
W-2059-0598 the back-up alarm wires (Item 2) [Figure 50-100-2] &
[Figure 50-100-3] from the control levers.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation
on Page 50-100-2.)
Figure 50-100-4
Figure 50-100-6
2
1
1 1
2
2 2
P-90612
1 1
P-85864
Figure 50-100-5
3 2 3
3 3 P-85848
Figure 50-100-7 2
2 2
1
3 1 3 3 P-85867
3
Figure 50-100-10
4
3
Page 442 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
1
P-85861
P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50-
100-8]. Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8]. Remove the control handle (Item 4) [Figure 50-100-10].
1 2 1
WARNING
P-85872
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
Remove the two bolts (Item 1) from the bellcrank (Item 2) fall or move and cause injury or death.
[Figure 50-100-11]. W-2017-0286
Remove the bellcrank from the bracket [Figure 50-100- Lift and block the loader. (See Procedure on Page 10-10-
11]. 1.)
Figure 50-100-12 Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Page 443 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-11] for wear and
replace as need.
2
1
2
P-48631
2
Remove the four steering linkage mounting bolts, nuts Figure 50-100-15
and rubber isolators (Item 2) [Figure 50-100-13].
Page 444 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 Nm) torque.
P-48632
2
5
2
P-48630
ITEM DESCRIPTION
1 Bolt
2 Bushings
3 Washer
Page 445 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
4 Bushing Spacer
5 Spring
6 Lock Nut
7 Centering Plate
8 Guide Bushings
Figure 50-100-17
1
1
P-48629
Figure 50-100-18
2
2
1
P-54615
3
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-21
18] from the pintle.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Page 446 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-100-19 2
1 3
1
2 P-48659
Inspect the washers (Item 2), pintle arm (Item 3) and the NOTE: After installing the linkage onto the
steering control lever (Item 4) for damage and replace as hydrostatic pumps the linkage neutral
needed [Figure 50-100-19]. adjusting procedure must be performed. (See
Linkage Neutral (Adjusting) on Page 50-100-
NOTE: The washers (Item 2) [Figure 50-100-19] are 10.)
hardened, and should only be replaced
through Bobcat Parts.
2
4
3 1
2
3
1 P-48619
P-54624
Inspect the torsion bushing (Item 4) [Figure 50-100-22] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-24] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2
Page 447 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
4
2
P-54626
Lift and block the loader. (See Procedure on Page 10-10- P-85845
1.)
Figure 50-100-25 Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing.
3
Figure 50-100-27
2
1
Page 448 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
100-25].
To make this tool use a locking grip C-Clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-100-27].
[Figure 50-100-25] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-100-25] is torsion bushing (Item 2) [Figure 50-100-27] to
also needed. The centering block can be placed as turn freely between the torsion bushing and
shown and welded to the C-clamp if desired. the steering linkage bar.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-100-28] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
Page 449 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-48451
P-48632
Page 450 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
pintle base.
Figure 50-100-31
P-54610
Figure 50-100-32
1
2 2 1
P-48632
WARNING
P-85845
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 Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
to fall and cause injury or death.
W-2059-0598
Figure 50-100-34
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. 2
Page 452 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Pre-load tension in the torsion bushings must be The bolts must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-34] to turn freely
between the torsion bushing and the linkage bar.
Figure 50-100-35
2
1
1 3
P-51132
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
3/8 in. (10 mm) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 35 - 40 ft.-lb. (48 - 54 Nm)
[Figure 50-100-36]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-38].
Figure 50-100-39
1
1
1
P-51132
Figure 50-100-40
Page 454 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-54613
WARNING
1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Tighten the two bolts and nuts (Items 1) [Figure 50-100- If the drift is excessive to the right, turn the left
43] to 35 - 40 ft.-lb. (47,5 - 54,2 Nm) torque at the adjustment bolt in.
steering bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-44 prevent over-correction and excessive
reduction in travel speed.
P-85877
Figure 50-100-46
1 2
P-85845
Page 456 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Tighten the nuts to 25 - 28 ft.-lb. (34 - 38
Nm) torque.
WARNING
Put jackstands under the front axles and rear corners
1
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-85879
Figure 50-101-2
1
1
Page 457 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 3
1 1
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
P-85881
support. Replace if damaged.
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-
101-2].
Description
Figure 50-110-1
2
3
P-85882
Page 459 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-110-2
P-85883A
Page 460 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-111-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.
Page 461 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-111-3
1 P-21860
Figure 50-111-4
5
Page 462 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
4
1 P-21862
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.
Figure 50-111-8
Page 463 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 neutral and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2 [Figure 50-111-10] as shown away from stop
P-21882
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Figure 50-111-11
1
1
N-17384
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
Figure 50-111-12 1
1 2
Page 464 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
N-17385
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item lever.
2) [Figure 50-111-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Check all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
N-22796
Figure 50-111-18
P-85883A
Page 466 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Description
Joystick Testing
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) 1
Figure 50-112-1
P-85891
P-85890
Figure 50-112-2
Page 468 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-85889
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item
2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer [Figure 50-120-2] from the front access panel.
(Item 2), and remove the left access panel (Item 3)
[Figure 50-120-1]. Remove the front access panel from the loader.
Figure 50-121-1
2 1
1
2
P-90587
P-85887
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1]. Figure 50-121-4
Figure 50-121-2
2
3 2
Page 471 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
1
1
2
P-90588
P-85884
Remove the bolt and throttle pedal (Item 1), and remove
the mounting screws (Item 2) [Figure 50-121-4].
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Remove the right inside access panel (Item 3) [Figure
50-121-4].
WARNING
1
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-0907
P-85705
Figure 50-130-1
7
Page 473 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
6
1
P-85706
5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] in until they disengage
from the window frame. 2
3
Push the rear window out the rear of the operator cab. 4
P-85704
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. Inspect and replace any damaged parts.
Clean the area before installing the rear window The items listed below refer to [Figure 50-130-3].
assembly.
1. Latch
Reverse the procedure to install the rear window.
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal
Figure 50-131-1
1 1
P-85807
Figure 50-131-2
1 1
Page 475 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-85808
From inside the operator cab, install and tighten the four
nuts (Item 1) [Figure 50-131-2] on the window bolts.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
1 1
Figure 50-132-1
1
1
1
1
2
P-85820
1 3 4 5
2
P-85819
Description
Figure 50-140-1
P-85828
Figure 50-140-4
2
P-85781A 1
2
Figure 50-140-2
2
3
2 1
1
P-85837
P-85588A P-85589A
4
3
1
1
1
P-85834
1 2
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].
2
Installation: Tighten the nut (Item 1) to 177 - 212 in.-lb.
(20 - 24 Nm) torque and nut (Item 2) [Figure 50-140-5] 1
to 80 - 97 in.-lb. (9 - 11 Nm) torque.
Page 480 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
140-5].
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].
Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Figure 50-140-13
1
1
P-85413
P-85830
Sit in operators seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
Page 482 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
to machine hours.
P-85831
Description
Figure 50-150-1
P-90837
Slide the seat and the backrest all the way forward.
1
Remove the seat belt (See Seat Belt Removal And
Installation on Page 50-30-1.)
Figure 50-150-2
P-90845
P-90835
Page 484 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-150-3
P-90836
Figure 50-150-5
1
1
P-90840
Figure 50-150-8
1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Page 485 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Figure 50-150-9
1 1
3
2
2
P-90844
1
Remove the two nuts (Item 1) and the slide rail (Item 2)
P-90842 [Figure 50-150-11] from the armrest mount.
Page 486 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3
6
5 2
4 1
P-90843
Remove the nut (Item 1), washer (Item 2), and the plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10].
Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
1
50-31-4.)
P-90867
Figure 50-160-5
2
1 1
P-90858
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].
Figure 50-160-6
Page 488 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 1
1
P-90852
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11
Page 489 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90865
Figure 50-160-12
1 1
1
1
P-90866
Figure 50-160-13
Page 490 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90864
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new when it has been removed.
side of the cab far enough to access the wire
harness. Figure 50-170-8
Figure 50-170-6
Page 492 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 1
1
P-90877
2
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove
the radio from the right side lower panel.
Disconnect the wire harnesses (Item 1) and the antenna
(Item 2) [Figure 50-170-6] (if equipped with radio). Installation: Insert a screwdriver into the slot (Item 2)
[Figure 50-170-8] to lock the tab into place.
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.
Figure 50-170-9
P-90875
Figure 50-170-10
Page 493 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
1
P-90876
Figure 50-180-1
1 1
1
P-90895
2
1
Figure 50-180-2
1
1
2
1 P-90896
Remove the air duct (Item 1) [Figure 50-180-2] (if NOTE: Replace the retainers if needed.
equipped).
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Page 497 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Page 498 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Viewing Service Codes (Standard Key Panel And Keyless Start Panel) . . . . . . . . . 60-90-1
Viewing Service Codes (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Page 500 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 FC1 FUSE CENTER 1 3
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 FC2 FUSE CENTER 2 3
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 T1 BATT GROUND 4
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T2 BUZZER GROUND 8
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 T3 FLASHER 13
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7 T6 BATT GROUND 4
C126 HORN 2 13 C441 TWO SPEED 2 7 T8 BATT GROUND 4
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 T13 BUZZER POWER 8
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5 T14 PRE HEATER 6
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C250 DOOR SENSOR 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C251 WIPER 5 9 C480 LEFT PANEL(GRAY) 12 8 T17 LEFT REAR WORK LIGHT (+) 11
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 T18 LEFT REAR WORK LIGHT (-) 11
C277 AIR RIDE SEAT 6 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C278 RIGHT SPEAKER 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C279 LEFT SPEAKER 2 9 C489 ACCESSORY 2 3,4
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8
C362 REAR AUX SOLENOID 8 7 C602 LEFT REAR TAIL LIGHT 2 11
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB CONNECTOR 48 3-5, 8-13 C611 BLOWER MOTOR 4 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW1 BRAKE SWITCH 9
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW2 BEACON SWITCH 13
C411 LEFT HANDLE 5 WAY 5 10,13 C667 DOOR KIT 6 9 SW3 HAZARD SWITCH 13
C412 HANDLE(HORN) 2 10,13 C670 EXTERIOR BEACON 6 13 SW4 HAND/FOOT, H/ISO SWITCH 9
C413 REAR ROD 2 7 C676 RADIO 6 9 SW5 POWER BOBTACH SWITCH 13
C414 REAR BASE 2 7 SW6 BUCKET POSITION SWITCH 13
C415 HIGH FLOW SOLENOID 2 7 SW8 FRONT WIPER SWITCH 9
C416 DIVERTER SOLENOID 2 7 SW9 TRAVEL CONTROL SWITCH 8
C417 REAR AUX RELIEF 2 7 J1A GATEWAY COTROLLER 34 SW10 BLOWER SWITCH 12
C418 FRONT ROD 2 7 J1B GATEWAY CONTOLLER 26 SW11 AC SWITCH 12
C419 FRONT BASE 2 7 J2A AUX CONTROLLER 34
C420 HYD LOCK 2 7 J2B AUX CONTROLLER 26
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 2 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 502 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 503 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3
T2
BUZZER (-)
C500
LEFT PANEL (BLACK) RH KEY SWITCH
9360/PUR C408 4 9360/PUR 2
C479 10 J1A 24 START
9320/PUR 9350/PUR 9350/PUR 4
BUZZER J1B 22 RUN/ENTER SW
2920/BLK C479 2 C408 40
SHEET 4 GROUND 1950/RNG/WHT 5
SHEET 3 Switched Power
1440/RED/WHT C479 1 1420/RED/WHT 1
SHEET 3 Battery (+) SHEET 3 Battery (+)
2960/BLK 3
1960/RNG/WHT 1620/RNG/WHT C479 5 SHEET 4 GROUND
SHEET 3 SHEET 3 Switched Power 6
SW9 6450/PNK C479 11
SHEET 13 Left Blinker Input
TRAVEL CONTROL C479 8
SWITCH (OPTIONAL) 6550/PNK
SHEET 13 Right Blinker Input
5 6 4500/LGN C479 9
SHEET 9 Park Break Input
4 C479 7
2700/BLK 2 3 4730/LGN
SHEET 4 Travel Control Input RH DLX PANEL
1
1590/RNG/WHT C503 5
C480 SHEET 3 Switched Power
LEFT PANEL (GRAY) C503 1
1240/RED/WHT
4750/LGN 12 SHEET 3 Battery (+)
SHEET 9 Reserved Output 5 C503 3
9310/PUR 2 2250/BLK
SHEET 9 Park Break Output SHEET 4 GROUND
PTOL
C499
(Press To Operate Loader)
9380/PUR C408 1 9380/PUR 2
J1A 20 PTOL OUTPUT
9370/PUR 9370/PUR 4
J1A 19 PTOL LED
C408 37
1930/RNG/WHT 1
SHEET 3 SWITCH POWER
2940/BLK 3
SHEET 4 GROUND
WIRING SCHEMATIC
POWER
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATTERY MEGAFUSE
FC1 FUSE 2
100.0 Amps 1180/RED/WHT
BATT_CABLE 25 A J2B 2
1025/RED 1160/RED/WHT 1150/RED/WHT
J2B 3
1240/RED/WHT
FC1 FUSE 1 SHEET 8
1400/RED/WHT
25 A C408 17 SHEET 9
1070/RED 1120/RED/WHT 1450/RED/WHT 1450/RED/WHT 1420/RED/WHT
SHEET 8
1110/RED/WHT 1440/RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130/RED/WHT
15 A J1B 3
1290/RED 1370/RED/WHT
SHEET 9
FC2 FUSE 2 1460/RED/WHT
25 A SHEET 13
1040/RED 1490/RED/WHT 1410/RED/WHT
SHEET 13
FC2 FUSE 1
25 A
1190/RED 1165/RED/WHT
SHEET 5
1010/RED
FRC 1 FUSE 6
1310/RED 30 A 1360/RED/WHT
SHEET 7
1050/RED FRC1 FUSE 5
30 A 1350/RED/WHT
SHEET 6
FRC1 FUSE 11
25 A
1300/RED 1140/RED/WHT
SHEET 12
FRC1 FUSE 10
1340/RED 20 A 1330/RED/WHT
SHEET 11
1620/RNG/WHT
FRC1 FUSE 9 SHEET 8
1940/RNG/WHT
15 A SHEET 8
1320/RED/WHT 1930/RNG/WHT
SHEET 11 SHEET 8
1060/RED 1775/RNG/WHT
SHEET 6 SHEET 9
1030/RED 1960/RNG/WHT
SHEET 6 SHEET 8
1785/RNG/WHT
SHEET 9
1950/RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
5A SHEET 8
1570/RNG/WHT
SHEET 10
FRC1 FUSE 2
1760/RNG/WHT 25 A 1850/RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A 1550/RNG/WHT
SHEET 13
FRC1 FUSE1
25 A 1750/RNG/WHT 1780/RNG/WHT
C489 A
SWITCHED 1720/RNG/WHT
POWER
C404 B Printable Version Click Here
1050/RED 30
87
1765/RNG/WHT 1790/RNG/WHT
SHEET 12
WIRING SCHEMATIC
SHEET 6
2055/BLK
2030/BLK
85 86
1795/RNG/WHT
FRC1 FUSE 7
25 A
1730/RNG/WHT
(STANDARD MACHINE)
SHEET 12 SHEET 5
FRC1 FUSE 8
25 A
S630 (S/N A3NT11001 AND ABOVE)
1580/RNG/WHT
SHEET 9
8000/TAN
1920/RNG/WHT
J1A 4
1920/RNG/WHT 1840/RNG/WHT
Sheet 4 of 13
SHEET 5
1830/RNG/WHT
C408 6 SHEET 5
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 504 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 505 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
C212
2795/BLK 1
+ POWER SOCKET
1375/RED/WHT 2
-
C209
2790/BLK C408 24 2790/BLK 2010/BLK B
C408 23 SHEET 4
1370/RED/WHT 1370/RED/WHT 1390/RED/WHT A DOME LIGHT
SHEET 3
4760/LGN C
*
C676
1885/RNG/WHT 1
2885/BLK 2
C129 C279
1210/RED/WHT A
SHEET 3
1580/RNG/WHT
C408 16
1580/RNG/WHT * 1865/RNG/WHT B LEFT SPEAKER
1
2
+ 7820/WHT
7830/WHT
3
4 RADIO CONN
2820/BLK C -
ACCESSORY
CONN C278
2 - 7810/WHT 6
RIGHT SPEAKER 1 7800/WHT 5
+
2730/BLK C408 33 2730/BLK
SHEET 4
C277
1510/RNG/WHT 4
2210/BLK 5 AIR RIDE
SEAT
C482 SEATBAR
SENSOR C667 C250 SENSOR SHOWN
3910/LBL C408 45 3910/LBL A GND
SHEET 4 4750/LGN 4740/LGN 4 4740/LGN 1 WITH DOOR OPEN
SHEET 8 DOOR SENSOR
1400/RED/WHT 5 1400/RED/WHT 2 C251
3920/LBL C408 46 3920/LBL B SIG SHEET 3
J1B 11 1860/RNG/WHT D SW PWR
6 7330/WHT C PARK WIPER
3930/LBL 3900/LBL C408 44 3900/LBL C PWR MOTOR
J1B 24 1570/RNG/WHT 7300/WHT A LOW
3500/LBL
+5V SHEET 6 B GND
1850/RNG/WHT 1850/RNG/WHT 1 1850/RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310/WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN 3 2 FRONT WIPER
SHEET 8 1 2840/BLK 2 2840/BLK SWITCH C252
9310/PUR 4 5
SHEET 8 7310/WHT L
1775/RNG/WHT 6
SHEET 3 WASHER
2930/BLK
SHEET 4 2845/BLK X MOTOR
WIRING SCHEMATIC
7165991Standard Cab Harness (STANDARD MACHINE)
7176098 Deluxe Cab Harness S630 (S/N A3NT11001 AND ABOVE)
Sheet 5 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7175752
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
GROUND
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
2080/BLK
SHEET 5
2070/BLK
SHEET 5 C408 32
2940/BLK 2950/BLK 2950/BLK
SHEET 8
2960/BLK 2510/BLK
SHEET 8 J1B 16
2920/BLK 2500/BLK 2110/BLK T6
SHEET 8 J1B 15 BATT GND
2250/BLK 2540/BLK
SHEET 8 J2B 16
2550/BLK 2090/BLK
J2B 15
2765/BLK
SHEET 11
2745/BLK
SHEET 12
2790/BLK T8
SHEET 9 BATT GND
2780/BLK
SHEET 13
2730/BLK
SHEET 9
2620/BLK
SHEET 11
2630/BLK 2720/BLK
SHEET 11 C103 B C489 B
2650/BLK 2600/BLK 2600/BLK
SHEET 10
2640/BLK 2810/BLK 2390/BLK
SHEET 11 SHEET6
2610/BLK
SHEET 11
2200/BLK
SHEET 7
2751/BLK
SHEET 13
2450/BLK
SHEET 7
2741/BLK
SHEET 13
2785/BLK 2710/BLK 2300/BLK T1
SHEET 13 SHEET 5 BATT GND
2930/BLK 2480/BLK
SHEET 9 C408 42 SHEET 7
2830/BLK 2900/BLK 2900/BLK
SHEET 13
2700/BLK 2000/BLK
SHEET 8 SHEET 11
3530/LBL
SHEET 7
3800/LBL
SHEET 6
3910/LBL
SHEET 9
3310/LBL 3010/LBL
SHEET 7 J1B 17
3410/LBL
SHEET 7
3110/LBL
SHEET 6
3510/LBL
SHEET 6
3710/LBL
SHEET 6
Printable Version Click Here
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 6 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 506 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 507 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
MANUAL
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
CONTROLS
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C409
K
G RIGHT HANDLE
1590/RNG/WHT A
4940/LGN H
J2A 30
4930/LGN J SKI CTRL
J2A 31
4920/LGN E DETENT FLOW
J2B 21
4910/LGN F
J2A 13 TWO SPD
4310/LGN C -
J2B 17
4320/LGN D
J2B 18 PWM
4300/LGN B +
J2B 23
C410
K
D LEFT HANDLE
4840/LGN C
J2A 28
4830/LGN B SKI CTRL
J2A 22
4820/LGN G
J2A 12
4810/LGN F SIDE SHIFT
J2A 11
1570/RNG/WHT 1710/RNG/WHT A
SHEET 3
1560/RNG/WHT J
J2B 22
H
E
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A 7100/WHT C103 C 7100/WHT T19 1 B
+ BACKUP ALARM
2650/BLK 7001923 A HORN
SHEET 4 -
T20 1
C421
2370/BLK 3
J1A 10
4370/LGN 1 TILT SPOOL LOCK Printable Version Click Here
J1B 7
2
CAN BUS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
9160/PUR/WHT
C503 2
9260/PUR RH DLX PANEL
C503 4
9200/PUR 9270/PUR 9230/PUR C408 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR
GWY CTRLR J1B 8 C479 4
9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
1830/RNG/WHT 1
#
SHEET 3
2070/BLK 2
SHEET 4 RIGHT
9560/PUR/WHT 3
JOYSTICK
9660/PUR 4
9220/PUR
J2B 8 AUX CTRLR C449
9120/PUR/WHT
J2B 9 1840/RNG/WHT 1 #
SHEET 3
2080/BLK 2
SHEET 4
9540/PUR/WHT 3 LEFT
9640/PUR 4 JOYSTICK
C426
9500/PUR/WHT A
J1B 14
9600/PUR B
J1B 20
9400/PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730/RNG/WHT E
SHEET 3
1165/RED/WHT F
SHEET 3
2710/BLK G
SHEET 4
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 8 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 508 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 509 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
LIGHTS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C434-1
2735/BLK B LEFT FRONT
6100/PNK A WORK LIGHT
37.00 Watts
C434-2
2765/BLK C408 28 2765/BLK 2750/BLK B
SHEET 4 LEFT FRONT
6110/PNK A WORK LIGHT
50.00 Watts
C435-1
6000/PNK C408 25 6000/PNK 6120/PNK A RIGHT FRONT
2760/BLK B WORK LIGHT
37.00 Watts
C435-2
6130/PNK A
RIGHT FRONT
2705/BLK B WORK LIGHT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610/BLK 2
1330/RED/WHT 30 C103 A 6310/PNK RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK 6320/PNK 1 TAIL LIGHT
2000/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 LEFT REAR
6320/PNK 2640/BLK 2 TAIL LIGHT
J1A 5 SHEET 4
6330/PNK
J1A 31
2620/BLK T16 1
SHEET 4 RIGHT REAR
6210/PNK WORK LIGHT
REAR
LIGHT T15 1
1320/RED/WHT 30 C103 H
SHEET 3 6200/PNK 6200/PNK T17 1
87
2630/BLK LEFT REAR
85 86 SHEET 4 WORK LIGHT
2045/BLK T18 1
2035/BLK
SHEET 7
6210/PNK
J1A 17
6230/PNK
J1A 28
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 9 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
ENGINE
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
STARTER
STARTER C109
1030/RED 30 J1A 22
8250/TAN B 8250/TAN R M
B SHEET 3
SHEET 3 87 8200/TAN A 8200/TAN S 1015/RED
C110
2005/BLK 85 86 8210/TAN B
SHEET 12 J1A 7 S 1020/RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800/RNG/WHT 1815/RNG/WHT
SHEET 12
EXCITATION
2015/BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120/TAN D5 8100/TAN B 8100 TAN PULL 24.5 OHM
1350/RED/WHT 30 0.33 OHM
SHEET 3 87 8150/TAN J1B 4 8800/TAN A 8800 TAN HOLD
J1A 30
2810/BLK 2800/BLK C 2800 BLK
85 86 SHEET4
2025/BLK 8110/TAN
SHEET 7 J1A 3
C106 GLOW
3600/LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550/TAN
3610/LBL B GND 1060/RED J1A 14
SHEET 3 87 8500/TAN
3800/LBL T14 PRE HEATER
SHEET 4
3210/LBL B SIG 85 86
ENGINE COOLANT 2016/BLK 8510/TAN
3200/LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055/BLK
SHEET 3
C104
C107
3500/LBL B +5V PWR
SHEET 9
3520/LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510/LBL A GND SENDER (0.5 ~ 4.5V)
SHEET 4
C406
C355 C FUEL
3100/LBL 3100/LBL A SIG
J1B 12 SENDER
3110/LBL 3110/LBL B GND
SHEET 4
Printable Version Click Here
C355 D
SHEET 4
3710/LBL
C405
B GND WIRING SCHEMATIC
3700/LBL A SIG
AIR FILTER
J1A 16 SWITCH
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 10 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 510 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 511 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HVAC
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C630
7021/WHT 7020/WHT C408 34 7020/WHT B
J1A 11
7023/WHT 2570/BLK C
3320/LBL A
THERMOSTAT
C350
B C483
7024/WHT A EVAPORATOR 2560/BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980/RNG/WHT A DBL
C486 7220/WHT B WHT (TEMP CONTROL
C355 A SWITCH)
7024/WHT 7025/WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290/BLK 2280/BLK D SIG
SHEET 13
D4 2130/BLK C GND HEATER
1900/RNG/WHT 1910/RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT C408 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3 6 C611
2005/BLK
SHEET 6 3 1970/RNG/WHT A 14.00 Amps High
1790/RNG/WHT
SHEET 3 1520/RNG/WHT B 7.50 Amps Med BLOWER
1815/RNG/WHT
SHEET 6 7320/WHT C 5.00 Amps Low MOTOR
8020/TAN
J1A 21 2580/BLK D
2745/BLK 2745/BLK
SHEET 4
C408 22
7040/WHT
SW11
AC SWITCH
1 C
2100/BLK
3
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 11 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
HYDRAULICS
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
TRACTION
LOCK C425 TRACK MACHINES
30 4150, LGN
1360, RED/WHT J1A
SHEET 3 87 4100, LGN B C308
BRAKE
2025, BLK 4200, LGN A 4200, RED A SOLENOID
SHEET 6 85 86 J1B
2035, BLK 4110, LGN 2200, BLK C 2200, BLK B 9.8 OHM
SHEET 11 J1A SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C
C362 C414
4440, LGN A 4440, LGN 1 SIG OPTIONAL REAR BASE
J2B
2440, BLK B 2440, BLK 2 GND SOLENOID
J2A 7.5 OHM 12V
C420
C413 2410, BLK B
4430, LGN C 4430, LGN 1 SIG OPTIONAL REAR ROD J1A HYD LOCK SOLENOID
J2B 4410, LGN A
2430, BLK D 2430, BLK 2 GND SOLENOID J1B 9.8 OHM 12V
J2A 7.5 OHM 12V
C105
C416 HYDRAULIC
3410, LBL B CHARGE
4450, LGN E 4450, LGN 1 SIG OPTIONAL DIVERTER
J2B SOLENOID 3420, LBL C PRESSURE
2450, BLK F 2450, BLK 2 GND J1B
SHEET 4 7.5 OHM 3400, LBL A 0.5-7.5V
J1B
12 V
C417 +8V
C108
4480, LGN G 4480, LGN 1 SIG
HYDRAULIC
J2B OPTIONAL REAR AUXILIARY 3310, LBL B TEMPERATURE
2480, BLK H 2480, BLK 2 GND SHEET 4
SHEET 4 RELIEF SOLENOID 3300, LBL A
J1A SENDER
9.8 OHM
12 V 500 - 3000 OHM
C112
C415
OPTIONAL HIGH FLOW 3430, LBL A HYDRAULIC
2460, BLK B GND J1A
J2A SOLENOID 3530, LBL B FILTER SWITCH
4460, LGN A SIG SHEET 4
J2B 7.5 OHM
12 V
C418
2330, BLK 2 GND FRONT ROD SOLENOID (MALE)
J2A
4330, LGN 1 SIG 3.3 OHM PWM
J2B
C419
2340, BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A
4340, LGN 1 SIG 3.3 OHM PWM
J2B
C437
2360, BLK 2 GND
J1A TWO SPEED
4360, LGN 1 SIG MAKEUP SOLENOID
J1B
C441 Printable Version Click Here
2350, BLK 2 GND
J1A
J1B
4350, LGN 1 SIG TWO SPEED SOLENOID
WIRING SCHEMATIC
C446
J1A
2910, BLK 2 GND HYDRAULIC
FAN SOLENOID
(STANDARD MACHINE)
4010, LGN 1 SIG
7.2 OHM
J1B
12 V S630 (S/N A3NT11001 AND ABOVE)
Sheet 12 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
Page 512 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 513 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
OPTIONS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SW5
POWER
BOBTACH
SWITCH
C408 26 1 7000/WHT C408 9 7000/WHT
C411 1410/RED/WHT 1410/RED/WHT 1380/RED/WHT 2
C408 15 SHEET 3
B 6010/PNK 6010/PNK 1430/RED/WHT 1200/RED/WHT 3
4 7010/WHT C408 10 7010/WHT
C 6550/PNK 5
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515/PNK 6500/PNK 6500/PNK 6530/PNK FLASHER CONN SW2
5 PIN E 6540/PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415/PNK 6400/PNK 6400/PNK 6430/PNK 6570/PNK
2725/BLK C607
6450/PNK 6 C355 E
SHEET 8 5 A 7010/WHT
SW3 1 4
C103 E HAZARD SWITCH 2 C670 STROBE 1 2 B 2770/BLK 2751/BLK 2751/BLK
6410/PNK (PINS 3 & 6 3
4 6700/PNK E BEACON C355 B
6510/PNK INTERNALLY 5 3 2290/BLK SHEET 4
2850/BLK 2420/BLK D SHEET 12
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK
F
2780/BLK C408 30 2780/BLK A 7000/WHT C355 F
SHEET 4 B
6440/PNK
6540/PNK RIGHT PWR BOB OPEN
BLINKER
WIRING SCHEMATIC
(STANDARD MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 13 of 13
(PRINTED APRIL 2009)
Printed In U.S.A. 7175752
CONNECTOR ASSIGNMENTS CONNECTOR ASSIGNMENTS (ACS)
NUM OF NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 J1A GATEWAY COTROLLER 34 C428 TILT ACTUATOR 8 14
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26 C429 LIFT ACTUATOR 8 14
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 J2A AUX CONTROLLER 34 C467 LIFT PEDAL LOCK 3 14
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7 J2B AUX CONTROLLER 26 C468 TILT PEDAL LOCK 3 14
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 J1-ACS ACS CONTROLLER 8 C469 TILT HANDLE 3 14
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11 J2-ACS ACS CONTROLLER 10 C470 TILT PEDAL 3 14
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 J3-ACS ACS CONTROLLER 10 C471 LIFT PEDAL 3 14
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 J5 DRIVE CONTROLLER 50 C472 LIFT HANDLE 3 14
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7
C126 HORN 2 13 C441 TWO SPEED 2 7 FC1 FUSE CENTER 1 3
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 FC2 FUSE CENTER 2 3
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5,15 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5,15
C250 DOOR SENSOR 2 9 C459 LEFT JOYSTICK 4 15
C251 WIPER 5 9 C460 RIGHT JOYSTICK 4 15 T1 BATT GROUND 4
C252 WASHER 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T2 BUZZER GROUND 8
C277 AIR RIDE SEAT 6 9 C480 LEFT PANEL(GRAY) 12 8 T3 FLASHER 13
C278 RIGHT SPEAKER 2 9 C482 SEATBAR SENSOR 3 9 T6 BATT GROUND 4
C279 LEFT SPEAKER 2 9 C483 TEMP CONTROL SWITCH 3 12 T8 BATT GROUND 4 CONNECTOR ASSIGNMENTS (SJC)
C308 BRAKE SOLENOID 2 7 C486 AC COMPRESSOR 2 12 T13 BUZZER POWER 8 NUM OF
CONN DESCRIPTION SHEET
C350 AC EVAPORATOR SWITCH 2 12 C489 ACCESSORY 2 3,4 T14 PRE HEATER 6 PINS
C355 DLX or STD FUEL HARNESS 6 6,12,13 C492 ACS/SJC/AWS 1 8 3,5,9,14,15 RIGHT REAR WORK LIGHT(+) C536 RIGHT SWASHPLATE 4 15
T15 11
C362 REAR AUX SOLENOID 8 7 C493 ACS/SJC/AWS 2 4 3,4,14,15 T16 RIGHT REAR WORK LIGHT(-) 11 C537 LEFT SWASHPLATE 4 15
C404 BACKUP ALARM 2 3,10 C497 SJC HORN/BLINKER 3 13 LEFT REAR WORK LIGHT (+) 11 C428 TILT ACTUATOR 8 15
T17
C405 AIR FILTER SWITCH 2 6 C499 PTOL 4 8 LEFT REAR WORK LIGHT (-) 11 C429 LIFT ACTUATOR 8 15
T18
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8 10 C453 RIGHT QUAD A DRIVE 4 15
T19 BACKUP ALARM
C408 CAB CONNECTOR 48 3-5, 8-13 C503 RH DLX PANEL 6 5,8 T20 BACKUP ALARM (GND) 10 C454 LEFT QUAD DIRVE 4 15
C409 RIGHT HANDLE 10 10 C602 LEFT REAR TAIL LIGHT 2 11 C474 BRAKE LIGHT 1 15
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11
C411 LEFT HANDLE 5 WAY 5 10,13 C606 POWER BOBTACH OPEN 2 13 SW1 BRAKE SWITCH 9 C501 A22 PUMP HARNESS 8 15
C412 HANDLE(HORN) 2 10,13 C607 POWER BOBTACH CLOSE 2 13 SW2 BEACON SWITCH 13 C544 LEFT FORWARD DRIVE 2 15
C413 REAR ROD 2 7 C611 BLOWER MOTOR 4 12 SW3 HAZARD SWITCH 13 C545 LEFT REVERSE DRIVE 2 15
C414 REAR BASE 2 7 C630 THERMOSTAT 3 12 SW4 HAND/FOOT, H/ISO SWITCH 9 C546 RIGHT FORWARD DRIVE 2 15
C415 HIGH FLOW SOLENOID 2 7 C635 HEATER VALVE 6 12 SW5 POWER BOBTACH SWITCH 13 C547 RIGHT REVERSE DRIVE 2 15
C416 DIVERTER SOLENOID 2 7 C667 DOOR KIT 6 9 SW6 BUCKET POSITION SWITCH 13 C542 LEFT SWASHPLATE 3 15
C417 REAR AUX RELIEF 2 7 C670 EXTERIOR BEACON 6 13 SW8 FRONT WIPER SWITCH 9 C543 RIGHT SWASHPLATE 3 15
C418 FRONT ROD 2 7 C676 RADIO 6 9 SW9 TRAVEL CONTROL SWITCH 8 C707 OBW STOP BRAKE LIGHT 3 15
C419 FRONT BASE 2 7 SW10 BLOWER SWITCH 12
C420 HYD LOCK 2 7 SW11 AC SWITCH 12
Printed In U.S.A.
Page 514 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 515 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 2 of 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
PTOL
C499 (Press To Operate Loader)
9380, PUR C408 9380, PUR 2
J1A
9370, PUR 9370, PUR 4
J1A
C408
1930, RNG/WHT 1
SHEET 3
2940, BLK 3
SHEET 4
WIRING SCHEMATIC
Printed In U.S.A.
Page 516 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 517 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
POWER
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
FC1 FUSE 3 ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
25 A COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
1270, RED 1170, RED/WHT
C493 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
FC1 FUSE 4 SJC CONTROL PAGE 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550, LGN C408 4550, LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS) C492
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
SWITCH
1785, RNG/WHT 2 1 4275, LGN C408 4275, LGN
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 C492
3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060, BLK 5 6 4235, LGN C408 4235, LGN 4230, LGN
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
4 SHEET 10
4220, LGN 4240, LGN
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14 C492 SHEET 10
SJC CONTROL PAGE 15
C212
2795, BLK 1
+
1375, RED/WHT 2 POWER SOCKET
-
C209
2790, BLK C408 2790, BLK 2010, BLK B
C408 SHEET 4
1370, RED/WHT 1370, RED/WHT 1390, RED/WHT A DOME LIGHT
SHEET 3
4760, LGN C
*
C676
1885, RNG/WHT 1
2885, BLK 2
C129 C279
1210, RED/WHT A
SHEET 3
1580, RNG/WHT
C408
1580, RNG/WHT * 1865, RNG/WHT B LEFT SPEAKER
1
2
+ 7820, WHT
7830, WHT
3
4 RADIO CONN
2820, BLK C -
ACCESSORY
CONN C278
2 - 7810, WHT 6
RIGHT SPEAKER 1 7800, WHT 5
+
2730, BLK C408 2730, BLK
SHEET 4
C277
1510, RNG/WHT 4
AIR RIDE
2210, BLK 5
SEAT
C482 SEATBAR
SENSOR C667 C250 SENSOR SHOWN
3910, LBL C408 3910, LBL A GND
SHEET 4 4750, LGN 4740, LGN 4 4740, LGN 1 WITH DOOR OPEN
SHEET 8
1400, RED/WHT 5 1400, RED/WHT 2 DOOR SENSOR C251
3920, LBL C408 3920, LBL B SIG SHEET 3
J1B 1860, RNG/WHT D SW PWR
6 7330, WHT C PARK
3930, LBL 3900, LBL C408 3900, LBL C PWR WIPER
J1B 1570, RNG/WHT 7300, WHT A LOW MOTOR
+5V 3500, LBL
SHEET 6 B GND
1850, RNG/WHT 1850, RNG/WHT 1 1850, RNG/WHT 3 E
SHEET 3
C408 1 2
3 7310, WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500, LGN 3 2 FRONT WIPER
SHEET 8 1 2840, BLK 2 2840, BLK SWITCH C252
9310, PUR 4 5
SHEET 8 7310, WHT L
1775, RNG/WHT 6
SHEET 3 WASHER
2930, BLK
SHEET 4 2845, BLK X MOTOR
WIRING SCHEMATIC
7165991 Standard Cab (ACS & SJC MACHINE)
7176098 Deluxe Cab S630 (S/N A3NT11001 AND ABOVE)
Sheet 5 of 15
GROUND
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
2765, BLK
SHEET 11
2745, BLK
SHEET 12
2790, BLK T8
SHEET 9 BATT GND
2780, BLK
SHEET 13
2730, BLK
SHEET 9
2620, BLK
SHEET 11
2630, BLK 2720, BLK
SHEET 11 C103 C489
2650, BLK 2600, BLK 2600, BLK
SHEET 10
2640, BLK 2810, BLK 2390, BLK
SHEET 11 SHEET 6
2610, BLK
SHEET 11
2200, BLK
SHEET 7
2751, BLK
SHEET 13
2450, BLK
SHEET 7
2741, BLK
SHEET 13
2785, BLK 2710, BLK 2300, BLK T1
SHEET 13 SHEET 5 BATT GND
2930, BLK 2480, BLK
SHEET 9 C408 SHEET 7
2830, BLK 2900, BLK 2900, BLK
SHEET 13
2700, BLK 2105, BLK
SHEET 8 SHEET 11
2530, BLK 2000, BLK
SHEET 10
2520, BLK
SHEET 10
3530, LBL
SHEET 7
3800, LBL
SHEET 6
3910, LBL
SHEET 9
3310, LBL 3010, LBL
SHEET 7 J1B
3410, LBL
SHEET 7
3110, LBL
SHEET 6
3510, LBL
SHEET 6
3710, LBL
SHEET 6
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 6 of 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
MANUAL
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
CONTROLS
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
C409
RIGHT HANDLE
2530, BLK K
SHEET 4
4230, LGN G
SHEET 9
1590, RNG/WHT A
4940, LGN H
J2A
4930, LGN J SKI CTRL
J2A
4920, LGN E DETENT FLOW
J2B
4910, LGN F
J2A TWO SPD
4310, LGN C -
J2B
4320, LGN D
J2B PWM
4300, LGN B +
J2B
C410
LEFT HANDLE
K
4640, LGN D
J2A
4840, LGN C
J2A
4830, LGN B SKI CTRL
J2A
4820, LGN G
J2A
4810, LGN F SIDE SHIFT
J2A
1570, RNG/WHT 1710, RNG/WHT A
SHEET 3
1560, RNG/WHT J
J2B
4240, LGN H
SHEET 9
2520, BLK E
SHEET 4
C411
E
C
A
D TURN SIGNAL
B
C412
C404 C103 T19
7100, WHT 7100, WHT B
+ BACKUP ALARM
2650, BLK 7001923 A HORN
SHEET 4 -
T20
C421
2370, BLK 3
J1A TILT SPOOL LOCK
4370, LGN 1
J1B
2
(NOT USED WITH ACS) Printable Version Click Here
2380, BLK
C422
3
WIRING SCHEMATIC
J1A LIFT SPOOL LOCK
J1B
4380, LGN 1
2
(NOT USED WITH ACS) (ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 7 of 15
Printed In U.S.A.
Page 520 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 521 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
CAN BUS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
9160, PUR/WHT
C503
9260, PUR RH DLX PANEL
C503
C408
9200, PUR 9270, PUR 9210, PUR 9280, PUR 9230, PUR 9230, PUR 9240, PUR 9250, PUR 9650, PUR 9630, PUR
J1B C479
GWY CTRLR 9100, PUR/WHT 9170, PUR/WHT 9110, PUR/WHT 9180, PUR/WHT 9130, PUR/WHT 9130, PUR/WHT 9140, PUR/WHT 9150, PUR/WHT 9550, PUR/WHT 9530, PUR/WHT LEFT PANEL
J1B C479
120 OHM C408 120 OHM
RESISTOR RESISTOR C450
SHEET 3
1830, RNG/WHT 1 #
2070, BLK 2
SHEET 4 RIGHT
9560, PUR/WHT 3 JOYSTICK
9660, PUR 4
9240, PUR
C492
9140, PUR/WHT ACS CTRLR C449
C492
9290, PUR 1840, RNG/WHT 1 #
C492 SHEET 3
9190, PUR/WHT DRIVE CTRLR 2080, BLK 2
C492 SHEET 4 LEFT
9540, PUR/WHT 3
JOYSTICK
9640, PUR 4
9220, PUR
J2B AUX CTRLR
9120, PUR/WHT
J2B
C426
9500, PUR/WHT A
J1B
9600, PUR B
J1B
9400, PUR D
J1B
C CAN (Remote Start Tool, ACD)
1730, RNG/WHT E
SHEET 3
1165, RED/WHT F
SHEET 3
2710, BLK G
SHEET 4
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 8 of 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
LIGHTS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
C434-1
2735, BLK B LEFT FRONT
6100, PNK A WORK LIGHT
37.00 Watts
C434-2
2765, BLK C408 2765, BLK 2750, BLK B
SHEET 4 LEFT FRONT
6110, PNK A WORK LIGHT
50.00 Watts
C435-1
6000, PNK C408 6000, PNK 6120, PNK A RIGHT FRONT
2760, BLK B WORK LIGHT
37.00 Watts
C435-2
6130, PNK A
RIGHT FRONT
2705, BLK B WORK LIGHT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610, BLK 2
1330, RED/WHT 30 C103 6310, PNK RIGHT REAR
SHEET 3 87 6340, PNK 6310, PNK 6320, PNK 1
TAIL LIGHT
2105, BLK 85 86 C602
SHEET 4
2045, BLK 6330, PNK 1
6320, PNK 2640, BLK 2 LEFT REAR
J1A SHEET 4 TAIL LIGHT
6330, PNK
J1A
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 9 of 15
Printed In U.S.A.
Page 522 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 523 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
ENGINE
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
30 J1A
8250, TAN B 8250, TAN R M
B SHEET 3
SHEET 3 1030, RED 8200, TAN A 8200, TAN
87 S 1015, RED
C110
2005, BLK 85 86 8210, TAN B
SHEET 12 J1A S 1020, RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800, RNG/WHT 1815, RNG/WHT
SHEET 12
EXCITATION
2015, BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120, TAN D5 8100, TAN B 8100 TAN PULL
1350, RED/WHT 30 24.5 OHM
SHEET 3 87 8150, TAN J1B 8800, TAN A 8800 TAN HOLD 0.33 OHM
J1A
2810, BLK 2800, BLK C 2800 BLK
85 86 SHEET 4
2025, BLK 8110, TAN
SHEET 7 J1A
C106 GLOW
3600, LBL A SIG PLUG
J1A ENGINE SPEED SENSOR 30 8550, TAN
3610, LBL B GND 1060, RED J1A
SHEET 3 87 8500, TAN
3800, LBL T14 PRE HEATER
SHEET 4
3210, LBL B SIG 85 86
ENGINE COOLANT 2016, BLK 8510, TAN
3200, LBL A GND J1A
J1B SENSOR (500-3000 OHM) 2055, BLK
SHEET 3
C104
C107
3500, LBL B +5V PWR
SHEET 9
3520, LBL C SIG ENGINE OIL PRESSURE
J1A
3510, LBL A GND SENDER (0.5-4.5V)
SHEET 4
C406
C355
3100, LBL 3100, LBL A SIG
J1B FUEL
3110, LBL 3110, LBL B GND SENDER
SHEET 4
C355 Printable Version Click Here
C405
SHEET 4
3710, LBL
3700, LBL
B
A
GND
SIG AIR FILTER
WIRING SCHEMATIC
J1A SWITCH
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 10 of 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
HVAC
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
C630
7021, WHT 7020, WHT C408 7020, WHT B
J1A
7023, WHT 2570, BLK C
3320, LBL A
THERMOSTAT
C350
B C483
7024, WHT A EVAPORATOR 2560, BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980, RNG/WHT A DBL
C486 7220, WHT B WHT (TEMP CONTROL
C355 SWITCH)
7024, WHT 7025, WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290, BLK 2280, BLK D SIG
SHEET 13
D4 2130, BLK C GND HEATER
1900, RNG/WHT 1910, RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140, RED/WHT 30 OFF
SHEET 3 1500, RNG/WHT C408 1500, RNG/WHT 5 2
87
1
2030, BLK 85 86 4
SHEET 3 6 C611
2005, BLK
SHEET 6 3 1970, RNG/WHT A 14.00 Amps High
1790, RNG/WHT
SHEET 3 1520, RNG/WHT B 7.50 Amps Med BLOWER
1815, RNG/WHT
SHEET 6 7320, WHT C 5.00 Amps Low MOTOR
8020, TAN
J1A 2580, BLK D
2745, BLK 2745, BLK
SHEET 4
7040, WHT
C408
SW11
AC SWITCH
1 C
2100, BLK
3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 11 of 15
Printed In U.S.A.
Page 524 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 525 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDRAULICS
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
TRACTION
LOCK C425 TRACK MACHINES
30 4150/LGN
1360/RED/WHT J1A 13
SHEET 3 87 4100/LGN B C308
BRAKE
2025/BLK 4200/LGN A 4200/RED A SOLENOID
SHEET 6 85 86 J1B 6
2035/BLK 4110/LGN 2200/BLK C 2200/BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C SOLENOID
C362 C414
OPTIONAL REAR BASE
4440/LGN A 4440/LGN 1 SIG
J2B 5 SOLENOID
2440/BLK B 2440/BLK 2 GND 7.5 OHM 12V
J2A 2
C420
C413 2410/BLK B HYD LOCK
OPTIONAL REAR ROD J1A 1 SOLENOID
4430/LGN C 4430/LGN 1 SIG 4410/LGN A
J2B 7 SOLENOID J1B 13 9.8 OHM 12V
2430/BLK D 2430/BLK 2 GND 7.5 OHM 12V
J2A 10
C105
C416 HYDRAULIC
3410/LBL B CHARGE
4450/LGN E 4450/LGN 1 SIG OPTIONAL DIVERTER
J2B 4 SOLENOID 3420/LBL C PRESSURE
2450/BLK F 2450/BLK 2 GND J1B 1
SHEET 4 7.5 OHM 3400/LBL A 0.5-7.5V
J1B 23
12 V
C417 +8V
C108 HYDRAULIC
4480/LGN G 4480/LGN 1 SIG OPTIONAL REAR AUXILIARY 3310/LBL B TEMPERATURE
J2B 6 RELIEF SOLENOID SHEET 4
2480/BLK H 2480/BLK 2 GND 3300/LBL A SENDER
SHEET 4 9.8 OHM J1A 32 500 - 3000 OHM
12 V
C112
C415 3430/LBL A HYDRAULIC OIL
2460/BLK B GND OPTIONAL HIGH FLOW J1A 34 FILTER SWITCH
J2A 26 SOLENOID 3530/LBL B
4460/LGN A SIG SHEET 4
J2B 26 7.5 OHM
12 V
C418
2330/BLK 2 GND
J2A 18 FRONT ROD SOLENOID (MALE)
4330/LGN 1 SIG 3.3 OHM PWM
J2B 19
C419
2340/BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
4340/LGN 1 SIG 3.3 OHM PWM
J2B 13
C437
2360/BLK 2 GND
J1A 27 OPTIONAL TWO SPEED
4360/LGN 1 SIG
J1B 25 MAKEUP SOLENOID
C441
2350/BLK 2 GND TWO SPEED
Printable Version Click Here
J1A 26
4350/LGN 1 SIG SOLENOID
J1B 26
C446
WIRING SCHEMATIC
HYDRAULIC
J1A 18
J1B 19
2910/BLK
4010/LGN
2
1
GND
SIG
FAN SOLENOID
7.2 OHM
(ACS & SJC MACHINE)
12 V
S630 (S/N A3NT11001 AND ABOVE)
Sheet 12 of 15
Printed In U.S.A.
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
OPTIONS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
SW5
POWER
BOBTACH
SWITCH
C408 7000, WHT C408 7000, WHT
C411 1410, RED/WHT 1410, RED/WHT 1380, RED/WHT 2 1
C408 SHEET 3
B 6010, PNK 6010, PNK 1430, RED/WHT 1200, RED/WHT 3
4 7010, WHT C408 7010, WHT
C 6550, PNK 5
LEFT C408 SHEET 8 D1 X T3 6
HANDLE A 6515, PNK 6500, PNK 6500, PNK 6530, PNK FLASHER CONN SW2
5 PIN E 6540, PNK L BEACON
C408 D2 SWITCH PWR BOB CLOSE
D 6415, PNK 6400, PNK 6400, PNK 6430, PNK 6570, PNK
C607
6450, PNK 2725, BLK 6 C355
SHEET 8 SW3 5 A 7010, WHT
1 4
C103 HAZARD SWITCH 2 C670 STROBE B 2770, BLK 2751, BLK 2751, BLK
6410, PNK 3 1 2
(PINS 3 & 6 6700, PNK E BEACON
6510, PNK 4 3 2290, BLK C355 SHEET 4
INTERNALLY SHEET 12
5 2850, BLK 2420, BLK D
INSULATED) 6
C103 C
LEFT C606
A
BLINKER B 2775, BLK
C408 F C355
2780, BLK 2780, BLK A 7000, WHT
SHEET 4 B
6440, PNK
6540, PNK RIGHT PWR BOB OPEN
BLINKER
SW6
BUCKET
POSITION
C408
1550, RNG/WHT 1550, RNG/WHT SWITCH
SHEET 3
3 2
7022, WHT 1
C126
SHEET 4 SHEET 4 4
C412 2785, BLK B 2830, BLK 5
B 7210, WHT C408 7210, WHT A 6 C423
LEFT HANDLE C408 D3
2 PIN A 1460, RED/WHT 7022, WHT 7030, WHT A
SHEET 3 BUCKET
B POSITION
2741, BLK 2740, BLK 9.8 OHM
SHEET 4
C497
7200, WHT C
J2A SJC
6420, PNK A HORN/BLINKER
J2A
6520, PNK B
J2A
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S630 (S/N A3NT11001 AND ABOVE)
Sheet 13 of 15
Printed In U.S.A.
Page 526 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 527 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
ACS
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
CONTROLS
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
J1-ACS
H 2280/BLK
2670/BLK See manual controls for harness
2770/BLK
2240/BLK
connection
MAINFRAME HARNESS 1170/RED/WHT HANDLE TILT
C409 C466
C492 HALL SENSOR
K A
G 2250/BLK 8 J3-ACS HANDLE
G B
7 B 1190/RED/WHT LOCK
A
C 4450/LGN 2 C 1180/RED/WHT H
4220/LGN 5 J SKI CTRL
4275/LGN 3 C429 LIFT ACTUATOR E DETENT
9240/PUR 1 D 4690/LGN 8 F FLOW
9140/PUR/WHT 4 7 C TWO SPD
1740/RNG/WHT 6 6 D
F 4680/LGN 5 PWM
B
C493 J 2260/BLK 4
A 4 H 2270/BLK 1 GND
3 C410
E 4670/LGN 2 SIG
2 K
D 1530/RNG/WHT 3 PWR
1 D
B FLOAT
C
C428 TILT ACTUATOR
B SKI CTRL
C472 K 4790/LGN 8
J2-ACS G
2650/BLK B B GND 7 SIDE
F
F 4650/LGN C C SIG HANDLE LIFT 6 SHIFT
A
1510/RNG/WHT A A PWR HALL SENSOR A 4780/LGN 5
J C465
4
H A
1630/RNG/WHT 3 PWR HANDLE
E B
4770/LGN 2 SIG LOCK
H 2770/BLK 1 GND
C411
E
C467 E
A 2 C
B 4280/LGN 1 A
C 2510/BLK 3 LIFT D TURN SIGNAL
D SOLENOID B
C468
2 C412
C471
1520/RNG/WHT 1 PWR
J 4660/LGN 3 SIG LIFT PEDAL
2660/BLK 2 GND HALL SENSOR
Printed In U.S.A.
J5 - DRIVE CONTROLLER
29 2510/BLK 2580/BLK
1540/RNG/WHT
C454
3
1
GND
PWR
4680/LGN
C429
5
6
LIFT
ACTUATOR SJC
LEFT SPEED
CONTROLS
33 3020/LBL 2 SIG SENSOR 4690/LGN 8
34 3080/LBL 4 SIG 2630/BLK 1 GND
40 1640/RNG/WHT C453
4
1530/RNG/WHT 1 PWR 4670/LGN 2 SIG
2570/BLK 3 GND 7
23 3000/LBL 2 SIG
RIGHT SPEED 1610/RNG/WHT 3 PWR
SENSOR
24 3070/LBL 4 SIG
1500/RNG/WHT
C428 TILT ACTUATOR
2250/BLK
2770/BLK
C536 1630/RNG/WHT 3 PWR SCHEMATIC INDEX
1810/RNG/WHT 2 C543 HARNESS, A22 PUMP 7169309 OVERVIEW PAGE 1,2
4
2810/BLK 4 2810/BLK 1 GND POWER PAGE 3
4770/LGN 2 SIG
8 4720/LGN 3 4720/LGN 3 SIG RIGHT GROUND PAGE 4
6
1710/RNG/WHT 1 1710/RNG/WHT 2 PWR
SWASHPLATE CAN BUS PAGE 5
1 GND
ENGINE PAGE 6
C537
4780/LGN 5
HYDRAULICS PAGE 7
1820/RNG/WHT 2 C542 7
CAB DISPLAY PAGE 8
2860/BLK 4 2860/BLK 1 GND 4790/LGN 8
CABIN PAGE 9
7 4950/LGN 3 4950/LGN 3 LEFT
SIG MANUAL CONTROLS PAGE 10
SWASHPLATE
1770/RNG/WHT 1 1770/RNG/WHT 2 PWR K LIGHTS PAGE 11
HVAC PAGE 12
J2-ACS
C501 C546 J
E OPTIONS PAGE 13
43 4260/LGN 1 4260/LGN 1
RIGHT FORWARD DRIVE H ACS CONTROL PAGE 14
42 2660/BLK 2 2660/BLK 2
F SJC CONTROL PAGE 15
C547
G
C WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
44 4250/LGN 3 4250/LGN 1
RIGHT REVERSE DRIVE D GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
45 2650/BLK 4 2650/BLK 2 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
B
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
C545 A
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
ACS CONTROLLER
31 4280/LGN 5 4280/LGN 1 GROUNDING 2000 THROUGH 2999 BLACK BLK
41 2680/BLK 6 2680/BLK 2 LEFT REVERSE DRIVE
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C544 G ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
J1-ACS
21 4270/LGN 7 4270/LGN 1 A LIGHTS 6000 THROUGH 6999 PINK PNK
11 2670/BLK 8 2670/BLK 2 LEFT FORWARD DRIVE ACCESSORIES 7000 THROUGH 7999 WHITE WHT
F
E ENGINE 8000 THROUGH 8999 TAN TAN
D COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
C474 HARNESS, OBW STOP LTS 7151696 C707 B COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
26 4210/LGN A 1730/RNG/WHT A H
6600/PNK B C HARNESS, JOYSTICK 7163706
C450 C460
87 2730/BLK C
30 1 1830/RNG/WHT +12V PWR 1
C492
4210/LGN 85 86 2 2070/BLK GND 2
12 9190/PUR/WHT 8 BRAKE RIGHT
LIGHT 4 9660/PUR CAN 4
22 9290/PUR 7 BRAKE LIGHT RELAY LOW JOYSTICK
4 4550/LGN 2
K 3 9560/PUR/WHT CAN 3
6 4220/LGN 5 HIGH
16 4275/LGN 3 A
D C449 C459
J3-ACS
9140/PUR/WHT 4
9240/PUR 1 F 1 1840/RNG/WHT +12V PWR 1
1740/RNG/WHT 6
MAINFRAME H
2 2080/BLK GND 2
50 1750/RNG/WHT HARNESS J LEFT
47 1250/RED/WHT C 4 9640/PUR CAN LOW 4
C493 JOYSTICK
48 1260/RED/WHT 1235/RED/WHT 2 B
3 9540/PUR/WHT CAN HIGH 3
27 2470/BLK 2235/BLK 3 E
28 2490/BLK 1170/RED/WHT 1 G
2240/BLK 4
B
SHEET4 -
BACKUP
(CONNECTS TO BACKUP ALARM
ALARM C404 ON MFR
HARNESS)
Printed In U.S.A.
Page 528 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
ELECTRICAL SYSTEM INFORMATION
CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520
3510
C
B
C
B
3520
3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
Page 529 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HOLD PULL
B
15 ohm
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch.
Page 530 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
3
700 3
710 SPLICE () - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
-
H
+
engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)
C129 C479
C480 C434-1
C434-2
C482
T13
T2
C499
C503
SW1
C435-1
C435-2
Page 532 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
C500
C408
C126
MS2824
C209
C499
T13
C482 T2
SW1
SW3
C500
C503 SW2
SW6
C435-1
C435-2
SW4
C667
Page 533 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
C426
SW5
SW9
C611 C252
C630
C635
C126
C129 C253
C277 C279
C449 C483
C450 S3
T3
C278
C676
C212
MS2827
C426
C405
C103 C 350
408
T11 T6
T1
T8 C355
T10 T4
C101 C105
C110 C104
C362
T12 C107
FRC1
C486 C446
Page 534 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
FC1
C108 FC2
C423 C362
C441 C489
C415 C497
J2A
C409 J2B
C419 J1A
C420 C410 J1B
C418 C404 C411
C421 C437 C412
C422
C425
C492
C493
MS2825
Description
Figure 60-10-1
P-13849
P-85472
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operators
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Page 536 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.
Figure 60-10-2
P-85411
Figure 60-10-3
Page 537 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85412
1 13 17 21 25
5 7 9 11
2 18 22 26
14
3 15 19 27
23
6 8 10 12
4 16 20 24 28
The location and sizes are shown in the table below and on the decal above. Relays are identified by the letter R in the
AMP column.
RE RE RE
ICON DESCRIPTION AMP ICON DESCRIPTION AMP ICON DESCRIPTION AMP
F F F
1 Alternator 15 11 Glow Plugs R 21 Bobcat 25
Controller
Page 538 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Power
Solenoid Testing
Figure 60-10-4
P9175
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Page 539 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
WARNING
1
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
P-85473
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F (16C) before
Disconnect the negative (-) cable (Item 1) [Figure 60-20- connecting to a charger. Unplug charger before
1]. connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Remove the battery hold down clamp (Item 2) [Figure
60-20-1]. Battery gas can explode and cause serious injury.
W-2066-0705
Disconnect the positive (+) cable (Item 3) [Figure 60-20-
1] from the battery.
Servicing
Figure 60-20-3
P-09589 P-09590
Page 542 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Using A Booster Battery (Jump Starting) After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
If it is necessary to use a booster battery to start the the positive terminal (Item 2) [Figure 60-20-4].
engine, BE CAREFUL! There must be one person in the
operators seat and one person to connect and
disconnect the battery cables.
Figure 60-20-4
2
4
3
P-85474
Belt Adjustment
1
The alternator belt is a special maintenance free type that
is pretensioned over the pulleys. This belt eliminates the
need for a tensioning device and does not require
periodic adjustment. Contact your Bobcat dealer for
replacement parts.
Belt Replacement
Figure 60-30-1
Remove the top alternator mounting bolt (Item 1) and
loosen the bottom alternator mounting bolt (Item 2)
[Figure 60-30-3].
Figure 60-30-4
Page 545 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90472
Figure 60-30-2
1
1
P-90475
WARNING
AVOID INJURY OR DEATH 2
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Check the fuse for the alternator in the fuse panel. If fuse
WARNING is burned, find the cause and repair / replace. If fuse is in
doubt, remove it and check for continuity.
Page 546 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
AVOID INJURY OR DEATH Check the electrolyte level in the battery. Add distilled
Keep arcs, sparks flames and lighted tobacco away water as needed. (Does not apply to maintenance free
from batteries. When jumping from booster battery batteries.)
make final connection (negative) at machine frame.
Verify the charge of the battery. Make sure battery is fully
Do not jump start or charge a frozen or damaged charged.
battery. Warm battery to 60F (16C) before
Disconnect the battery cables (negative first, then
connecting to a charger. Unplug charger before
positive). Inspect the cable clamps and battery posts for
connecting or disconnecting cables to battery. Never
corrosion. Remove acid or corrosion from the battery and
lean over battery while boosting, testing or charging.
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
Battery gas can explode and cause serious injury.
prevent corrosion. Reconnect the cable to the positive
W-2066-0705
terminal.
Figure 60-30-6
P-85914
P-85916
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-7] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Figure 60-30-8
1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
Page 547 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70 F (Alternator Temperature).
Figure 60-30-9
P-85917
Page 548 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
If voltage is still above 14.7 volts at 70 F (Alternator
Temperature), then remove alternator for replacement or
repair.
IMPORTANT 2
Figure 60-30-12
Figure 60-30-10
1
Page 549 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
2
1
P-85609
P-85914
2 4 7 13 14
3 12
2
P-85611
10 11
5
Remove the top alternator mounting bolt (Item 1) and the 9
bottom alternator mounting bolt (Item 2) [Figure 60-30- 8
13].
18
Page 550 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
17
16
15 C-3529B
2
Bat
S 3
M
1
Cranking
Motor
3
A-1992 P-85857
The key switch must be in the OFF position. Open the rear door.
The battery must be at full charge. Disconnect the negative (-) cable from the battery.
The cable connections on the battery must be clean and Disconnect the wires and positive (+) cable (Item 1)
tight. [Figure 60-40-3] from the starter solenoid.
Connect a jumper wire between S terminal and BAT Installation: Tighten the nut to 10.8 - 12.3 ft.-lb. (14,7 -
Page 551 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
If the starter turns but does not turn the engine, the Disconnect the wire connector (Item 2) [Figure 60-40-3]
starter drive has a defect. from the two solenoid wires.
Figure 60-40-2 Remove the three mounting bolts (Item 3) [Figure 60-40-
3].
Cranking
Motor
A-1991
Parts Identification
15
12 37
16
14
17 20
19 18
Page 552 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
14
6
29
1 4
3
28
2
27
24. Yoke
35 25. Holder
26. Bracket
27. Ring
22 26
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
35. Boot
24
36. Bracket
37. Bearing
B-19824
Left Panel
Figure 60-50-1
2 3 12
7
1
16
4 13
6 8 11
9 10 15
5 14
17
20
18 19
Page 553 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
21 22
23
P-90726B
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left flasher signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right flasher signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED will
light.) Press a second time to add REAR work lights. (Left and right green LEDs
will light.) Press a third time to turn all lights off. (Left and right green LEDs will
be off.)
Page 554 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Press and hold five seconds to display software version in display screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green LED
will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED will
light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
Hourmeter (On start up)
Engine RPM
Battery voltage
Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running. Press
once to unlock the brakes. Allows you to use the steering levers or joystick(s)
to move the loader forward or backward when using the backhoe attachment or
for service. (See TRACTION LOCK OVERRIDE in this manual.) Press a
second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS System when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold three seconds to engage Drive Response and Steering Drift
Compensation. (See DRIVE RESPONSE and STEERING DRIFT
COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all loaders) Press the top to engage the Parking Brake. Press the bottom to disengage.
(See PARKING BRAKE in this manual.)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)
Display Screen
Operating hours.
Engine revolutions per minute (RPM).
Speed management setting.
Maintenance clock countdown.
Battery voltage.
Service codes.
Engine preheat countdown.
Steering drift compensation setting.
Drive response setting.
Figure 60-50-2
2
Page 555 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3 4 5 6 7
P-76461A
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
7. Service
Figure 60-50-3
FUNCTION /
REF. DESCRIPTION
OPERATION
ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
Controls.
Page 556 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
ROTATING Press the top to turn
BEACON (Option) light ON; bottom to
P-85285 or turn OFF.
STROBE LIGHT
(Option)
This machine may be equipped with a Standard Key
Panel [Figure 60-50-3].
Figure 60-50-4
FUNCTION /
REF. DESCRIPTION
OPERATION
ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
1 Controls.
5
FOUR-WAY Press the top to turn
6 FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
7
Page 557 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Right Panel (Deluxe Instrumentation Panel) 6. STOP Button: Used to stop the engine and shut
down the loaders electrical system.
Figure 60-50-5
7. RUN Button: Used to turn on the loaders electrical
system.
1
The switch location (Item 8) [Figure 60-50-5] can have
different functions depending on machine configuration.
2 See the following table for more information.
3 FUNCTION /
REF. DESCRIPTION
OPERATION
ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
Controls.
4
5
6
SELECTABLE Press the top to select
7 JOYSTICK ISO Control Pattern;
CONTROLS (SJC) bottom to select H
(Option) Control Pattern.
Page 558 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
FOUR-WAY Press the top to turn
FLASHER LIGHTS lights ON; bottom to
P-90212A
(Option) turn OFF.
1. Keypad (1 through 0): The keypad has two ROTATING Press the top to turn
functions: BEACON (Option) light ON; bottom to
or turn OFF.
- To enter a number code (password) to allow starting STROBE LIGHT
the engine. (Option)
Right Panel (Deluxe Instrumentation Panel) (Contd) Use the numbers on the keypad to enter the password.
An asterisk will appear on the display screen for each
Figure 60-50-6 number entered [Figure 60-50-6]. The left scroll button
can be used to backspace if an incorrect number is
entered.
P-90388
The first screen you will see on your new loader will be as
shown in [Figure 60-50-6].
Change Language:
Figure 60-50-7
Page 560 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85320
P-85319
This machine may be equipped with a Right Switch Panel
[Figure 60-50-8].
This machine may be equipped with a Left Switch Panel
[Figure 60-50-7].
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER Press and hold the up arrow to
NO.
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
(Option)
3 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
POSITIONING bottom to disengage.
(Option)
1 1
1 1 2
2
P-85929
P-85928
NOTE: Inspect and replace the seal as needed (Item 3) [Figure 60-50-11].
3) [Figure 60-50-9].
Figure 60-50-12
Figure 60-50-10
1 P-85931
P-85930
Figure 60-50-13
3
3
1
1 1
1
2
2 P-90527
P-90819A
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-15].
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-13]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 25 - 35
panel mounting bolts to prevent stripping of the threaded in.-lb. (3 - 4 Nm) torque.
holes in the panels. Tighten the panel screws to 25 - 35
in.-lb. (3 - 4 Nm) torque. NOTE: Inspect and replace the seal as needed (Item
Page 562 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
3) [Figure 60-50-15].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-13]. Figure 60-50-16
Figure 60-50-14
P-90530
P-90818A
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-16].
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-14]. Remove the panel from the loader cab.
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Removal And Installation on Page 60-50-9.)
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-18
Figure 60-50-17
2
P-85947
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) Removal And Installation on Page 60-50-9.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-9.) Figure 60-50-21
Figure 60-50-19
1 2
1
P-85943
1
P-85945
Remove the two fasteners (Item 1) and the knob (item 2)
[Figure 60-50-21].
Remove the two fasteners (Item 1) [Figure 60-50-19].
Figure 60-50-22
Figure 60-50-20
Page 564 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-85944
P-85946
Figure 60-60-1
1
P-85436
1
Figure 60-60-4
P-85433
Figure 60-60-2
P-85435
1
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
1 turn.
P-85434
Figure 60-60-5
1 2
P-85274
P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 & 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light to far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.
Page 566 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85437 P-85783
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Description
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B
Page 568 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
Page 569 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
J1B
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL
12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
Page 570 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL
Connector Identification
Auxiliary Controller
1 1
34 26
J2A J2B
Page 571 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645
J2A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
Page 572 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA
J2B
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 1180 RED/WHT COMPUTER FUSE POWER OUT
3 1150 RED/WHT COMPUTER FUSE POWER OUT
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
Page 573 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 574 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85900
Description
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
Page 576 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-21843
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 60-71-1
P-85903
Page 577 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-71-2
P-85902
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operators right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
RIGHT
HAND DRIVE HYDRAULIC
PANEL CONTROL MOTOR
ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS
GEAR ENGINE
INTERNAL CAN BUS
Page 579 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
PUMP
SERIAL TT BUS
RIGHT
JOYSTICK
FWD / REV
ISO SWASH PLATE
SWITCH LEFT
JOYSTICK SENSORS
AUXILIARY DRIVE
CONTROL PUMP
LEFT SPEED
HAND SENSOR
PANEL
ACD HYDRAULIC
EXTERNAL CONTROL MOTOR
CAN BUS
GATEWAY
CONTROL
NA1208
60-72-2
P-64295
60-72-3
P-64296
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4
Page 582 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-72-2
J S
P-64325
P-64324
Figure 60-80-1
1
P-28302
P-64765
The tools listed will be needed to do the following
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loaders controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness
drive motor is rotating. The end of the sensor is magnetic [Figure 60-80-2]
and counts the magnetic pulses as a rotating disc,
attached to the motor carrier shaft, rotates by the sensor MEL1563 or 6689779-Remote Start Tool
end. Multimeter
The speed sensor is sealed with an O-ring (Item 1) Raise the lift arms and install an approved lift arm support
Page 583 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
[Figure 60-80-1] to keep hydraulic oil inside the motor device. (See Installing on Page 10-20-1.)
carrier and dirt out.
Raise the operator cab. (See Raising on Page 10-30-2.)
P-64762
Page 584 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Disconnect the speed sensor wire connector (Item 3)
[Figure 60-80-3] from the loader harness wire connector.
Figure 60-80-4
P-64976
Figure 60-80-5 1
1 P-64764
Raise the lift arms and install an approved lift arm support Figure 60-80-8
device. (See Installing on Page 10-20-1.)
Figure 60-80-6
2
P-64765
1
P-64762
Figure 60-80-9
1
1
P-26292
Figure 60-80-12
The electrical connector can be replaced.
Figure 60-80-10
Page 586 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
4 1
1
3 2 P-26295
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
2 2 2
The ACTIVE WARNINGS
screen displays active
service codes. Press [9]
to view the next service
code if more than one is
present. Press [4] to
display a history of
service codes.
P-76461H
P-76461P
1 P-76455G
The WARNINGS >
HISTORY screen will list
the Service Code
Press the INFORMATION button (Item 1) to cycle the Number (CODE),
DATA DISPLAY (Item 2) [Figure 60-90-1] until the Hourmeter reading when
service code screen is displayed. If more than one the error occurred
SERVICE CODE is present, the codes will scroll on the (HOUR), and the User
DATA DISPLAY. (USER) who was logged
Page 587 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 588 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
A8332 ACD output D overcurrent D7541 Right swash plate sensor out of range high
A8402 ACD output E error ON D7542 Right swash plate sensor out of range low
A8403 ACD output E error OFF D7543 Left forward drive short to battery
A8405 ACD output E short to battery D7544 Left reverse drive short to battery
A8406 ACD output E short to ground D7545 Right forward drive short to battery
A8407 ACD output E open circuit D7546 Right reverse drive short to battery
A8432 ACD output E overcurrent D7547 Right front steer extend short to battery
A8502 ACD output F error ON D7548 Left front steer extend short to battery
A8503 ACD output F error OFF D7549 Right rear steer extend short to battery
A8505 ACD output F short to battery D7550 Left rear steer extend short to battery
A8506 ACD output F short to ground D7551 Steer pressure short to battery
A8507 ACD output F open circuit D7552 Back-up alarm error ON
A8532 ACD output F overcurrent D7553 Left forward drive short to ground
A8602 ACD output G error ON D7554 Left reverse drive short to ground
A8603 ACD output G error OFF D7555 Right forward drive short to ground
A8605 ACD output G short to battery D7556 Right reverse drive short to ground
A8606 ACD output G short to ground D7557 Right front steer extend short to ground
A8607 ACD output G open circuit D7558 Right front steer retract short to ground
A8702 ACD output H error ON D7559 Left front steer extend short to ground
A8703 ACD output H error OFF D7560 Left front steer retract short to ground
A8705 ACD output H short to battery D7561 Right rear steer extend short to ground
A8706 ACD output H short to ground D7562 Right rear steer retract short to ground
A8707 ACD output H open circuit D7563 Left rear steer extend short to ground
D7564 Left rear steer retract short to ground
D3905 Left joystick X-axis not in neutral D7565 Steer pressure short to ground
H1221 Right Primary out of range high L0102 Left panel button 1 error ON
H1222 Right Primary out of range low L0202 Left panel button 2 error ON
H1224 Right Primary not in neutral L0302 Left panel button 3 error ON
H1321 Left Primary out of range high L0402 Left panel button 4 error ON
H1322 Left Primary out of range low L7404 Left panel main controller no communication
H1324 Left Primary not in neutral L7672 Left panel programming error
H2305 Rear base solenoid short to battery
H2306 Rear base solenoid short to ground M0116 Air filter not connected
H2307 Rear base solenoid open circuit M0117 Air filter plugged
H2332 Rear base solenoid overcurrent M0216 Hydraulic/Hydrostatic filter not connected
H2405 Rear rod solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2406 Rear rod solenoid short to ground M0309 Battery voltage low
H2407 Rear rod solenoid open circuit M0310 Battery voltage high
H2432 Rear rod solenoid overcurrent M0311 Battery voltage extremely high
H2505 Rear aux relief short to battery M0314 Battery voltage extremely low
H2506 Rear aux relief short to ground M0322 Battery voltage out of range low
H2605 Front base solenoid short to battery M0409 Engine oil pressure low
Page 590 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
M0821 Engine coolant temperature out of range high M2602 Glow plug relay error ON
M0822 Engine coolant temperature out of range low M2603 Glow plug relay error OFF
M0909 Fuel level low M3128 Interrupted power failure
M0921 Fuel level out of range high M3204 Workgroup no communication
M0922 Fuel level out of range low M3304 Deluxe panel no communication
M1016 Hydraulic charge filter not connected M3505 Hydraulic fan short to battery
M1017 Hydraulic charge filter plugged M3506 Hydraulic fan short to ground
M1121 Seat bar sensor out of range high M3507 Hydraulic fan open circuit
M1122 Seat bar sensor out of range low M3532 Hydraulic fan overcurrent
M1305 Fuel hold solenoid short to battery M3705 Two-speed secondary short to battery
M1306 Fuel hold solenoid short to ground M3706 Two-speed secondary short to ground
M1307 Fuel hold solenoid open circuit M3707 Two-speed secondary open circuit
M1402 Fuel pull output error ON M3732 Two-speed secondary overcurrent
M1403 Fuel pull output error OFF M3805 Auxiliary hydraulic lock short to battery
M1407 Fuel pull output open circuit M3806 Auxiliary hydraulic lock short to ground
M1428 Fuel pull output failure M3807 Auxiliary hydraulic lock open circuit
M1502 Traction lock pull output error ON M3832 Auxiliary hydraulic lock overcurrent
M1503 Traction lock pull output error OFF M4109 Alternator low
M1507 Traction lock pull output open circuit M4110 Alternator high
M1528 Traction lock pull output failure M4404 Auxiliary no communication
M1605 Traction lock hold solenoid short to battery M4621 5 volt sensor supply out of range high
M1606 Traction lock hold solenoid short to ground M4622 5 volt sensor supply out of range low
M1607 Traction lock hold solenoid open circuit M4721 8 volt sensor supply out of range high
M1705 Hydraulic lock valve solenoid short to battery M4722 8 volt sensor supply out of range low
M1706 Hydraulic lock valve solenoid short to ground M4802 Front light relay error ON
M7002 Switched power output error ON W3263 Pedal lock short to ground
M7003 Switched power output error OFF W3264 Pedal lock short to battery
M7007 Switched power output open circuit W3265 Sensor supply out of range
M7028 Switched power output failure W3266 Battery voltage out of range
M7304 Remote control no communication W3267 Handle/pedal switch flipped while operating
M7316 Remote control no signal from transmitter W3275 Recovery mode error
M7423 Main controller not programmed W3276 CAN joystick information error
M7497 Main controller software updated W3277 Remote control information error
M7504 Drive no communication W3905 Left joystick X-axis not in neutral
M7604 Left display panel no communication W4005 Right joystick X-axis not in neutral
M7748 Key switch multiple W4007 Right joystick Y-axis not in neutral
Description
Figure 60-100-1
1 2 3
4
3
P-85413C
Page 594 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
bar, start engine and press the PRESS TO OPERATE
2. Raise seat bar fully. All three BICS lights (Items 1, 2
LOADER button.
and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE and PARKING BRAKE] on left instrument
10. Raise lift arms about 6 feet (2 meters) off the ground.
panel must be ON. The PRESS TO OPERATE
LOADER button light will turn OFF.
11. Turn key OFF or press STOP button and wait for the
engine to come to a complete stop.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
3. Sit in operators seat, lower seat bar and press the
(foot pedal, hand control or joystick) to lower the lift
PRESS TO OPERATE LOADER button (Item 6).
arms. Lift arms must not lower.
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
13. Move the control (foot pedal, hand control or joystick)
60-100-2]. Raise the seat bar. The light must be OFF.
to tilt the bucket (or attachment) forward. The bucket
(or attachment) must not tilt forward.
Inspecting The Seat Bar Sensor (Engine RUNNING)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
Page 595 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
Page 597 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Testing
Figure 60-110-1
1
P-4698
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adapter (MEL1567) for the following procedure:
Page 598 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-110-2
P-4699
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor.
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. circuit test. (See Bobcat Interlock Control System (BICS)
Circuit Test on Page 60-110-4.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.
Figure 60-110-5
3
N-19383
2 IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Page 599 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-110-7 NOTE: The sensor test light (Item 3) [Figure 60-110-8]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
P-85653
Page 600 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-110-8
P-4703
Figure 60-110-9
P-85413
Figure 60-110-10
Page 601 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-4699
Description
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
SOLUTION SUGGESTIONS
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesnt, 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 Page 60-01.)
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Check the brake solenoid mounting nut for correct torque.
8. Check wire connections for loose connector body.
Page 604 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check the flywheel RPM sensor and wiring.
Inspecting
Figure 60-120-1
P-85923
1
Check the wire connections at the engine speed sensor
P-85413 (Item 1) [Figure 60-120-2].
Description
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
Page 608 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-130-1
1
3
2
1 P13733
1 1
1 1
P13725
P13725 P13732
Figure 60-130-4
3 1
2
P13735
2 1
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.
Page 610 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
Figure 60-130-5
P13725 P13732
P13725 P13732
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
Page 611 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 6 inch piece of heat
shrink tube side on the end of the wires. Remove the
Cut the wires (Item 2) [Figure 60-130-12] below the heat shrink tube from the end of the wires before routing
switch handle and remove switch handle. through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
Page 612 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700 C-Terminal - Purple/White
Figure 60-130-17
3 1
2
1 P13735
Figure 60-130-20
1
Page 614 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
3
P-90994 2
Figure 60-130-21
N-17741
Connect the handle harness connectors to the sensor Lift and Tilt Actuator
and lock solenoid connectors [Figure 60-130-21]. 1. Terminal-Black/Green-Larger diameter wire (16
gauge)
Actuator Connector Disassembly And Assembly 2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
NOTE: Actuator shown removed for clarity. Not gauge)
necessary for procedure. 4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
Page 615 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-66842
Figure 60-130-24
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
Disconnect the harness connector (Item 1) [Figure 60-
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 35 - 40 ft.-lb. (47 - 54 Nm)
Disconnect the harness connector (Item 2) [Figure 60- torque.
130-24] from the handle lock solenoid connector.
Figure 60-130-27
Figure 60-130-25
Page 616 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-21789
P-21832
Figure 60-130-28
2
1
1
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].
Figure 60-130-29
1
Page 617 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90982
Figure 60-130-31
1 1
P-90992
1
P-24269
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Tighten the bolts to 90 in.-lb. (10,2 Nm) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite #242 to the threads. and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 Nm)
torque.
Figure 60-130-32
Figure 60-130-34
Page 618 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
5
4
3 1
2
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130- Check the O-ring (Item 1) [Figure 60-130-34] for
32]. damage. Replace as necessary.
Identification Chart
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA1014A / B-15781E
6 STEERING LEVERS
7 LIFT ARM PEDAL
8 TILT PEDAL
9 LIFT ARM BYPASS CONTROL
10 ATTACHMENT FUNCTION CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS
Description
Group 0 = No Jumpers
Page 620 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Page 622 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Page 624 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Identification Chart
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA1164A / B-15781E
4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9 TILT PEDAL
10 LIFT ARM BYPASS CONTROL
11 ATTACHMENT FUNCTION CONTROL
12 FRONT AUXILIARY HYDRAULICS
13 NOT USED
14 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS
Description
Group 0 = No Jumpers
Page 626 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
14 9 1 4,5,6 1 4,5,6 K,H 3
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
14 9 1 1 1 1 K,M,H 3
Page 628 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
14 9 - - - - K,H 3
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
2 2 2 - - K from front 11
12 7 (pin side of 9
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
14 9 - - - - K,H 3
Page 630 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Identification Chart
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA1165A / B-19874A
Description
Group 0 = No Jumpers
Page 632 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Page 634 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
12
4 5
7
2 2 2 - - K from front 9 11
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Page 636 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Figure 60-150-1
1 2
2
3
1
P-76450
P16119
The tools listed will be needed to do the following
procedure:
The tools listed will be needed to do the following
procedure: Order from Bobcat Parts P/N: 6689779 - Remote Start
Tool (Service Tool) Kit
MEL1563 or 6689779 - Remote Start Tool
MEL1565 - Service Tool Harness Control Kit Includes:
MEL1566 - Service Tool Harness Communicator
(Computer Interface) 6689778 - Remote Start Tool (Service Tool)
NOTE: Make all connections with the key in the OFF 6689747 - Loader Service Tool Harness
Page 637 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Connect the remote start tool to the loader. (See Connect the other end to the connector on the Remote
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Start Tool (Service Tool).
1.)
Connect the Remote Start Tool (Service Tool) to the
NOTE: Refer to BobcatNET for PC requirements and loader. (See REMOTE START TOOL (SERVICE TOOL)
the latest Service Analyzer software. KIT - 6689779 on Page 10-61-1.)
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting
controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
Page 639 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
controller or actuator.
If a Service PC is not available, (See Lift And Tilt
The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-11.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path cannot be attained or replacing the 72 F (22 C), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
Actuator out of neutral. The spool did not return to the Contamination in the spool.
neutral window during the test.
The spool end cap may be defective or the centering
NOTE: A time out will occur if the test cannot be spring may be broken. Inspect the end cap and the
completed within 8 seconds. If this happens, centering spring, replace if necessary.
retry the test.
The wire harness or connectors may have an
Figure 60-160-2 intermittent short. Check the connections and wire
Page 640 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Run Actuator Test harnesses.
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
Misaligned Assembly Actuator
Pin End Cap / Center Spring
Contamination in Spool Wire Harness
Controller
Contamination in Spool
SJC
Page 642 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85307
Figure 60-160-5
P-85413C
P-85493A
Figure 60-160-6 NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
SJC complete, code W3224 (Calibration
Performed) will be generated.
P-85307
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-85493A
Page 644 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
P-85307
P-85307
Figure 60-160-11
B-19873
P-85960
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
Page 645 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85413C
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-12] while holding the left joystick in
position.
Figure 60-160-15
P-85307
Allow the left joystick to go to the neutral position [Figure Figure 60-160-18
60-160-15].
Figure 60-160-16
Page 646 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85760A
1
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-85962
NOTE: If the wheels or tracks do not stop moving in
Full Speed Forward in 2 minutes or less, there
Move and hold the left joystick to the forward position was an error in the calibration procedure. The
[Figure 60-160-19] until the forward calibration is operator must shut the loader OFF, and start
completed. the calibration procedure from the beginning.
Page 648 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2 After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
P-64321
P-85307B 1
Figure 60-160-26
P-85413C
Page 650 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Performed) will be generated.
Calibration is complete.
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to activate the BICS.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
6. Current drive response setting will be displayed briefly
Driving on uneven terrain such as crowned road in the data display.
surfaces.
NOTE: Raising the seat bar or changing control
Figure 60-161-1 mode (ISO / H) will cause the machine to
disengage from steering drift compensation.
STEERING DRIFT COMPENSATION The last displayed setting will remain in effect
until the machine is turned OFF.
Page 651 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
B-23580C
2
1 2
1
NA1011
NA1011
3 4 5
3 4
P-76461L
P-76461N
P-76461M
P-76461K
P-76461O
Left Joystick Right Joystick
Page 652 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
saved by pressing and holding the PRESS TO
6 7 OPERATE LOADER button (Item 1) for three seconds.
[SET] (Item 3) will appear in the data display (Item 2)
P-24820C P-24802C [Figure 60-161-3] and the machine will exit from the
steering drift compensation adjustment menu.
Press and hold the PRESS TO OPERATE LOADER
OR
button (Item 1) for three seconds to enter the drive
response adjustment menu. Press the PRESS TO
Press the PRESS TO OPERATE LOADER button to exit
OPERATE LOADER button (Item 1) again to adjust the
from the steering drift compensation adjustment menu
loaders steering drift compensation setting. The current
without saving the current setting. [DONE] (Item 4) will
steering drift compensation setting will appear in the data
appear in the data display (Item 2) [Figure 60-161-3] and
display (Item 2) [Figure 60-161-2].
the upper left and upper right buttons on the left joystick
will no longer make changes to steering drift
Press the upper left button (Item 6) on the left joystick to
compensation.
adjust the machine left. [S-L01] (Item 3) through a
maximum of [S-L10] will appear in the data display (Item
NOTE: The last displayed steering drift
2) [Figure 60-161-2]. The number will increase by one
compensation setting will remain in effect
each time you press the button. The higher the number,
until the machine is turned OFF. The machine
the greater the amount of steering drift compensation to
will revert back to the last saved setting the
the left. Adjustments to steering drift compensation will
next time it is started.
be effective immediately.
Description
1
2
P-85922
Page 654 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-170-2
P-85921
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0.050 in. (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
2 2
Select
[2. LANGUAGES].
ICON DESCRIPTION
DATE / TIME
ENTER button
ALARM CLOCKS
(Owner password required if Job Clock is locked.)
Page 656 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Select [3. ALARM CLOCK]
Select alarm using keypad. P-90394 / P-90380 / P-90382 / P-90381
Use the keypad to enter time.
Use the right scroll button to set AM / PM / 24 hour.
Press [4] to pause alarm or [9] to reset.
Select
VITALS screen icon
Press [6] to cycle between METRIC or ENGLISH (M /
E) readouts.
Master Password:
Owner Password:
Allows for full use of the loader and to setup the Enter new owner
Deluxe Instrumentation Panel. There is only one password and press
owner password. It must be used to change the owner [ENTER].
Page 657 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
User Password:
Press [ENTER].
Allows starting and operating the loader; cannot
change password or any of the other setup features.
Select user.
Page 658 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90394 / P-90399 / P-90397 / P-90400
Press [ENTER].
P-90394/P-90399/P-90397/P-90400/P-90401/P-90395/P-90383/P-90407
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Press the RUN button to turn on the loaders electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
P-90805
Page 659 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
Enter the five digit owner password using the number
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.
The Maintenance Clock alerts the operator when the next Figure 60-200-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-200-1
1
1
3 P-90404
P-76461R
The Deluxe Instrumentation Panel, if equipped, will
display a bar (Item 1) [Figure 60-200-3] showing time
During machine operation, a two beep alarm will sound remaining until next service. This bar will turn red when
when there are less than 10 hours until the next planned service is past due. NEXT MAINTENANCE DUE will
maintenance. change to MAINTENANCE PAST DUE and display the
number of hours past due.
The remaining hours before maintenance is required will
appear in the data display (Item 1) for five seconds while Keys [4] and [9] can be used to adjust the service
the service icon (Item 3) and hourmeter icon (Item 2) interval when the owner is logged in [Figure 60-200-3].
[Figure 60-200-1] flash.
Page 661 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 60-200-2
P-90402
Setup
Figure 60-200-4
P-76110
P-64243A
Figure 60-200-5
Page 662 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
1
P-76113
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.
Setup (Contd)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller. 1
Figure 60-200-9 4 2
P-76111
Setup (Contd)
Figure 60-200-12
1
2
P-76110
Figure 60-200-15
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-12].
Page 664 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NOTE: If the interval is set to 10 hours or less, the
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13
P-76111
Reset
Figure 60-200-16
P-76455H
Description
Inspecting
Figure 60-210-1
2
P-90531A
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
NOTE: Joystick equipped machines do not have Torque the screws (Item 3) [Figure 60-210-4] securing
back-up alarm switches and cannot be the switch to the bracket to 14 - 19 in.-lb. (1,6 - 2,1 Nm).
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound. Repeat adjustment procedure for the other switch.
Standard Controls and ACS (If Equipped) Lower the operator cab. (See Lowering on Page 10-30-
3.)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.) Inspect back-up alarm system for proper function. (See
Inspecting on Page 60-210-1.)
Place the steering levers in the neutral position.
Figure 60-210-3
Page 668 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85722
Figure 60-210-4
2
3
P-85723A
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6
Page 670 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
5. The wiring is damaged.
6. The joystick controller is not working correctly.
Figure 60-210-5
2
1
P-85723A
Switch Removal And Installation bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
NOTE: Joystick equipped machines do not have installation of switches, adjust the switches (See
back-up alarm switches. Adjusting Switch Position on Page 60-210-2.) and
inspect back-up alarm operation (See Inspecting on
Standard Controls and ACS (If Equipped) Page 60-210-1.) are required.
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-220-1
1
1
1
P-90886
1
P-90885 P-90901
Figure 60-220-2
2
Page 673 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 3
P-90903 P-90902
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Page 676 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-80-11
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm And Bridge Arm Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm Shaft - Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Description
Figure 70-10-1
P-85028
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Free Length (Intake and Exhaust) 1.39 - 1.40 (35,1 - 35,6)
Allowable Limit 1.36 (34,6)
Fitted Length (Intake and Exhaust) 1.24 (31,5)
Setting Load/ Setting Length (Intake and Exhaust) 14.3 lb./1.24in (63,5 N/31,5 mm)
Allowable Limit 10.3 lb./1.24in (45,9 N/31,5 mm)
Tilt Allowable Limit (Intake and Exhaust) 0.039 (1,0)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 40 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 14 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 0.58949 - 0.58992 (14,973 - 14,984)
I.D. of Rocker Arm Bushings 0.59056 - 0.59125 (15,000 - 15,018)
Oil Clearance Between Rocker Arm & Bushing 0.00063 - 0.0017 (0,016 - 0,045)
Allowable Limit 0.0059 (0,15)
Page 680 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Camshaft
Journal O.D. 1 1.3754 - 1.3759 (34.934 - 34,950)
Bearing I.D. 1 1.3780 - 1.3789 (35,0 - 35,025)
Journal O.D. 2 1.7297 - 1.7303 (43,934 - 43,950)
Bearing I.D. 2 1.7323 - 1.7332 (44,000 - 44,025)
Oil Clearance 0.002 - 0.0035 (0,050 - 0,091)
Allowable Limit 0.0059 (0,15)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height (Intake) 1.476 (37,50)
Allowable Limit (Intake) 1.457 (37,00)
Cam Lobe Height (Exhaust) 1.492 (37,90)
Allowable Limit (Exhaust) 1.472 (37,40)
Side Clearance Allowable Limit 0.0039 (0,10)
Tappet
Oil Clearance Between Tappet & Guide 0.0079 - 0.0019 (0,020 - 0,050)
Allowable Limit 0.003 (0,07)
Tappet O.D. 0.3924 - 0.3929 (9,965 - 9,980)
Tappet Guide I.D. 0.39370 - 0.39429 (10,000 - 10,015)
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Liner
Cylinder Bore I.D. 3.7008 - 3.7016 (94,000 - 94,022)
Allowable Limit 3.431 (87,15)
Oversized Cylinder Liner (Bore) I.D. 3.7205 - 3.7213 (94,500 - 94,522)
Allowable Limit 3.726 (94,65)
Piston Rings
Ring Gap (Top Ring) 0.0099 - 0.015 (0,25 - 0,40)
Allowable Limit 0.0492 (1,25)
Ring Gap (2nd Ring) 0.012 - 0.017 (0,30 - 0,45)
Allowable Limit 0.0492 (1,25)
Ring Gap (Oil Ring) 0.0099 - 0.017 (0,25 - 0,45)
Allowable Limit 0.0492 (1,25)
Side Clearance of Ring Groove:
Top Ring 0.0020 - 0.0035 (0,050 - 0,090)
Allowable Limit 0.0059 (0,15)
Second Ring 0.0035 - 0.0047 (0,090 - 0,12)
Allowable Limit 0.20 (0,0079)
Oil Ring 0.00079 - 0.0023 (0,020 - 0,060)
Allowable Limit 0.0059 (0,15)
Page 681 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Pistons
Piston Pin Bore 1.1024 - 1.1028 (28,000 - 28,013)
Allowable Limit 0.0059 (28,05)
Connecting Rod
Piston Pin O.D. 1.1026 - 1.1027 (28,006 - 28,011)
Small End Bushing I.D. 1.1036 - 1.1041 (28,031 - 28,046)
Oil Clearance Between Piston Pin & Small End Bushing 0.00079 - 0.0015 (0,020 - 0,040)
Allowable Limit 0.0059 (0,15)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure Rated RPM 28 - 57 PSI (197 - 392 bar)
Allowable Limit 21 PSI (147 bar)
Idle Speed Allowable Limit 7 PSI (49 bar)
Clearance Between Inner Rotor & Outer Rotor 0.002 - 0.003 (0,030 - 0,090)
Clearance Between Outer Rotor & Pump Body 0.00394 - 0.00724 (0,100 - 0,184)
End Clearance Between Inner Rotor & Cover 0.00099 - 0.0029 (0,025 - 0,075)
Specifications (Contd)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
Crankshaft Alignment Limit Permitted 0.0008 (0,02)
Oil Clearance Between Journal & Bearing 0.0012 - 0.0028 (0,030 - 0,073)
Limit Permitted 0.0079 (0,020)
Journal O.D. 3.1487 - 3.1492 (79,977 - 79,990)
Oil Clearance Between Crank Pin & Bearing 0.00067 - 0.0018 (0,017 - 0,048)
Limit Permitted 0.0079 (0,20)
Crank Pin O.D. 1.9678 - 1.9681 (49,980 - 49,991)
Crank Pin I.D. (Blue) 2.0870 - 2.0874 (53,010 - 53,020)
Crank Pin I.D. (No Color) 2.0867 - 2.0870 (53,000 - 53,010)
Crankshaft Side Clearance 0.0059 - 0.013 (0,15 - 0,35)
Limit Permitted 0.020 (0,50)
Timing Gear
Timing Gear Backlash:
Crank Gear-Cam Gear 0.00162 - 0.00547 (0,0410 - 0,139)
Allowable Limit 0.0087 (0,22)
Idle Gear-Cam Gear 0.00162 - 0.00527 (0,0410 - 0,134)
Allowable Limit 0.0087 (0,22)
Idle Gear-Injection Pump Gear 0.00162 - 0.00527 (0,0410 - 0,134)
Page 682 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Allowable Limit 0.0087 (0,22)
Oil Clearance Between Idle Gear Shaft & Idle Gear Bushing: 0.0020 - 0.0035 (0,050 - 0,091)
Idle Gear Bushing I.D. 1.3790 - 1.3799 (35,025 - 35,050)
Idle Gear Shaft O.D. 1.3764 - 1.3769 (34,959 - 34,975)
Idle Gear Side Clearance 0.0059 - 0.0098 (0,15 - 0,25)
Allowable Limit 0.035 (0,90)
Thermostat
Valve Opening Temperature 166.1 - 173 F (74,5 - 78,5 C)
Valve Fully Open 194 F (90 C)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Torque Values
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
Page 683 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11
Troubleshooting (Contd)
Page 684 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery
DANGER
1
P-90328 2
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure P-90575
WARNING 1
Page 685 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Raise the lift arms and install an approved lift arm support P-85852
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.) Disconnect engine ground cable (Item I) and chassis
ground cable (Item 2) [Figure 70-10-3].
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
2 3
3
4
1
4
P-85857
5
Disconnect flywheel rpm sensor (Item 1) [Figure 70-10-
P-85849 6].
Page 686 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Disconnect fuel shut-off solenoid connector (Item 4)
[Figure 70-10-4].
P-85854
P-85853
Figure 70-10-8
P-85894
Figure 70-10-9
1
Page 687 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85892
1
P-85909
Page 688 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 Figure 70-10-15
2
1
1
2
P-85897
Figure 70-10-16
1 P-85911
Figure 70-10-17
Page 689 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85910
Remove rear engine mounting bolt (Item 1) [Figure 70- Installation: Tighten the mounting bolt to 100 ft.-lb. (135
10-17]. Nm).
Figure 70-10-20
P-85912
Figure 70-10-22
Page 690 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-76872
Tighten the all bolts and nuts that hold the engine
removal attachment onto the engine.
Figure 70-10-23
P-85918
Figure 70-10-24
1
Page 691 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85919
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame
8 P-90300
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-27].
Replace all three engine mounts one rear and two sides. 5 2
Page 692 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Use the parts shown to install the new engine mounts 6 3
[Figure 70-10-25]:
7
Hex Nut - (Item 1)
Washer - (Item 2)
Figure 70-10-28
Washer
Engine
Mounting 1
Bracket
Engine
Mount
Snubbing
Washer
Spacer P-85940
Loader
Frame P-85987
The tools listed will be needed to do the following
procedure:
Install the new engine mount as shown in the cut away
side view [Figure 70-10-27]. MEL10630 - Engine Compression Kit
MEL1655 - Compression Adapter
Tighten the mounting bolts to 100 ft.-lb. (135 Nm) torque.
The engine must be at operating temperature.
Figure 70-10-30
P-85939
Page 694 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Crank the engine with the starter cranking rpm.
Figure 70-20-1
1 2
P-85791
P-85789
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the two nuts (Item 1) [Figure 70-20-1].
Remove the handle (Item 3) [Figure 70-20-3].
Figure 70-20-2
Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].
Figure 70-20-4
P-85790
Raise the lift arms and install an approved lift arm support
1
device. (See Installing on Page 10-20-1.)
Figure 70-20-5
P-85801
Figure 70-20-8
1 2
1
P-85806
Page 696 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove the bolt (Item 1) [Figure 70-20-5] from the
clamp that secures the cable.
Figure 70-20-6 3
P-90575
1
P-90735
Figure 70-21-4
Remove the two mounting nuts (Item 1) [Figure 70-21-1]
from the right side foot rest. 1
Remove the foot rest from the loader. 1
Figure 70-21-2
Page 697 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
2
1 P-90754
2
Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
P-90734
Remove panel assembly from the loader.
2 1
3
P-90769
1
Remove the nut (Item 1) and pivot bolt (Item 2) from the
P-90756 engine speed control hand bracket assembly (Item 3)
[Figure 70-21-7].
Remove the spring (Item 1) from the engine speed Remove the engine speed control hand throttle cam lever
control foot pedal pivot assembly (Item 2) and the engine (Item 4) [Figure 70-21-7].
speed control hand throttle bracket (Item 3) [Figure 70-
21-5] Figure 70-21-8
Figure 70-21-6
Page 698 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90767
P-90755
The pivot assembly shown disassembled [Figure 70-21-
8].
Remove the two bolts (Item 1) [Figure 70-21-6] from the
engine speed control hand assembly. NOTE: No lubrication is necessary or recommended
on the engine speed control.
Figure 70-21-9
P-90773
Figure 70-21-10
Page 699 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90771
Figure 70-30-1
2
1
1 1
3 3
P-85843
Open the rear door and remove the rear grill and side
Page 701 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 70-40-1
1
1
2
P-85694
P-85689 Loosen the hose clamp (Item 2) and disconnect the hose
(Items 3) [Figure 70-40-3] from the air cleaner.
Remove the top two mounting bolts (Item 1) [Figure 70- Installation: Tighten the hose clamp (Item 2) [Figure 70-
40-1] from the air cleaner mount bracket. 40-3] to 30 - 35 in.-lb. (3,4 - 4,0 Nm) torque.
P-85688
Figure 70-40-4
P-85691
Page 704 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
WARNING
P-85606
AVOID BURNS
Do not remove radiator cap when the engine is hot. Remove hose (Item 1) [Figure 70-50-2] on the engine oil
You can be seriously burned. cooler and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1
1
Page 705 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
3
4
2
P-85949
P-90574
Figure 70-50-4
2 2
1 P-85954
Page 706 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90590
Figure 70-50-7 Installation: Tighten coil valve stem (Item 3) [Figure 70-
50-8] to 21 - 25 ft.-lb. (28 - 34 Nm) torque.
Figure 70-50-9
4
1
3
1
P-76714A 2
Page 708 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Tighten filter cover (Item 4) [Figure 70-50-7]
to 35 - 40 ft.-lb. (47,5 - 54 Nm) torque.
Figure 70-50-8
1
4
3
P-76717
2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 10].
Figure 70-50-11
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 70-50-12
Page 709 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
2
P-90063
1
Figure 70-50-14
1
1 2
2
5
4
5 1
P-90313
3
P-85897 Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-16].
Remove the fan motor inlet hose (Item 1) and outlet hose Installation: Tighten the bolts to 7.5 ft.-lb. (10,2 Nm)
(Item 2) [Figure 70-50-14]. torque.
Remove the fan case drain hose (Item 3) [Figure 70-50- Figure 70-50-17
14].
Page 710 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
50-14].
Figure 70-50-15
P-90065
P-90268
Figure 70-50-18
2 2
P-90062
Installation: Tighten the nuts to 7.5 ft.-lb. (10,2 Nm) NOTE: If a puller is not available one can be made if
torque. needed to remove the hub from the shaft.
Page 711 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 70-50-19 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.
P-90076
1 P-90019
Remove the water pump (Item 1) [Figure 70-50-21]. Remove the seal (Item 4) [Figure 70-50-22].
Page 712 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Always use a new gasket (Item 2) [Figure Install a new seal (Item 4) [Figure 70-50-22] when
70-50-21] when installing the water pump. assembling the water pump.
Figure 70-50-23
7 4
5
Page 713 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
6
P-90166
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-23].
Thermostat - Checking
Figure 70-50-24
P-37172
Page 714 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Figure 70-60-1
2 1
1
P-85061
Remove the bolts from the front cover / oil pump (Item 1)
[Figure 70-60-3].
soft mallet will break loose the oil pan from the engine
block.
Figure 70-60-2
2
1
P-85056
Figure 70-60-4 Installation: Tighten cover screws to 5.8 - 6.8 ft.-lb. (7,9 -
9,3 Nm)
Figure 70-60-6
1
2
4
3 P-85057
Page 716 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Free Length 2.37 - 2.38 in.
P-85059
(60,0 - 60,5 mm)
Allowable Limit 2.17 in. (55,0 mm)
Measure the clearance between the outer rotor and
Installation: Tighten relief valve retaining screw (Item 1) pump body [Figure 70-60-6].
[Figure 70-60-4] 51 - 57 ft.-lb. (69 - 78 Nm) torque.
Clearance 0.00394 - 0.00724 in.
Oil Pump Inspection Between Outer (0,100 - 0,184 mm)
Rotor & Body
Figure 70-60-5 Allowable limit 0.012 in. (0,30 mm)
P-85058
Figure 70-60-7
1
3
2
P-85072
P-85060
Remove the cooling hoses (Item 1) [Figure 70-60-8].
Put a piece of press gauge on the rotor face [Figure 70- Remove oil filter cartridge (Item 2) and the oil cooler joint
60-7]. screw (Item 3) [Figure 70-60-8].
Install the cover and tighten the bolts. Remove oil cooler (Item 4) [Figure 70-60-8].
Remove the cover carefully. Measure the width of the Installation: Tighten oil cooler joint screw (Item 3) [Figure
press gauge [Figure 70-60-7]. 70-60-8] 47 - 54 ft.-lb. (64 - 73 Nm) torque.
Page 717 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 70-60-9
PI-10010
Page 718 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
the following items:
Figure 70-70-1
P-85956
P-85956
Stop the engine and open the rear door.
Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].
Figure 70-70-2
Page 719 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85957
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 2702
PSI (186 bar).
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can Turn the flywheel back approximately one-half turn. Keep
penetrate skin or eyes, causing serious injury or the flywheel at this position, and measure the time it
death. Fluid leaks under pressure may not be visible. takes the pressure to decrease from 2560 PSI (176,5
Use a piece of cardboard or wood to find leaks. Do bar).
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention Fuel Tightness of Delivery 5 Seconds
from a physician familiar with this injury. Valve Allowable Limit
W-2072-0807
Page 720 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
pump, use the following procedure:
Figure 70-70-5
B-8235
Figure 70-70-6 2
1
P-85082
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-7] from the injection pump
vent.
.
Clean the area around the injection pump thoroughly.
Figure 70-70-8
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-6] from the fuel injectors.
Page 721 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
IMPORTANT 1
2
P-85082
Figure 70-70-9
P-85215
Remove the window cover for the fuel injection pump B 4.09 in. (104 mm)
assembly (Item 1) [Figure 70-70-9] from the flywheel C 0.787 in. (20,0 mm)
housing. D 0.394 in. dia. (10,0 mm dia.)
Page 722 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 H 1.26 in. (32,0 mm)
I 0.630 in. (16,0 mm)
Figure 70-70-12
M8 X 1.25
0.20 in.
0.20 in. (5.0mm) (5,0mm) dia
45(0,79 rad)
P-85094
Look for the alignment mark on the idler gear and 1.8 in.(45mm)
P-85091
injection pump gear (Item 1)[Figure 70-70-10] then using
a white marking pen or the like put a alignment mark to
help reassemble these gears in mesh later. Construct two fuel camshaft lock screws as shown above
[Figure 70-70-12]
NOTE: When the already existing marks align with
each other, there is no need to put another
alignment mark.
Figure 70-70-13
P-85093
Figure 70-70-16
2
1
P-85090
P-85095
Install one lock tool in the upper plug opening (Item 1)
and tighten until it comes in contact with the fuel
camshaft. Make sure the fuel camshaft is not moving. Remove injection pump support (Item 1) [Figure 70-70-
Install second lock tool in lower opening (Item 1) [Figure 16].
70-70-14] and repeat the process.
Remove injection pump assembly (Item 2) [Figure 70-
NOTE: Do not over tighten the lock screws after they 70-16].
have contacted the fuel camshaft. Otherwise
the injection pump may become damaged.
The governor serves to keep the engine speed constant Q 0.1164 - 0.1167 in. dia. (2,955 - 2,965 mm
by automatically adjusting the amount of fuel supplied to dia.)
the engine according to changes in the engine load. R 0.1189 - 0.1192 in. dia. (3,020 - 3,030 mm
dia.)
Disassemble and assemble the governor and fuel S Ra = 1.6a
camshaft as shown in figure. AA Governor housing side
BB Press in side
Check all the parts for wear or damage and replace as a 0.024 in. radius (0,60 mm radius)
needed. b 0.039 in. radius (1,0 mm radius)
C0.2 Chamfer 0.0079 in. (0,20 mm)
Figure 70-70-17
C0.4 Chamfer 0.016 in. (0,40 mm)
C0.5 Chamfer 0.020 in. (0,50 mm)
C1 Chamfer 0.039 in. (1,0 mm)
C2 Chamfer 0.079 in. (2,0 mm)
Page 724 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85182
P-85095
P-85100
Remove the fuel injection pump assembly. (See Fuel
Injection Pump Assembly Removal And Installation on
Page 70-70-3.). Slide off the governor connecting rod (Item 1) [Figure 70-
70-19] from the rack pin of injection pump assembly.
Remove the governor lubricating pipe (Item 1) [Figure
70-70-18]. For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod.
Remove the stop solenoid (Item 2) [Figure 70-70-18].
Remove the governor housing mounting bolts.
Page 725 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85099
P-85097
Unhook the start spring (Item 1) from the rack pin (Item 2)
[Figure 70-70-19] of injection pump assembly.
Remove the governor housing assembly (Item 1) [Figure
Remove the nut (Item 3) [Figure 70-70-19]. 70-70-21] from the injection pump unit.
Installation: Reverse procedure to install. Tighten the nut NOTE: The injection pump unit is lubricated with
to 2.1 - 2.9 ft.-lb. (2.9 - 4,0 Nm) torque. engine oil. Oil will leak when the governor
housing is removed from the injection pump.
NOTE: Be careful not to drop the nut inside.
Figure 70-70-22
1
1
2
P-85189
Figure 70-70-25
Remove the governor fork shaft lever (Item 1) using a
bolt 0.16 in. dia. (4 mm dia.), pitch 0.03 in. (0,7 mm) at
least a inch long (Item 2) [Figure 70-70-22].
Figure 70-70-23 2
Page 726 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
P-85190
P-85188
Figure 70-70-26
P-85192
Figure 70-70-27
Page 728 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85123
1
2
P-85186A
1
P-85183
Remove the governor sleeve (Item 1) and remove the
two fuel camshaft lock allen screws (Item 2) [Figure 70-
70-28]. Install injection pump housing to the engine and tighten.
Fix the flywheel with the flywheel stop tool (Item 1)
NOTE: Do not use the fuel camshaft locks screws [Figure 70-70-32].
when removing governor weight, otherwise
damage may occur to the allen screws or the Loosen the injection pump gear mounting nut (Item 2)
governor housing. [Figure 70-70-32].
Page 729 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
P-85215
Figure 70-70-32
2
2
1
1
1
3 P-85199
P-85122
Remove all injection pipes (Item 1) [Figure 70-70-34].
Loosen fuel camshaft stopper mounting bolts (Item 1) Remove overflow hose (Item 2) [Figure 70-70-34].
and remove camshaft stopper (Item 2) [Figure 70-70-
32]. Remove fuel stop solenoid (Item 3) [Figure 70-70-34].
Installation: Tighten fuel camshaft stopper mounting bolts Remove sight cover from housing (Item 4) [Figure 70-
to 7.24 - 8.37 ft.-lb. (9,81 - 11,2 Nm). 70-34].
NOTE: When reassembling fuel camshaft stopper NOTE: The injection pump can be removed and
Page 730 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
make sure the oil path hole (Item 3) [Figure 70- installed with the crankshaft at any position.
70-32] is the proper alignment.
Figure 70-70-35
Figure 70-70-33
3 1
1
2
2
P-85099
P-85120
Unhook the start spring (Item 1) from the rack pin (Item 2)
Remove fuel camshaft (Item 1), then remove fuel [Figure 70-70-34] of injection pump assembly.
camshaft stopper bearing screws (Item 2) [Figure 70-70-
33]. Remove the nut (Item 3) [Figure 70-70-34].
If replacing the fuel camshaft bearings tighten the fuel Installation: Reverse procedure to install. Tighten the nut
camshaft stopper bearing plate screws (item 2) [Figure to 2.1 - 2.9 ft.-lb. (2.9 - 4,0 Nm) torque.
70-70-33] to 2.9 - 3.1 ft.-lb. (3,9 - 4,2 Nm) torque.
NOTE: Be careful not to drop the nut inside.
Figure 70-70-36
1
2
P-85200
Figure 70-70-37 4
Page 731 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 2
3 5
1 P-85203
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
P-85104
Remove the fuel shutoff solenoid. (See Fuel Shutoff
Solenoid Removal And Installation on Page 70-70-1.)
Rotate the flywheel counterclockwise (viewed from the
Figure 70-70-40 flywheel side) until fuel fills up the hole of the delivery
valve holder for the number one cylinder as shown in
[Figure 70-70-41] below.
1
Figure 70-70-42
Page 732 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85102
Figure 70-70-43
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
1 W-2072-0807
P-85103
IMPORTANT
Check to see the degree marks on the flywheel (Item 1)
[Figure 70-70-43]. The flywheel has a 1TC mark for the Do not bend the high pressure fuel injection tubes
crank angle before the top dead center of cylinder when removing or installing them.
number one. I-2029-0289
P-85117
Page 734 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-44] from the fuel injectors and from the injection
pump.
Fuel Injector Removal And Installation (Contd) The tool listed will be needed to do the following
procedure:
Figure 70-70-47
OEM1064 - Injector Nozzle Tester
Figure 70-70-49
P-85119
Pull on the injector nozzle to remove the injector nozzle Set the injection nozzle to the nozzle tester.
from the cylinder head.
Slowly move the tester handle to measure the pressure
Figure 70-70-48 at which fuel begins jetting out from the nozzle.
Page 735 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-37583
Nozzle Spray 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
Figure 70-70-50
Correct Incorrect
3EEABAC1P014A
3EEABAC1P013A
Set the injection nozzle to a nozzle tester.
Set the injection nozzle to a nozzle tester, and check the Raise the fuel pressure, and keep at 2418 PSI (166,7
nozzle spraying condition. bar) for 10 seconds.
Page 736 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
If the spraying condition is defective, replace the injection If any fuel leak is found, replace the injection nozzle
nozzle assembly. assembly.
Figure 70-80-1 1 2
1 3
2
3
P-85178
P-85178
Disconnect the glow plug nuts (Item 1),remove glow plug
connecting strap (Item 2) and glow plugs (Item 3) [Figure
Disconnect the glow plug nuts (Item 1), remove glow plug 70-80-3].
connecting strap (Item 2) and glow plugs (Item 3) [Figure
70-80-1]. Installation: Tighten the glow plug to 5.7 - 6.8 ft.-lb. (7,7 -
9,3 Nm) torque.
Installation: Tighten the glow plug to 5.7 - 6.8 ft.-lb. (7,7 -
9,3 Nm) torque. Figure 70-80-4
Figure 70-80-2
Page 737 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 1
P-85179
P-85179
NOTE: Adjust the direction of the ditch (Item 1)
[Figure 70-80-4] to the terminal side when the
Touch one probe to the end of the glow plug (Item 1) and seal is installed on the glow plug.
the other probe to the body of glow plug (Item 2) [Figure
70-80-2].
Figure 70-80-5
2
1
3
P-85181
P-48708
Adjust the valve clearance as follows:
Photo [Figure 70-80-5] shows the glow plug removed Loosen the lock nut (Item 1) [Figure 70-80-6].
from the engine. Inspect the glow plugs and replace
when necessary. Turn the adjustment screw (Item 2) [Figure 70-80-6] until
the correct clearance is obtained.
Page 738 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 70-80-7 3 4
2
4 3 2 1
B 8 7 6 5 4 3 2 1 A
1 P-85974
B-05569
Stop the engine and open the rear door.
NOTE: (A) is the front cover side, (B) is the flywheel Remove the engine / hydrostatic pump package from the
housing side. loader. (See Engine Removal And Installation on Page
70-10-7.)
Figure 70-80-8
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-120-1.)
Cylinder Number 1 2 3 4
Remove the timing gearcase cover. (See Timing
Page 739 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
4 2 1
1
3
P-85118
P-85174
Page 740 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
8 ft.-lb. (9,81 - 11,2 Nm) torque. Tighten center bolts first,
then work your way to the front and back of the valve
cover.
1
Installation: Tighten injection pipe retaining nuts to 17 -
26 ft.-lb. (23 - 36 Nm) torque.
Figure 70-80-11
P-85119
1
P-85117
1 2
P-85170
Figure 70-80-15
Page 741 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85168
P-47245 NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Installation: The push rod (Item 1) must be seated in the Installation: Put oil on the bolt threads. Tighten the bolts
tappet (Item 2) [Figure 70-80-15] correctly or the push in the correct sequence in order of #1 - #10 to 138 - 144
rods will be damaged. ft.-lb. (187 - 196 Nm).
After installing the rocker arm assembly and push rods, NOTE: It is not necessary to retighten the cylinder
the valve lash must be adjusted. (See Valve Clearance head bolts after the engine has been run for 30
Adjustment on Page 70-80-2.) minutes.
Figure 70-80-18 1
P-47252
Figure 70-80-21
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-18].
Figure 70-80-19 a b c
2 B
Page 742 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85967
NOTE: (A) is the front cover side, (B) is the flywheel Select the correct gasket size (thickness) from the chart
housing side. [Figure 70-80-22].
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.
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-25] on the
spring [Figure 70-80-23]. cylinder head.
Figure 70-80-26
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-23] & [Figure 70-80-24]. and two diagonal as shown in figure [Figure 70-80-26].
Figure 70-80-29
P-85172 1
Page 744 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
the valves.
B-14335
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque Measure the valve stem O.D. (Item 1) [Figure 70-80-29].
in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-80-4.) Measure the valve guide I.D. (Item 2) [Figure 70-80-29].
Turn the crankshaft until the piston exceeds T.D.C. Calculate the clearance. If the clearance exceeds the
Remove the cylinder head. allowable limit, replace the valve and/or valve guide.
Figure 70-80-28
Valve Guide I.D. 0.2768 - 0.2773in.
(7,030 - 7,045 mm)
Valve Stem O.D. 0.2741 - 0.2746 in.
(6,960 - 6,975 mm)
Clearance Between 0.0022- 0.0033 in.
Valve Stem and Guide (0,055 - 0,085 mm)
Allowable Limit 0.0039 in.
(0,10 mm)
P-85173
Figure 70-80-30
8.86 (225 mm)
0.461-0.468
(11,7-11,9 mm) 0.256-0.259
(6,50-6,60 mm)
0.2 0.335-0.350 0.79
(5,0 mm) (8,50-8,90mm) (20,0 mm)
0.264-0.275 PI-9993
0.98 0.493-0.503
(6,70-7,00mm) (25,0 mm) (12,5-12,8 mm)
MC-1364
Grind the valve face to the correct angle using a valve
refacer [Figure 70-80-32].
To remove and replace the valve guide, make the driver
tools as shown in figure [Figure 70-80-30]. Clean the valve seat and combustion chamber.
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-31]. recessing with a depth gauge [Figure 70-80-33].
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-36].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-34].
If the seat surface (b) needs correction, slightly correct
the seat using a 45 degree cutter and then resurface the
Recessing 0.026 - 0.33 in.
seat surface with a 15 degree cutter to get the correct
(0,65 - 0,85 mm)
width (Item 2) [Figure 70-80-36].
Allowable Limit (Recessing) 0.0472 in. (1,20 mm)
Valve Seat Width
Figure 70-80-35
Page 746 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Intake & Exhaust 0.13 - 0.14 in.
(3,3 - 3,6 mm)
Intake 45 degrees
Exhaust 45 degrees
45 Exhaust
15 Exhaust 45 Intake
15 Intake
PI-9994
Valve Spring
Figure 70-80-37
A-2759
Valve Tappets
Remove the oil pan and oil pump strainer. ((See Oil Pan
Removal And Installation on Page 70-60-1.))
1 P-85175
Page 748 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
valve tappets (Item 1) [Figure 70-80-39].
Figure 70-80-40
P-85142
Figure 70-80-42
1
1
2
P-85177
B-3697
Measure the bridge arm ID (Item 1) [Figure 70-80-43].
Measure the rocker arm I.D. (Item 1) [Figure 70-80-42] If the clearance exceeds the allowable limit, replace the
with an inside micrometer. bridge arm (Item 1) [Figure 70-80-43].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70- Bridge arm ID. 0.3170 - 0.3181 in.
80-42] with an outside micrometer. (9,050 - 9,065 mm)
If the clearance exceeds the allowable limit, replace the Figure 70-80-44
bushing.
Page 749 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 70-80-45
1
P-85972
Remove the used valve bridge arm shaft (Item 1), then
P-85969 clean valve bridge arm shaft mounting hole. Use the
valve bridge arm replacing tool to press in new shaft
[Figure 70-80-46].
Make valve bridge arm shaft replacement tool as shown
above [Figure 70-80-45]. Figure 70-80-47
Page 750 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
E 0.492 in. dia. (12,5 mm dia.) through hole
F 2.40 in. (61,0 mm)
G 0.736 in. (18,7 mm)
H 1.217 - 1.248 (30,90 - 31,70 mm)
a 0.012 in. radius (0,30 mm radius)
C0.5 Chamfer 0.020 in. (0,50 mm)
C1 Chamfer 0.039 in. (1,0 mm) P-85973
Figure 70-80-48
P-76926
P-85970
Place the push rod on V blocks [Figure 70-80-49].
Set the depth of the bridge arm shaft (Item 1) to 1.23 - Measure the push rod alignment [Figure 70-80-49].
1.24 in (31,1 - 31,7 mm) [Figure 70-80-48].
If the push rod exceeds the allowable limit, replace the
push rod.
Remove the oil pan and oil pump strainer. (See Oil Pan
Removal And Installation on Page 70-60-1.)
Figure 70-90-1
P-85143
P-85142
P-85145
Figure 70-90-5
Page 754 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-85144
Figure 70-90-7 2
1 2 3 4 5 6
1
3
7
4 PI-10015
Figure 70-90-10
B-3622
Measure the O.D. of the piston pin (Item 1) [Figure 70- If the gap exceeds the allowable limit, replace the ring.
90-10].
Top Ring Gap 0.0099 - 0.015 in.
Measure the I.D. of the connecting rod small end bushing (0,25 - 0,40 mm)
(Item 2) [Figure 70-90-10].
Oil Ring Gap 0.0099 - 0.017 in.
(0,25 - 0,45 mm)
Calculate the oil clearance. If the clearance exceeds the
Allowable Limit 0.0492 in.
allowable limit, replace the connecting rod. If it still
(1,25 mm)
Page 756 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
exceeds the specifications, replace the piston pin.
Second Ring Gap 0.012 - 0.017 in.
Piston Pin O.D. 1.1026 - 1.1027 in. (0,30 - 0,45 mm)
(28,006 - 28,011 mm)
Bushing I.D. 1.1036 - 1.1041 in.
(28,031 - 28,046 mm)
Oil Clearance Between 0.00079 - 0.0015 in.
Piston Pin & Bushing (0,020 - 0,040 mm)
Allowable Limit 0.0059 in.
(0,15 mm)
Figure 70-90-12
B-4066
PI-10017
Use a gauge to check the inside measurement of the
cylinder bore [Figure 70-90-13].
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler Figure 70-90-14
gauge [Figure 70-90-12].
Connecting Rod Alignment Remove the crankshaft. (See Crankshaft And Bearings
Removal And Installation on Page 70-90-7.)
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before Figure 70-90-16
doing this check.
Put the gauge over the piston pin and move it against the
face plate. 1
2
Figure 70-90-15 4
2
P-85149
Page 758 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
B-4067 Figure 70-90-17
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-15].
1
2
3
P-85148
Figure 70-90-18
2
0.0335 - 0.0452 in. (0,850 - 1,15 mm)
2
1 3
P-85153
Figure 70-90-19
P-85995
Installation: Tighten the crankcase mounting bolts from Material (Item 1) [Figure 70-90-21]: SS400
K to Z to 44 - 47 ft.-lb. (59 - 63 Nm).
P-85156
Page 760 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
the groove facing out.
1
Figure 70-90-23
1 4
P-85996
2 2
1
P-85159
P-85160
Set a dial indicator with its tip on the end of the crankshaft
(Item 1) [Figure 70-90-26]. Place plastigage on the crankshaft (Item 3) [Figure 70-
90-28].
Measure the side clearance by moving the crankshaft
side to side (Item 2) [Figure 70-90-26]. Place crankcase 2 (Item 2) on crankcase 1 (Item 1)
[Figure 70-90-28] and torque the bolts.
If the misalignment exceeds the allowable limit, replace
the crankshaft. Torque the bolts A to Z [Figure 70-90-19]. (See
Page 761 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
A-2763
Figure 70-90-29
P-37145
Page 762 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
radius) radius) again.
*Dimension 0.040 - 0.059 in. 0.040 - 0.059 in. Measure the amount of the flattening with the scale, and
B relief relief get the oil clearance.
(1,0 - 1,5 mm (1,0 - 1,5 mm
relief) relief) If the oil clearance exceeds the allowable limit, replace
Dimension C 3.1409 - 3.1413 3.1330 -3.1334 the crank pin bearing.
in. dia. in. dia.
(79,777 - 79,790 (79,577 - 79,590 If the same size bearing cannot be used because of the
mm dia.) mm dia.) crank pin wear, replace it with an undersized one
referring to the table.
The crankshaft journal must be fine-finished to higher
than (0.8-S) Crankpin Factory spec. 1.9678 - 1.9681 in.
*Holes are to be de-burred and edges rounded with O.D. (49,980 - 49,991 mm)
0.040 - 0.059 in (1.0 - 1.5 mm) relief
Oil clear- Factory spec. 0.00067 - 0.0018 in.
ance (0,011 - 0,058 mm)
between Allowable 0.0079 in. (0,20 mm)
crank pin and limit
crank pin
bearing
Figure 70-90-31
P-85162
2
Undersize dimensions of crankpin.
P-37147
Undersize 0.0079 in. 0.016 in.
(0,20 mm) (0,40 mm)
NOTE: To replace it with a specific STD service part,
make sure the crank pin bearing has the same Dimension 0.13 - 0.14 in. 0.13 - 0.14 in.
ID color as the connecting rod [Figure 70-90- A radius radius
31]. (3,3 - 3,7 mm (3,3 - 3,7 mm
radius) radius)
ID Connecting Crank pin bearing *Dimen- 0.040 - 0.059 in. 0.040 - 0.059 in.
Color rod sion B relief relief
(1,0 - 1,5 mm relief) (1,0 - 1,5 mm
Large-end Class Part Center
Page 763 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
relief)
in. dia. code wall thick
Dimension 1.9599 - 1.9602 in. 1.9520 - 1.9524
Blue 2.0870 - L 1G77 0.05890 -
C dia. in. dia.
2.0874 in. 2- 0.05909
(49,780 - 49,791 (49,580 - 49,591
(53,010 - 22310 in.
mm dia.) mm dia.)
53,010 mm) (1,496 -
1,501 (0.8-S)
mm) The crank pin must be fine-finished to higher than
with- 2.0867 - S 1G77 0.05870 -
*Holes to be de-burred and edges rounded with 0.040
out 2.0870 in. 2- 0.05889
- 0.059 in. (1,0 -1,5 mm) relief.
Color (53,000 - 22330 in.
53,010 mm) (1,491 -
1,496
mm)
Figure 70-100-1
P-90121
Figure 70-100-2
P-90004A
Page 766 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
(82,036 - 82,071 mm dia.)
G 3.03 in. dia.
(77,0 mm dia.)
H 2.24 in. dia. (57,0 mm dia.)
I 1.38 in. dia. (35,0 mm dia.)
J 1.18 in. dia. (30,0 mm dia.)
K 3.31 in. (84,0 mm)
L 0.14 in.(3,5 mm)
M 0.12 in. (3,0 mm)
N 0.260 - 0.267 in. (6,60 - 6,80 mm)
O 0.31 in. (8,0 mm)
P 2.64 in. dia. (67,0 mm dia.)
Q 0.16 in. (4,0 mm dia.) through hole
a Ra = 1.6 a
b 0.059 in. radius (1,5 mm radius)
c Ra = 3.2 a
d 0.031 in. radius (0,80 mm radius)
C0.5 Chamfer 0.020 in. (0,50 mm)
C1.0 Chamfer 0.039 in. (1,0 mm)
Figure 70-100-4
P-85218
P-90006
Figure 70-100-6
P-85997B
1
Tighten the seven outside timing gearcase cover
P-85998 mounting bolts (Item 1) [Figure 70-100-8].
Page 768 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85217
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
When the gears are installed, check the backlash of the
gears. Remove the valve tappets. (See Valve Tappets on Page
70-80-12.)
Figure 70-100-9
Figure 70-100-10
1 2 3
1
2
4
P-85205
P-90008
Hold one gear while turning the other gear [Figure 70- Remove the three camshaft set bolts (Item 2) and
remove the cam (Item 3) [Figure 70-100-10].
Page 769 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
100-9].
If the backlash exceeds the allowable limit, check the oil Remove the idle gear mounting bolts (Item 4) and
clearance of the shaft and gear. If the oil clearance is remove idle gear (Item 5) [Figure 70-100-10].
correct, replace the gear.
Installation: Make sure the timing marks are in correct
Crank Gear & Cam Gear 0.00162 - 0.00547 in. alignment when installing the timing gears.
(0,0410 - 0,139 mm)
Allowable Limit 0.0087 in.
(0,22 mm)
Cam Gear & Idler Gear 0.00162 - 0.00527 in.
(0,0410 - 0,134 mm)
Allowable Limit 0.0087 in.
(0,22 mm)
Injection Pump Gear & Idler 0.00162 - 0.00527 in.
Gear (0,0410 - 0,134 mm)
Allowable Limit 0.0087 in.
(0,22 mm)
Camshaft - Servicing
Figure 70-100-11
1 2
1
P-85212
2
Page 770 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Allowable Limit
Camshaft Journal 2 O.D. 1.7297 - 1.7303
(43,934 - 43,950 mm)
Figure 70-100-12
Oil Clearance of Cam- 0.0020 - 0.0035 in.
shaft Journal (0,050 - 0,091 mm)
Allowable Limit 0.0059 in.
(0,15 mm)
P-47263
P-85214
2
Measure the cam lobes at their highest point (Item 2)
[Figure 70-100-14].
P-85207
P-85213
Figure 70-100-19
1 2
P-85208
Page 772 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Idler Shaft & Gear Bushing (0,050 - 0,091 mm)
P-85210
Allowable Limit 0.0039 in.
(0,10 mm)
When removing idle gear bushing, press out bushing as
Installation: If the oil clearance exceeds the allowable shown above (item 1) [Figure 70-100-19].
limit, replace the idle gear bushing.
When replacing idle gear bushing, press in bushing as
Figure 70-100-18 shown above (item 2) [Figure 70-100-19].
P-85211
Figure 70-110-2
1
1
P-85976
WARNING
Turbochargers, operate at high speed and high 1
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Page 774 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
P-85979
P-85975
Figure 70-110-6
P-85127
Figure 70-120-1
Make flywheel stop tool as shown above in [Figure 70-
120-2].
1 2
H 1.26 in. (32,0 mm)
P-85138
I 0.630 in. (16,0 mm)
Figure 70-120-3
Remove the six mounting bolts (Item 1) from the pulley
(Item 2) [Figure 70-120-1].
P-85218
Figure 70-120-4
P-85140A
Page 778 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Installation: Apply engine oil to the bolts and tighten to
72.4 - 79.5 ft.-lb. (98,1 - 107 Nm) torque.
Ring Gear Removal And Installation Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
Figure 70-120-7 70-10-7.)
Figure 70-120-8
The ring gear (Item 1) [Figure 70-120-7] 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.
P-85137
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
3
12
11
1
Page 781 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
7 5
13
2
7
9
15
10
9
14
P-85105
1. Thermo Valve
2. Mechanical EGR Valve 9. Cooled EGR Gas
3. Cylinder Head 10. To The Intake Manifold
4. Reed Valve 11. Fresh Air
5. EGR Cooler 12. Cooled EGR Gas Merges With Fresh Air
6. Intake Manifold 13. Exhaust Gas
7. Boost Pressure 14. Coolant Inlet
8. Coolant Temperature 15. Coolant Outlet
Page 782 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
1
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 70-130-3
1
1
P-85108
P-85984
Temperature Test.
Figure 70-130-6
1
P-85108
If the surface temperature of the EGR system stays Disconnect the intake hose (Item 1) [Figure 70-130-6].
above 302 F (150 C), the EGR valve has failed.
Testing (Contd)
Figure 70-130-7
P-85108
Page 784 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
P-85981
1
WARNING
4
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting 3
diagnostic tests.
1
Allow the engine to cool before servicing. P-85110
W-2716-0208
Allow the engine to cool before working on the EGR Remove the four EGR cooler mounting bolts (Item 1) and
system. the EGR system assembly (Item 2) [Figure 70-130-11].
Figure 70-130-12
1
3
Page 785 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85982
2
Disconnect and cap the EGR valve coolant hoses (Item P-85113
1) [Figure 70-130-10].
Disconnect the boost pressure hose (Item 2) [Figure 70- NOTE: The gasket (Item 3) [Figure 70-130-11] and
130-10]. [Figure 70-130-12] is marked with the letter
F and must be installed downward.
Figure 70-130-13 3
6
4
8 5
4
2
1 7
6 1
5 P-85111
3
2
4 Remove the two mounting bolts (Item 1) from the EGR
valve (Item 2) and EGR valve flange (Item 6) [Figure 70-
P-85112 130-14].
Page 786 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
5) and the EGR valve (Item 7) [Figure 70-130-13].
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Page 787 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-2
Page 788 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
80-10-1
S630 Service Manual
AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-3.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-3.)
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 entering the evaporator coil (Item 5) (See Chart on Page 80-10-3.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across 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 which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.
Page 790 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
Page 791 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R134a_______________________________________________
Components
1
Figure 80-10-1
2
P-89545
Page 792 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Components (Cont'd)
Figure 80-10-5 4 2
3
1
P-89497
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-92602 10-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-10-7]
1) [Figure 80-10-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
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 Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater/Evaporator Blower: The blower (Item 4) [Figure
Page 793 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-92659
Components (Cont'd)
Figure 80-10-8
1
1
2
3
4 P-89545
Page 794 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]
will be illuminated when the A/C is engaged.
Figure 80-10-9
P-90353
Safety Equipment
WARNING
Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-10-12
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.
Page 795 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 80-20-1 1
3
2
2
1 P-90490A
Figure 80-20-3
P-85993
Condenser
P-85942A
Page 798 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
The condenser should be cleaned with the oil cooler and
the radiator.
NOTE: The engine is shown removed for visual
clarity. Air Conditioning Lubrication
Loosen the top air conditioning pump mounting bolts Run the air conditioning for about five minutes every
(Item 1) [Figure 80-20-3]. week to lubricate the internal components.
Figure 80-20-5
P-90419A
Figure 80-20-6
Page 800 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
P-90420A
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
Page 801 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86 - 96 F (30 -
38 C) and compressor speed of approximately 3200 RPM are:
High pressure side pressure: 210 - 265 PSI
Low pressure side pressure: 15 - 33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
Page 802 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostats tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.
80-30-4
P-90410
80-30-5
P-90411
80-30-6
P-90412
80-30-7
P-90413
Page 808 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
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 F to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 F to the ambient temperature to get
the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Conditions and pressures will vary from system to system. Check with MCC for system specifications.
Page 809 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Start the loader, lock the park brake, and engage the A/C
system with the blower fan on High. Run the loader at full
throttle for approximately 15 minutes, with the loader cab
door closed.
Figure 80-30-1
N-22411
Page 810 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 80-130-1.)
Check the A/C evaporator coil for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
110-1.)
Figure 80-30-3
P-85954
Electrical System
Figure 80-30-4
P-90357
Figure 80-30-7
P-92638
Page 812 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
P-90358
P-85412
Figure 80-30-8
P-90360
1
Figure 80-30-9
1
P-90360
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.
Figure 80-30-12
P-90363
P-90363
Disconnect the blower wiring connector (Item 1) [Figure
80-30-14] from the loader wiring harness.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
Page 814 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2
1
2 P-90362
1
Check the loader harness (Item 1) [Figure 80-30-15] for
P-90362 voltage. The voltage should be 12 volts.
If there is voltage at the wiring harness, check the If there is no resistance value replace the blower. (See
thermostat (Item 2) [Figure 80-30-13] for resistance. Removal And Installation on Page 80-130-1.)
The resistance value of the thermostat should be 10 If there is a resistance value check the climate controls at
Ohms at 68 F (20 C). the control panel inside the loader cab.
Figure 80-30-16 C
H
B
1 M
N-22288
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
1
P-90367
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Page 816 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 80-30-20 Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be 12 volts.
1
2
N-22289
Figure 80-30-22
A C
A C
B
N-22290
B
If there is voltage at the wiring harness, check the Check the resistance between the wire terminal C and
potentiometer [Figure 80-30-22] for resistance. wire terminal B frame [Figure 80-30-24] should be
around 10 K ohm.
The resistance should be 10K Ohms between wire pin A
and wire pin C frame [Figure 80-30-22].
Figure 80-30-23
P-90368
Electrical System (Cont'd) Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-25
Figure 80-30-27
2 3
1 1
P-90369
P-90364A
Page 818 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
A C
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
N-22290
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-29
P-90370
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
N-23024
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-40-2
N-22291
WARNING
P-90372
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
Locate the low pressure port (Item 1), and high pressure if it contacts the eyes and may cause serious
port (Item 2) [Figure 80-40-2]. frostbite if it contacts the skin.
Page 822 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
WARNING NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of 134A to the system must be done by a competent
refrigerant can cause severe injuries to eyes. In refrigeration dealer who has the proper equipment,
contact with a flame, R134a refrigerant gives a toxic knowledge, and experience to service refrigeration
gas. equipment.
W-2371-0500 W-2373-0500
Figure 80-40-4
N-22292
2
Page 823 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90373
N-22381
Figure 80-50-1
1
P-89543
P-90357
Figure 80-50-4
1
2 1
P-89538
P-89534
P-90486
Page 826 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
When ever the evaporator, condenser or receiver-
drier is replaced.
Oil Check
Figure 80-50-6
1
P-90486
Figure 80-50-9
P-16534A
P-90487
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Cap and plug the hose and the condenser fittings with
1 the proper A/C caps and plugs.
Figure 80-60-3
Page 829 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-85824 1
WARNING P-89548
WARNING P-90493
In the event of a leak, wear safety goggles. Escaping Note the flow direction on the receiver / drier (Item 1)
refrigerant can cause severe injuries to eyes. In [Figure 80-70-2] for proper installation.
Page 831 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 80-70-1
P-90488
Figure 80-70-3
1
N-22205
P-92665
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver
/ drier (Item 2) [Figure 80-70-3]. Figure 80-70-6
Figure 80-70-4
Page 832 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
N-22206
P-89521
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
Remove the two mount bolts (Item 1) [Figure 80-70-4] 535 PSI (3689 bar).
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.
Figure 80-70-7
1
1 P-90488
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-70-9
N-22166
Page 834 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove the pressure switch.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
P-90421
Figure 80-80-4
P-90363
3
Page 835 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90422
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
NOTE: The EDT has a six second delay before start 5. Temperature sensor open and short detection
up to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 35.6 F (2 C). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor
temperature is below 28.4 F (-2 C), the EDT will turn off
Temperature At A/C start up 2x per second
the clutch and status LED.
sensor open and
short detection
Figure 80-90-1
Compressor Continuous 3x per second
clutch short to
battery
1
Page 837 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90576
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-90-5
1 2
Page 838 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-92606
P-92603
2
1
WARNING P-90416
In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
contact with a flame, R134a refrigerant gives a toxic
gas. Remove the four screws (Item 1) and the cover (Item 2)
W-2371-0500 [Figure 80-100-2].
Figure 80-100-3
Figure 80-100-1
Page 839 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
2
1
1
P-90417
P-92659
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Figure 80-100-4
P-90418
Page 840 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Remove the expansion valve from the loader.
Figure 80-100-5
N-22085
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
1
Raise the operator cab. (See Raising on Page 10-30-2.)
1
2
Evacuate the A/C system. (See Reclamation And 1
Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 80-110-1
Page 841 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1
1
1
1
P-90418
Figure 80-110-4
2
2
3
P-90420A
Page 842 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure 80-110-5
P-90424
P-90440
Figure 80-120-4
1
P-90419A
Page 843 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
2 1
Remove the nine screws (Item 1) and the cover (Item 2)
[Figure 80-120-1].
Figure 80-120-2 1
2
1
P-90445
1
Remove the five screws (Item 1) and cover (Item 2)
3
[Figure 80-120-4].
P-90439
Figure 80-120-5
P-90441
Figure 80-120-6
Page 844 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
P-90443
Figure 80-130-1
1 1
2
P-90458
2
P-90465
Figure 80-130-4
P-90463
Figure 80-130-7
NOTE: Mark the wires for proper installation.
Figure 80-130-5
Page 846 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
1 1
P-90461
P-90460
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-
8] from the blower motor shaft and inspect for wear.
Figure 80-140-1
NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the
system.
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Page 851 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Machine Dimensions
Dimensions are given for loader equipped with standard tires and 74 inch Construction & Industrial bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
83.4 in.
(2119 mm)
72.1 in.
(1832 mm) 74 in.
(1880 mm)
59.3 in.
(1507 mm)
96.9
Page 853 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
155.5 in.
(3950 mm)
42.4
21.4 in.
(544 mm)
121 in.
(3073 mm)
93.2 in.
81.3 in. (2367 mm)
(2065 mm)
25.2
30
45.3 in.
8.1 in. (1150 mm)
(207 mm)
108.4 in.
(2754 mm)
136.8 in.
(3474 mm)
NA-1247A
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.
Engine
Page 854 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Low Idle RPM 1250 - 1450
High Idle RPM 2525 - 2650
Number of Cylinders 4
Displacement 203 cu. in. (3,3 L)
Bore / Stroke 3.70 in. / 4.72 in. (94 mm / 120mm)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Drive System
Controls
Vehicle Steering Direction and speed controlled by two hand operated steering levers or optional
joystick(s)
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System (ACS)
or optional Selectable Joystick Controls (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control; key-type start switch or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Glow plugs automatically activated as needed by Instrument Panel
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Mechanical disc, manually operated switch on left instrument panel
Parking Brake (Two-Speed Option) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel
Hydraulic System
System Relief at Quick Couplers 3450 - 3550 PSI (237,8 - 244,7 bar)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter:Lift Cylinder (2) 2.50 in. (63,5 mm)
Tilt Cylinder (2) 3.00 in. (76,2 mm)
Rod Diameter:Lift Cylinder (2) 1.75 in. (44,5 mm)
Tilt Cylinder (2) 1.63 in. (41,4 mm)
Stroke:Lift Cylinder (2) 33.87 in. (860,3 mm)
Tilt Cylinder (2) 13.97 in. (354,8 mm)
Control Valve - Standard 3-Spool, open center, manually operated with spring detent for lift float and
electrically controlled auxiliary spool
Control Valve - ACS and SJC 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 Gal.)
6903118 - (5 Gal.)
6903119 - (55 Gal.)
Hydraulic Function Time:
Raise Lift Arms 3.4 Seconds
Lower Lift Arms 3.0 Seconds
Bucket Dump 2.3 Seconds
Bucket Rollback 1.7 Seconds
Electrical System
Page 856 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Capacities
Tires
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
in.-lb. 0.250 80 - 90 110 - 120
(Nm) (9,0 - 10,2) (12,4 - 13,6)
0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27,1)
ft.-lb. 0.375 25 - 28 35 - 40
(Nm) (34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
(54 - 61) (81 - 88)
0.500 65 - 70 90 - 100
(88 - 95) (122 - 136)
0.5625 90 - 100 125 - 140
(122 - 136) (170 - 190)
0.625 125 - 140 175 - 190
(170 - 190) (240 - 260)
0.750 220 - 245 300 - 330
(300 - 330) (410 - 450)
0.875 330 - 360 475 - 525
Page 857 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Page 858 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure SPEC-30-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Figure SPEC-30-2
O-ring Boss
Page 859 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Tightening Torque
x TORQUE
x ft.-lb.
Thread Size (Nm)
7/16 - 20 13 18)
9/16 - 18 22 (30)
3/4 -1 6 40 (54)
7/8 - 14 60 (81)
1-1/16 - 12 84 (114)
1-3/16 - 12 98 (133)
1-5/16 - 12 118 (160)
1-7/16 - 12 154 (209)
1-5/8 - 12 163 (221)
P-85926
Page 860 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
Figure SPEC-30-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (Nm)
1/4 7/16 - 20 13 (18)
5/16 1/2 - 20 17 (23)
3/8 9/16 - 18 22 (30)
1/2 3/4 - 16 40 (54)
5/8 7/8 - 14 60 (81)
3/4 1-1/16 - 12 84 (114)
7/8 1-3/16 - 12 98 (133)
1 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)
Specifications WARNING
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (32F [0C] and below), do not
AND VISCOSITY INDEX (VI) 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.
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
CONVERSIONS
SPEC-50-1
S630 Service Manual
SPEC-50-2
S630 Service Manual
Page 864 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
ALPHABETICAL INDEX
Page 866 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
HYDROSTATIC MOTOR CARRIER . . .30-30-1 SERVICE MANUAL REVISION . . . . . . SMR-1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-51-1 SERVICE PC (LAPTOP COMPUTER)
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
HYDROSTATIC SYSTEM INFORMATION SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SPARK ARRESTOR MUFFLER . . . . 10-170-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SPEED SENSORS (SJC) . . . . . . . . . . 60-80-1
LEFT SIDE LOWER PANEL . . . . . . .50-160-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 STEERING DRIFT COMPENSATION 60-161-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 STOPPING THE ENGINE AND LEAVING THE
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
LIFTING AND BLOCKING THE LOADER SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16 TIRE MAINTENANCE . . . . . . . . . . . 10-160-1
LOADER STORAGE AND RETURN TO TORQUE SPECIFICATIONS FOR BOLTS
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-190-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
LUBRICATING THE LOADER . . . . . .10-150-1 TOWING THE LOADER . . . . . . . . . . . 10-50-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-30-1 TRANSPORTING LOADER ON A TRAILER
MAINTENANCE CLOCK . . . . . . . . . .60-200-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 TROUBLESHOOTING . . . . . . . . . . . . 80-30-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .70-30-1 TURBOCHARGER . . . . . . . . . . . . . . .70-110-1
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER 50-70
ALPHABETICAL INDEX 50-100
50-121
Page 869 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
10-30
10-40 60-90
10-90 60-180
10-120
10-140 70-10
10-141 70-20
10-210 70-50
20-01 80-01
20-21 80-30
20-60 80-90
20-61
20-70 SPEC-10
20-80
20-90
20-110
30-40
30-60
30-70
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER
70-10
Page 871 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER 60-10
FOREWORD 60-50
60-90
Page 875 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
10-30 60-130
10-150 60-140
10-200 60-141
10-210 60-142
60-150
20-10 60-160
20-80 60-190
60-191
30-10 60-200
60-220
50-10
50-20 70-40
50-80
50-150 SPEC-10
50-160
50-170 ALPHABETICAL INDEX
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER
10-100
Page 877 - OSS# 2072104 - All rights reserved by Bobcat Company - 01/20/2010 - 17:21:56 - Produced by Ken Cook Co. with media1off
20-120
30-20
30-21
50-70
50-91
50-120
60-50
60-60
60-130
70-20
70-21 ADDED
70-70
SPEC-10
SPEC-40
ALPHABETICAL INDEX