T40140 - T40170 6986768 enUS SM

Service Manual
T40140, T40170 Telescopic Handler
S/N A8GA11001 & Above

S/N A8GB11001 & Above
Dealer Copy -- Not for Resale
6986768 (08-08) Revised (08-12) Printed in Belgium © Bobcat Company 2012
1 of 895
2 of 895
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.
P-90216
Never service the Bobcat
VersaHANDLER without instructions.
CORRECT WRONG WRONG

B-16082 B-16080 B-16079
Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER
required daily. hydraulic tubeline, hose, fitting, with boom up unless boom is
component or a part failure can held by an approved boom stop.
cause boom to drop. Do not go Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
WRONG WRONG WRONG
B-16081 B-16078 B-6589
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW12-0409
3 of 895
4 of 895
CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
5 of 895 1-3 T40140, T40170 Service Manual


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14


FOREWORD
This manual is for the Bobcat Telescopic Handler mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat Telescopic Handler 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 Telescopic Handler has had service
or repair:
1. Check that ROPS/FOPS 8. The parking brake must
(including right side window) function correctly.
is in good condition and is not
modified.
2. Check that ROPS mounting 9. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 10. Attachment locking pins must

correctly installed, functional function correctly and be in

and in good condition. good condition. Bob-Tach
wedges and linkages (if
equipped) must function
correctly and be in good
condition.
4. Check boom stop, replace if 11. Safety treads must be in good
damaged. condition.
5. Machine signs (decals) must 12. Check for correct function of

be legible and in the correct indicator lamps and gauges.
location.
6. Joystick control lever and foot 13. Check hydraulic fluid level,
pedals must return to neutral. engine oil level and fuel
supply.
7. Check for correct function of 14. Inspect for fuel, oil or

the work lights. hydraulic fluid leaks.
FW VH-0308 SM

15. Lubricate the telescopic 20. Check for any field
handler. modification not completed.
16. Check the condition of the 20. Operate the machine and
battery and cables. check all functions.
17. Inspect the air cleaner for 21. Check for correct function of
damage or leaks. Check the the Lateral Operator Restraint
condition of the element. System (LORS) if equipped.
18. Check the electrical charging 22. Check function or condition of

system. all equipped options and
accessories (examples: back-

up alarm, fire extinguisher,
rotating beacon, front
stabilisers, etc.).
19. Check tyres for wear and 23. Recommend to the owner
pressure. Use only approved that all necessary corrections
tyres. be made before the machine
is returned to service.
20. Inspect for loose or broken

parts or connections.
FW VH-0308 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, Operator’s 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 • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0807

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
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.
• The Telescopic Handler Operator Training Course is
DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Telescopic Handler.
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury. • The Telescopic Handler Safety Video is available from
D-1002-1107 your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
The dealer and owner / operator review the
WARNING recommended uses of the product when delivered. If the

owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
The signal word WARNING on the machine and in the recommendations on the new use.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI VH EMEA-0409 SM

SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION
Maintenance
The machine and some attachments have components

that are at high temperatures under normal operating
Cutting or drilling concrete containing sand or rock conditions. The primary source of high temperatures is
containing quartz can result in exposure to silica dust. the engine and exhaust system. The electrical system, if
Use a respirator, water spray or other means to control damaged or incorrectly maintained, can be a source of
dust. arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating.
All fuels, most lubricants and some coolants mixtures are

flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire.
Operation
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material,
explosive dust or gases.
Electrical
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI VH EMEA-0409 SM

FIRE PREVENTION (CONT’D) Welding And Grinding
Hydraulic System Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
Check hydraulic tubes, hoses and fittings for damage controllers before welding. Cover rubber hoses, battery
and leakage. Never use open flame or bare skin to check and all other flammable parts. Keep a fire extinguisher
for leaks. Hydraulic tubes and hoses must be properly near the machine when welding.
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage. Have good ventilation when grinding or welding painted
parts. Wear dust mask when grinding painted parts.
Always clean fluid spills. Do not use petrol or diesel fuel Toxic dust or gas can be produced.
for cleaning parts. Use commercial non-flammable
solvents. Dust generated from repairing non-metallic parts such as
hoods, fenders or covers can be flammable or explosive.
Fueling Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Stop the engine and let it cool before adding fuel. No

smoking! Do not refuel a machine near open flames or

sparks. Fill the fuel tank outdoors.
Starting
Do not use ether or starting fluids on any engine that has

glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you or bystanders. located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Use the procedure in the Operation & Maintenance Obey the recommendations on the instructions plate.
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
Check the spark arrester exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrester muffler (if equipped).
SI VH EMEA-0409 SM

SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the Telescopic Handler Figure 2

when requesting service information or when ordering
parts.
Telescopic Handler Serial Number
Figure 1
P-52151
P-24121
P-24121

The front, on the right side of the frame [Figure 1].
P-52152
The engine serial number is stamped on a plate near the

injection pump or at the rear of the cylinder block [Figure
2]. Always use the full number when ordering
replacement parts.
Other Serial Numbers
Some components can also have serial numbers. Always

use these serial numbers when requesting parts.

DELIVERY REPORT
Figure 3
B-16315
The Delivery Report must be completed by the dealer

and signed by the owner or operator when the Telescopic
Handler is delivered. An explanation of the form must be
given to the owner. Make sure it is complete [Figure 3].

BOBCAT TELESCOPIC HANDLER IDENTIFICATION
Ref. Designation
1 Telescopic boom
2 Stabilisers
3 Fuel tank
4 Mirror
5 Operator Cab
6 Battery compartment 1 10 7
7 Boom stop (option)
8 Engine exhaust
9 Lights 5
10 Working lights
11 Engine cover
12 Rotating beacon
13 Pallet forks
3
2

13
8 2 10 12 11 4
S1793

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
OPERATOR CAB (ROPS / FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER . . . . . . . . . . . . . . . . 10-30-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TOWING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Primary Fuel Filter (Pre-Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-100-3
Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
ATTACHMENT CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Draining Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Checking Oil Level (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Draining Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Checking Oil Level (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Draining Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TYRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Installing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Checking And Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Extend / Retract Chain Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-2
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-180-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER . . . . . . . . . 10-190-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER
Procedure
Always park the machine on a level surface.
WARNING
The seat bar system must deactivate the lift, and tilt
control functions when the seat bar is up. See your
Bobcat dealer for service if joysticks do not
deactivate. S4680
W-2461-1210
Figure 10-10-1 Put the floor jack under the centre of the rear axle. Lift the
Telescopic Handler and install jackstands [Figure 10-10-
2].

S4627
STOP the engine. Put the floor jack under the centre of
the front axle. Lift the Telescopic Handler and install
jackstands as shown in [Figure 10-10-1].
19 of 895 10-10-1 T40140, T40170 Service Manual


OPERATOR CAB (ROPS / FOPS) Emergency Exit
Figure 10-20-1 Figure 10-20-1
P-34374 P-34373
S7430
The telescopic handler has an operator cab (ROPS and Turn the handle (Inset) [Figure 10-20-1] and push the
FOPS) (Item 1) [Figure 10-20-1] to protect the operator rear window open. (Models with enclosed cab only.) Exit
from rollover and falling objects. Check with your dealer if through the rear window opening.
the operator cab has been damaged. Never operate

without right window. The seat belt must be worn for roll
over protection.
ROPS / FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449 (FOPS Level II).
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
death.
W-2906-0211

OPERATOR CAB (ROPS / FOPS) (CONT’D) Cab Door Window
Cab Door Figure 10-20-4
Figure 10-20-2
1
1
P-47202
P-47350
Turn the handle (Item 1) [Figure 10-20-4] (as shown).
Push open the window fully until it latches against the
Figure 10-20-3 cab.

Figure 10-20-5
1 1
P-47201
P-47203
The cab door can be opened from the outside of the cab
using the latch (Item 1) [Figure 10-20-2] and open from
the inside of the cab when you squeeze the latch (Item 1) Pull the lever (Item 1) [Figure 10-20-5] inside the cab to
[Figure 10-20-3] (as shown). disengage the latch and close the window.
The cab door can be locked (Item 2) [Figure 10-20-2]

with the start key.

TRANSPORTING THE TELESCOPIC HANDLER ON A Fastening
TRAILER
Figure 10-30-2
Loading And Unloading
Figure 10-30-1
3
2
4
1 1
S3519
1
P-97038 Fasten the telescopic handler to the transport vehicle to
prevent if from moving during sudden stops or when
going up or down slopes.
The telescopic handler must be loaded backward on the

trailer. • Block the wheels (Item 1) [Figure 10-30-2].
The rear of the trailer must be blocked or supported (Item • Fasten the machine frame to the transport vehicle
1) [Figure 10-30-1] when loading or unloading the (Items 2 and 3) [Figure 10-30-2].
telescopic handler to prevent the front end of the trailer
from raising up. • Attach the forks or bucket attachment to the transport
vehicle (Item 4) [Figure 10-30-2].
Be sure the transport and towing vehicles are of
adequate size and capacity. For the weight of telescopic
handler (See Weights on Page SPEC-10-2.)
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807


TOWING THE TELESCOPIC HANDLER Figure 10-40-4
Procedure DEACTIVATE - ACTIVATE
The telescopic handler can be towed a short distance

such as removing it from mud or loading onto a transport
vehicle.
1
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH S1394
• Block wheels to prevent roll away before

adjusting screws to bypass the park brake At each end of the central part of the front axle are two
system. bolts (see (Item 1) [Figure 10-40-3] and (Item 1) [Figure
• Return adjustment screws to the operating 10-40-4]). When screwed in, these bolts will remove the
position before operating the machine. spring pressure that engages the brake discs.
W-2808-0909
[Figure 10-40-4] shows the function of such a bolt inside

Block the wheels to prevent the machine from rolling. the axle.
The work will first be carried out on the two bolts on one

Releasing The Parking Brake Discs side of the front axle then the two bolts on the other side:
The brakes are engaged by spring pressure and released Loosen the locking nuts (Item 2) [Figure 10-40-3] of the
by hydraulic pressure. The park brake must be released bolts and create some clearance for the bolts.
manually before towing. Only the front axle has brakes.
Turn the two bolts (Item 1) [Figure 10-40-3] IN, 90° at a
The following procedure describes how to release the time, alternating between the two bolts until the bolts are
brakes: firmly seated.
Figure 10-40-3 Repeat this on the two opposite side bolts on the front
axle.
2
2 The brakes are now released for towing the machine.
Please note that the vehicle will not be able to brake until
the bolts are returned to their original position.
1
1
S2722

TOWING THE TELESCOPIC HANDLER (CONT’D) Engaging Brake Discs
Procedure (Cont’d)
Figure 10-40-5
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
1 SERIOUS INJURY OR DEATH
Operating • Block wheels to prevent roll away before
Position
adjusting screws to bypass the park brake
system.
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909
Towing
Position Block the wheels to prevent the machine from rolling.
After towing is completed, turn the tow valve (Item 1)

S6802 [Figure 10-40-5] clockwise 90° to the OPERATING
POSITION.
Raise the engine cover.
Figure 10-40-6

Turn the tow valve (Item 1) [Figure 10-40-5]
anticlockwise 90° to TOWING POSITION. 2
2
Tow the telescopic handler at a slow speed.
1
1
S2722
To reactivate the park brake, release the four bolts (see

(Item 1) [Figure 10-40-6] on the front axle to their
original position (turn the two bolts out, 90° at a time, until
no resistance can be felt. Repeat this procedure for the
opposite side two bolts).
Make sure that all four bolts have been turned out until
they can easily be loosened by hand. Tighten the locking
nuts (Item 2) [Figure 10-40-6].
This will allow the park brake piston to be active again.

SERVICE SCHEDULE
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 telescopic handler.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals when making repairs, adjustments
WARNING 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-EN-0903
SERVICE SCHEDULE HOURS

[5]
ITEM SERVICE REQUIRED 10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with lithium based multipurpose grease.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety tread and mirrors. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl / water trap.
Nuts and Bolts Check for loose nuts and bolts. Tighten as needed.
Seat Belt Check the condition of the seat belt.
Brakes Check for function. Service as necessary.
Back-up Alarm (if equipped) Check for function. Replace as necessary.
Tyres Check for wear or damage. Inflate to correct pressure. Be sure all tyres are
inflated to the same pressure. Use only approved tyres.
Engine Air Filter And Air System Check condition indicator, replace element when required and empty dust

cup as needed. Check air system for leaks.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. check
coolant level cold in reservoir. Add premixed coolant as needed. (See
ENGINE COOLING SYSTEM.) Check cooling system for leaks.
King Pins, Axle Oscillation (Rear), Lubricate with lithium based multipurpose grease.
Attach. Frame Pivot(s), Tilt / Lift
Cyl., Boom Pivot, Self-Levelling /
Side Shift Cyl. and Structure
Telescopic Boom Slide Lubricate with lithium based multipurpose grease. Check wear blocks for
adjustment or replacement.
Hydraulic Hoses, Tubelines and Check condition of hoses, tubelines and connectors. Repair or replace as
Connections needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed (300 N•m [221 ft-lb]). [1]
Boom Chain Check and apply chain lubricant as needed. Check chain tension and wear.
Adjust or replace as necessary.
Alt. & Air Cond. Belt (if equipped) Check belt tension and adjust as needed. [2]
Door hinges Lubricate door hinges with lithium based multipurpose grease.
Engine Oil and Filter Replace the engine oil and filter. See (See Fluid Capacities on Page SPEC-
10-4.) for correct capacity. Use a genuine Bobcat filter. [2]
Engine Air Filter Replace the outer filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, secondary Replace the secondary fuel filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, primary Replace the primary fuel filter (pre-filter) element. Use a genuine Bobcat filter. [2]
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. [2]
Hydraulic Tank Breather Replace the hydraulic tank breather.
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. See (See Fluid Capacities on
Page SPEC-10-10.)
Front and Rear Axle Fluid Replace the axle fluid. See (See Fluid Capacities on Page SPEC-10-4.) [3] [4]
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Engine valve lash Check and adjust as needed.
Stabilisers: Cylinders and pivots Lubricate with lithium based multipurpose grease.
Engine Coolant Check freeze protection of antifreeze -30°C (-34°F). Flush cooling system
and replace with premixed coolant Every 2 years
[1]Check wheel nut torque every 8 hours for the first 24 hours.
[2] Perform service first time, then as indicated in chart.
[3] Check level.
[4] Replace fluid first time, then as indicated in chart.
[5] Or every 12 months.


AIR CLEANER SERVICE Figure 10-60-2
Replacing Filter Element
Outer Filter
Figure 10-60-1
S6804
1
Pull the element straight out [Figure 10-60-2].
NOTE: Make sure all sealing surfaces are free of dirt

S3571
and debris.
Replace the large (outer) filter element only when the red Install a new outer element.

ring shows in the window of the condition indicator
(Item 1) [Figure 10-60-1]. Install the dust cover and fasten [Figure 10-60-1].
NOTE: Before replacing the filter element, push the
Connect the filter housing clamps.
button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the red
ring does not show, do not replace the filter
element.
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.
Figure 10-60-1
2 1 S6803
Loosen the filter housing clamps (Item 1) [Figure 10-60-

1].
Release the fastener and remove the cover (Item 2)

[Figure 10-60-1].

AIR CLEANER SERVICE (CONT’D)
Replacing Filter Element (Cont’d)
Inner Filter
Remove the outer element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Figure 10-60-3

S6805
Remove the inner filter (Item 1) [Figure 10-60-3] and

install a new element.
Install the outer element.
Install the dust cover and fasten [Figure 10-60-1].
Connect the filter housing clamp (Item 1) [Figure 10-60-

1].

ENGINE COOLING SYSTEM Use low air pressure or water pressure to clean the
radiator, oil cooler and intercooler [Figure 10-70-2].
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage. Removing And Replacing The Coolant
WARNING WARNING
AVOID INJURY OR DEATH AVOID BURNS
Wear safety glasses to prevent eye injury when any Do not remove radiator cap when the engine is hot.
of the following conditions exist: You can be seriously burned.
• When fluids are under pressure. W-2070-1203
• Flying debris or loose material is present.
• Engine is running. Open the engine cover.
• Tools are being used.
W-2019-0907 Figure 10-70-3
Cleaning
1
Figure 10-70-1

2
MAX
1
MIN
S3528
Remove the cap (Item 1) [Figure 10-70-3] from the

S3527
coolant reservoir.
Remove the fan shield.

Open the engine cover (Item 1) [Figure 10-70-1].
Figure 10-70-2
S6815

ENGINE COOLING SYSTEM (CONT’D) Follow the following steps when using concentrated
coolant instead of a ready-to-use premix:
Removing And Replacing The Coolant (Cont’d)
• mix the coolant in a separate container:
Figure 10-70-4 4,3 L (one gallon and one pint) of ethylene glycol
mixed with 3,8 L (one gallon) of water is the correct
mixture of coolant to provide a -37°C (-34°F) freeze
protection.
• Add premixed coolant, 47% water and 53% ethylene

glycol to the coolant tank until the coolant level
reaches the MIN marker on the tank (Item 1) [Figure
10-70-3].
1 Run the engine until it is at operating temperature.
Stop the engine.
2 Check the coolant level (COLD) in the reservoir when

S6817
cool.
Add coolant to the reservoir as needed.

Remove the engine block drain plug (Item 1) [Figure 10-
70-4].

Open the drain valve (Item 2) [Figure 10-70-4] and drain
all of the coolant into a container. Dispose of used IMPORTANT
coolant in an environmentally safe manner.
AVOID ENGINE DAMAGE
Close the drain valves. Always use the correct ratio of water to antifreeze.
NOTE: The cooling system is factory filled with Too much antifreeze reduces cooling system
ethylene glycol (EG) coolant. DO NOT mix efficiency and may cause serious premature engine
ethylene glycol with propylene glycol. damage.
Add premixed coolant to the reservoir if the coolant level
Too little antifreeze reduces the additives which
is low.
protect the internal engine components; reduces the
Use a refractometer to check the condition of ethylene boiling point and freeze protection of the system.
glycol in your cooling system.
Always add a premixed solution. Adding full strength
Fill the radiator with the premixed coolant. Install the concentrated coolant can cause serious premature
radiator cap. engine damage.
I-2124-0497
Add coolant to the reservoir. The coolant level must be
between the MIN and MAX marks (Item 2) [Figure 10-
70-3] on the coolant reservoir.

ENGINE COOLING SYSTEM (CONT’D)
Checking Level
Open the engine cover.

IMPORTANT
Check the coolant level in the coolant reservoir. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Figure 10-70-5
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
1 Always add a premixed solution. Adding full strength

MAX concentrated coolant can cause serious premature
engine damage.
MIN
I-2124-0497
S3528

The coolant level must be between the MIN and MAX
marks (Item 1) [Figure 10-70-5] on the coolant reservoir
when the engine is cold.


FUEL SYSTEM Biodiesel Blend Fuel
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 problems in cold • Biodiesel blend fuel is an excellent medium for
temperatures: microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
TEMPERATURE NO. 2 NO. 1 • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
-9°C (+15°F) 100% 0%
fuel filters and deteriorated fuel lines.
Down to -29°C (-20°F) 50% 50%
• Shorter maintenance intervals may be required, such
Below -29°C (-20°F) 0% 100%
as cleaning the fuel system and replacing fuel filters
and fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
must be used in this machine: • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
The following fuels may also be used in this machine: deterioration of hoses, tubelines, injectors, injector
pump and seals.
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
Apply the following guidelines if biodiesel blend fuel is

used:
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
• Ensure the fuel tank is as full as possible at all times
sulfur petroleum based diesel. This is commonly
to prevent moisture from collecting in the fuel tank.
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or • Ensure that the fuel tank cap is securely tightened.
EN590 (EU Standard) specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabiliser and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term
stability and should not be stored for more
than 3 months.

FUEL SYSTEM (CONT’D) Secondary Fuel Filter
Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the secondary fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 10-80-2
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
1
Figure 10-80-1
S6824

Remove the filter element (Item 1) [Figure 10-80-2].
Clean the area around the filter housing.
Install the new filter element with a new seal, and hand
tighten.
S3524 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
Remove the fuel fill cap (Item 1) [Figure 10-80-1].
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
WARNING
SMOKING!
Always clean up spilled fuel or oil. Keep heat, flames,
Install and tighten the fuel fill cap [Figure 10-80-1].
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Figure 10-80-5
Primary Fuel Filter (Pre-Filter)

1
See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
2
Replacing Element
Figure 10-80-3
S36232
Remove the filter element (Item 1), bowl (Item 2) and

bottom cover (Item 3) [Figure 10-80-5] from the filter
housing.
Clean the area around the filter housing and reinstall

1 using a new filter element (Item 1) [Figure 10-80-5].

S36232 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
Open the drain valve (Item 1) [Figure 10-80-3] on the Removing Water
bottom cover of the fuel primary filter and allow the fluid
to drain into a container. Figure 10-80-6
Tighten the drain valve (Item 1) [Figure 10-80-3] by hand
pressure.
Figure 10-80-4
1
1 S36232
Open the drain valve (Item 1) [Figure 10-80-6] on the

fuel pre-filter bottom cover to remove water from the filter.
S36233
When clean fuel drains from the water separator, tighten

the drain valve (Item 1) [Figure 10-80-6] by hand
Hold the filter assembly (Item 1) and remove the screw pressure.
(Item 2) [Figure 10-80-4].

FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System
Figure 10-80-7
WARNING
2
sparks or lighted tobacco away from fuel and oil.
1
explosion or fire.
W-2103-0508
WARNING
S36409 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.
After replacing the filter element or when the fuel tank Use a piece of cardboard or wood to find leaks. Do
has run out of fuel, the air must be removed from the fuel not use your bare hand. Wear safety goggles. If fluid

system before starting the engine. enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Turn the Start key switch to the Preheat position (Item 1) W-2072-0807
[Figure 10-80-7] (this will activate the electrical pump
relay).
Leave the Start key switch in the Run position (Item 2)

[Figure 10-80-7] for 3 minutes.
Crank the engine with the accelerator pedal released

(low idle position) until the engine starts.
Run the engine at low idle for approximately 5 seconds

then cycle the accelerator pedal rapidly from the low idle
position to the high idle position three times. The time
taken to cycle the accelerator pedal to be typically one to
3 seconds. This will assist in displacing any residual
trapped air in the fuel injection pump.
Check for fuel leaks in the fuel system.

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2
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 10-90-1 CRANKCASE)
S6807

Open the engine cover and remove the dipstick (Item 1) TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-90-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick [1] Synthetic Oil - Use recommendation from Synthetic
(Inset) [Figure 10-90-1]. Oil Manufacturer.
Use a good quality engine oil that meets API Service Use good quality engine oil that meets API Service
Classification of CI-4 or better. (See Oil Chart, [Figure Classification of CI-4 or better. (See Oil Chart, [Figure
10-90-2].) 10-90-2].)

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4
Removing And Replacing Oil And Filter
See the SERVICE SCHEDULE for the service interval for

replacing the engine oil and filter. (See SERVICE
Run the engine until it is at operating temperature. Stop

1
the engine.
Figure 10-90-3
S6814
1
Open the engine cover. (See Opening And Closing on

Page 10-160-1.)
Remove the oil filter (Item 1) [Figure 10-90-4].
Clean the filter housing surface.

Put clean oil on the new oil filter gasket. Install the filter
and hand tighten.
S3525
Figure 10-90-5
Remove the access panel at the rear of the engine

1
compartment. Route the hose (Item 1) [Figure 10-90-3]
out through the access hole. Remove the cap.
Drain the oil into a container and recycle or dispose of 2

used oil in an environmentally safe manner.
Install cap and put the drain hose into the engine
compartment, install the access cover.
WARNING S6809
AVOID INJURY OR DEATH Remove the filler cap (Item 1) [Figure 10-90-5].
sparks or lighted tobacco away from fuel and oil. Put oil in the engine. For capacity, (See Fluid Capacities
Failure to use care around combustibles can cause on Page SPEC-10-4.). For type, (See Oil Chart, [Figure
explosion or fire. 10-90-2].)
W-2103-0508
Install fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Remove the dipstick (Item 2) [Figure 10-90-5] and check

the oil level. Add oil as needed if it is not at the top mark
on the dipstick.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-100-3

HYDRAULIC / HYDROSTATIC FLUID
Use only recommended fluid in the hydraulic system. RECOMMENDED ISO VISCOSITY GRADE (VG)
(See Hydraulic / Hydrostatic Fluid Chart on Page 10-100- AND VISCOSITY INDEX (VI)
1.)
Stop the machine on a level surface. Lower the boom all

the way.
Stop the engine.
Figure 10-100-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 120
[2] VG 46; Minimum VI 140

[3] Synthetic Fluid; VG 46; Minimum VI 150
[4] BOBCAT Hydraulic / Hydrostatic Fluid
1
Use only recommended fluid in the hydraulic system
P-97034
[Figure 10-100-3]. (See Specifications on Page SPEC-
50-1.)
Check the fluid level at the sight gauge (Item 1) [Figure
10-100-1].
Figure 10-100-2
P-97033
Remove the fill / breather cap (Item 1) [Figure 10-100-2]

and add hydraulic fluid.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-5
Removing And Replacing Hydraulic Fluid
WARNING
Diesel fuel or hydraulic fluid under pressure can
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-52179
from a physician familiar with this injury.
W-2072-0807
Remove the reservoir drain plug (Item 1) [Figure 10-100-
5] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner. Reinstall the drain plug and
WARNING tighten.

Add fluid until it is at the centre of the sight gauge (Item 1)
AVOID INJURY OR DEATH [Figure 10-100-5].
sparks or lighted tobacco away from fuel and oil. Install the fill cap.
explosion or fire.
W-2103-0508
Figure 10-100-4
P-97033
Remove the fill / breather cap (Item 1) [Figure 10-100-4].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Hydraulic Tank Breather
Removing And Replacing Hydraulic / Hydrostatic (See SERVICE SCHEDULE on Page 10-50-1.) for the
Filter correct replacement interval.
See the SERVICE SCHEDULE for the correct service Open the engine cover. (See Opening And Closing on
intervals. (See SERVICE SCHEDULE on Page 10-50-1.) Page 10-160-1.)
Figure 10-100-6 Figure 10-100-8
1
1
P-97034 P-97033

Unscrew the plug (Item 1) [Figure 10-100-6] by hand. Remove and discard the breather (Item 1) [Figure 10-
100-8].
Figure 10-100-7
Install the new breather.
1
S6819
Remove the cartridge (Item 1) [Figure 10-100-7] from

the oil filter.
NOTE: Be careful to keep impurities from getting into

the hydraulic / hydrostatic system.
Put the new cartridge in the oil filter.

Top up the oil if necessary.
Inspect the seal and replace if necessary.
Replace the plug.


ATTACHMENT CARRIER Figure 10-110-3
Inspection And Maintenance
Figure 10-110-1
P-23856
The telescopic handler attachment locking pins (Item 1)

P-23854 [Figure 10-110-3] must move freely. The pins must not
be bent or the ends deformed.
The telescopic handler mounting hooks (Item 1) [Figure Figure 10-110-4

10-110-1] must not be damaged. Check for cracked or

broken hooks.
Figure 10-110-2
S3547
1
The pins must extend through the holes in the

P-23858 attachment mounting frame (Item 1) [Figure 10-110-4].
Lubricate the attachment carrier. (See SERVICE

The stop blocks (Item 1) [Figure 10-110-2] must not be SCHEDULE on Page 10-50-1.) (See LUBRICATING THE
damaged. Check for bent or broken stop blocks. TELESCOPIC HANDLER on Page 10-130-1.)


AXLES (FRONT AND REAR) Draining Oil (Planetary Carrier)
Checking Oil Level (Planetary Carrier) (See SERVICE SCHEDULE on Page 10-50-1.) for the
correct service interval.
Figure 10-120-1
Figure 10-120-2
S1954
S1954
Put the machine on a level surface with the plug (Item 1)

[Figure 10-120-1] positioned as shown. Put the machine on a level surface with the plug (Item 1)

[Figure 10-120-2] positioned as shown.
Remove the plug (Item 1) [Figure 10-120-1]. The oil level
should be at the bottom edge of the plug hole. Remove the plug (Item 1) [Figure 10-120-2] and drain
into a container. Recycle or dispose of the used lubricant
Add gear lube through the hole if the oil level is below the in an environmentally safe manner.
hole. For quantity, (See Fluid Capacities on Page SPEC-
10-4.) For type, (See Specifications on Page SPEC-50- Reposition the plug hole and add gear lube until the lube
1.) level is at the bottom edge of the plug hole (Item 1)
[Figure 10-120-1]. For quantity, (See Fluid Capacities on
Install and tighten the plug. Page SPEC-10-4.) For type, (See Specifications on Page
SPEC-50-1.)
Repeat the procedure for the other side.
Install and tighten the plug.
Repeat the procedure for the other side.

AXLES (FRONT AND REAR) (CONT'D) Checking Oil Level (Front Differential)
Checking Oil Level (Rear Differential) Figure 10-120-5

Figure 10-120-3
S1843
S1841
Figure 10-120-6
With the machine on a level surface, remove the plug
(Item 1) [Figure 10-120-3]. The oil level should be at the 2
bottom edge of the plug hole.
1

Add oil through the hole if the oil level is below the bottom
edge of the hole. For quantity, (See Fluid Capacities on
Page SPEC-10-4.) For type, (See Specifications on Page
SPEC-50-1.)
Install and tighten the plug.
Draining Oil (Rear Differential)
(See SERVICE SCHEDULE on Page 10-50-1.) for the

correct service interval. S1851
Figure 10-120-4
Remove the plugs (Item 1) [Figure 10-120-5] and (Items
1 and 2) [Figure 10-120-6]. The oil level should be at the
bottom edge of the plug holes.
Add oil through the holes if the oil level is below the
bottom edge of the holes. For quantity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See
Specifications on Page SPEC-50-1.)
Install and tighten the plugs.

1
S1842
With the machine on a level surface remove the plug

(Item 1) [Figure 10-120-4] and drain into a container.
Recycle or dispose of the used lubricant in an
environmentally safe manner. Add oil through the hole till
the oil level is at the bottom edge of the plug hole (Item 1)
[Figure 10-120-3].

AXLES (FRONT AND REAR) (CONT'D) Figure 10-120-9
Draining Oil (Front Differential)
(See SERVICE SCHEDULE on Page 10-50-1.) for the

correct service interval.
1
Figure 10-120-7
S1844
1 Figure 10-120-10
S1845

Figure 10-120-8
1
S1843

(Item 1) [Figure 10-120-9] and [Figure 10-120-10] and
1 drain into a container. Recycle or dispose of the used
lubricant in an environmentally safe manner.
S1846

(Item 1) [Figure 10-120-7] and [Figure 10-120-8] and
drain into a container. Recycle or dispose of the used
lubricant in an environmentally safe manner.


LUBRICATING THE TELESCOPIC HANDLER Figure 10-130-3
Lubrication Locations
Lubricate as specified in the SERVICE SCHEDULE for 1 1

the best performance of the machine. (See SERVICE
Record the operating hours each time you lubricate so

that it is performed at the correct interval.
Always use a good quality lithium based multipurpose

grease. Apply lubricant until extra grease shows.
Lubricate the following locations on the telescopic

handler: S3539
Figure 10-130-1
3. Attachment Frame Pivot (Item 1) [Figure 10-130-3].
Figure 10-130-4

1
1
S4507
S3540
1. Axle Pivots - Top and bottom (Item 1) [Figure 10-130-
1] all four wheels.
4. Base end tilt cylinder (Item 1) [Figure 10-130-4].
Figure 10-130-2
S4508
2. Axle Oscillation - Rear Axle (Item 1) [Figure 10-130-

2].

(CONT'D)
Lubrication Locations (Cont’d)

1
Figure 10-130-5
S4511
7. Cant and Side Offset Correction Frame (on both

1 sides) (Item 1) [Figure 10-130-7].
S4509
Figure 10-130-8
5. Rod end tilt cylinder (Item 1) [Figure 10-130-5].

Figure 10-130-6
2 2 2
1
1
3 3
1
S4512
8. Cant and Side Offset Correction Cylinder (Item 1)

2 2 2 [Figure 10-130-8] (photograph from under machine).
S4510
6. Tilt Cylinder pivot (on both sides) (Item 1).

Boom Slide (Item 2) (T40170 shown, which has four
boom sections versus three sections for the T40140
model).
Chain Pulley Pivot (on both sides) (Item 3) [Figure
10-130-6] (T40170 shown, which has two front chain
pulleys versus 1 for the T40140)

(CONT'D)
Figure 10-130-9
1
2
S4525
1
11. Lift (Item 1) and Slave (Item 2) [Figure 10-130-11]
Cylinder Base End.
S4514
NOTE: The rear cover must be removed.
9. Stabiliser Cylinder (Item 1) [Figure 10-130-9]. Figure 10-130-12

Figure 10-130-10
2 1
1
1 S4525
S4513
12. Lift and Slave Cylinder Pivot Pin (Item 1) [Figure 10-
130-12] (both sides).
10. Lift and Slave Cylinder Rod End (Item 1) and Pivot
(Item 2) [Figure 10-130-10]
NOTE: Raise the boom and install the boom stop

(See Installing The Approved Boom Stop on
Page 10-150-1.) before lubricating the boom
cylinder.

(CONT'D)

1
Figure 10-130-13
1 1
1
P-52182
15. Cab Door Hinges (Item 1) [Figure 10-130-15]

1 1
(Lower).
S4515
13. Boom Slide (T40170: 12 grease nipples / T40140:

eight grease nipples) (Item 1) [Figure 10-130-13].
NOTE: The rear cover must be removed.
Figure 10-130-14
P-52183
14. Cab Door Hinges (Item 1) [Figure 10-130-14]

(Upper).

TYRE MAINTENANCE Mounting
Wheel Nuts
Figure 10-140-1
WARNING
When the engine is running during service, the Travel
Direction Lever must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2397-0301
Tyres are to be repaired only by an authorised person

using the correct procedures and type of equipment.
Tyres and rims must always be checked for correct size

before mounting. Check rim and tyre bead for damage.
S2004
The rim flange must be cleaned and free of rust. The tyre
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tyre.
(See SERVICE SCHEDULE on Page 10-50-1.) [Figure
10-140-1] for the service interval to check the wheel nuts. Avoid excessive pressure which can rupture the tyre and

The correct torque is 360 N•m (266 ft-lb) torque. cause serious injury or death.
Rotation During inflation of the tyre, check the tyre pressure

frequently to avoid over inflation.
Check the tyres regularly for wear, damage and pressure.
(See Traction on Page SPEC-10-3.) for the correct tyre
pressure.
Rear tyres usually wear faster than front tyres. To keep

the wear even, move the front tyres to the rear and rear
tyres to the front.
It is important to keep the same size tyres on each side of

the telescopic handler. If different sizes are used, each
tyre will be turning at a different rate and cause excessive
wear. The tread bars of all the tyres must face the same
direction.
Recommended tyre pressure must be maintained to

avoid excessive tyre wear and loss of stability and
handling capacity. Check for the correct pressure before
operating the telescopic handler.


APPROVED BOOM STOP Figure 10-150-2
If the boom is raised for service or maintenance, use the

following procedure to install and remove the boom stop.
Installing The Approved Boom Stop
• Put the telescopic handler on a flat, solid and level

surface.
• With the operator in the seat, seat belt fastened,

Travel Direction Control in neutral and the parking
brake engaged, start the engine and raise the boom.
Stop the engine.
Figure 10-150-1 S4516
• Install the boom stop over the rod of the boom

cylinder [Figure 10-150-2].
• Install the pins and secure the fasteners

[Figure 10-150-2].
1

• Start the engine and lower the boom slowly [Figure
10-150-2] so that the boom stop is held securely.
Removing The Approved Boom Stop
• Start the engine and raise the boom. Stop the engine.
P-58126
• Remove the fasteners, pins and boom stop.
• Have a second person remove the boom stop (Item 1) • Put the boom stop in the storage position and secure
[Figure 10-150-1] from the storage position. with pins and fasteners.
• Start the engine and lower the boom


ENGINE COVER
Opening And Closing
Figure 10-160-1
P-52162
Pull the latch handle (Item 1) [Figure 10-160-1] out and

rotate anticlockwise. Raise the engine cover to provide

access for maintenance.


CHAIN Extend Chains Tightness
Checking And Adjustment Procedure Figure 10-170-2
Retract Chains Tightness 1
Figure 10-170-1
3
2 4
2
1
3
S3574
4 Loosen the two lock nuts (Item 1) [Figure 10-170-2].

S3573
Check the tightness of the adjustment nuts (located
behind the lock nuts). The correct torque value is 18 N•m

Loosen the lock nuts (Item 1) [Figure 10-170-1]. (13.5 ft-lb).
Check the tightness of the adjustment screw (Item 2) Tighten the adjustment nuts as required.
[Figure 10-170-1]. The correct torque value is 30 N•m
(22.1 ft-lb). Tighten the adjustment nuts alternately and evenly as
required to achieve the desired torque value. Distance
Tighten the adjustment screws as required. The chain between the mounting surface on the top of the outer
anchor (Item 3) must be perpendicular to the bottom of boom section (Item 2) and the chain anchors (Item 3)
the intermediate boom section. Re-position the chain MUST be even. DO NOT tighten one chain (Item 4)
anchor as required using screw (Item 4) [Figure 10-170- [Figure 10-170-2] more than the other.
1] and lock nut to position the anchor correctly.
Re-tighten the lock nuts.
Re-tighten the lock nuts.
Start the engine and operate the extend / retract function
through several cycles to check for proper operation.
Repair as required.

CHAIN (CONT’D)
Extend / Retract Chain Wear Check
Start the engine. Extend the boom completely in the

horizontal position. Shut off the engine.
Figure 10-170-3
S0581

As shown in [Figure 10-170-3], use a Vernier caliper to
measure the length “L” of 11 links of the extend chain.
Measure from the outside edge of link pin 1 to outside
edge of link pin 11.
The wear is considered normal as long as “L” is less than

169,50 mm (6.68 in).
If “L” is equal to or longer than 169,50 mm (6.68 in), the

chains, pins, rollers, tension rods and attachment screws
MUST be replaced.
Each time the chain wear is checked, record the date,

machines hours and measurement “L” for future
reference.

TELESCOPIC HANDLER STORAGE AND RETURN TO
SERVICE
Storage
Return To Service
Sometimes it may be necessary to store your Bobcat
telescopic handler for an extend period of time. Below is After the Bobcat telescopic handler has been in storage,
a list of items to perform before storage. it is necessary to follow a list of items to return the
telescopic handler to service.
• Thoroughly clean the telescopic handler including the
engine compartment. • Check the engine and hydraulic fluid levels; check
coolant level.
• Lubricate the telescopic handler.
• Install a fully charged battery.
• Replace worn or damaged parts.
• Remove grease from exposed cylinder rods.
• Park the telescopic handler in a dry protected shelter.
• Check all belt tensions.
• Lower the boom all the way and put the attachment (if
equipped) flat on the ground. • Be sure all shields and guards are in place.
• Put grease on any exposed cylinder rods. • Lubricate the telescopic handler.
• Put fuel stabiliser in the fuel tank and run the engine • Check tyre inflation and remove blocks from under

a few minutes to circulate the stabiliser to the pump frame.
and fuel injectors.
• Remove cover from exhaust pipe opening.
If biodiesel blend fuel has been used, perform the
following: • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
Drain the fuel tank, refill with 100% petroleum diesel correct operation.
fuel, add fuel stabiliser and run the engine for at least
30 minutes. • Operate machine, check for correct function.
• Drain and flush the cooling system. Refill with • Stop the engine and check for leaks. Repair as
premixed coolant. needed.
• Replace all fluids and filters (engine, hydraulic /
hydrostatic).
• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is

correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage

condition.


STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER
Procedure WARNING
• Stop the telescopic handler on solid, flat and level
ground. Before you leave the operator’s position:
• Put the travel Direction Control Lever and the
• Put the Travel Direction Control Lever and Joystick in Joystick in neutral.
neutral. • Engage the parking brake.
• Retract and lower the boom and attachment flat
• Engage the parking brake. (See the Operation & on the ground.
Maintenance Manual for the correct procedure.) • Stop the engine. Raise the restraint bar (if
equipped).
Figure 10-190-1 SEE THE MACHINE OPERATION & MAINTENANCE
MANUAL FOR MORE INFORMATION.
W-2637-0607

S3518
• Retract and lower the boom and attachment flat on

the ground [Figure 10-190-1].
• Turn the key switch to STOP and unfasten the seat

belt.
• Use grab handles, safety tread and steps when

getting off.
DO NOT JUMP


EMERGENCY EXIT
Rear Window
Figure 10-200-1
S3520
Turn the handle (see picture inset) [Figure 10-200-1] and

push the rear window open. Exit through the rear window

opening.


HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
STEERING CYLINDER (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
QUICK-TACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
FRAME LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4

Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Checking Drain Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Valve Section Troubleshooting (Auxiliary Section Example) . . . . . . . . . . . . . . . . . . 20-170-1
Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-13
Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-13
Inlet Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-18
Inlet Section Disassembly And Assembly (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . 20-170-19
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

Parking Brake Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

Parking Brake Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-2
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1
TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1

STABILISER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-5
STABILISER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-4


Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
T40140 (S/N A8GA11001 AND ABOVE)
T40140 (S/N A8GC11001 AND ABOVE)
T40170 (S/N A8GB11001 AND ABOVE)
T40170 (S/N A8GD11001 AND ABOVE)
(Printed JANUARY 2012)
6927504-A-legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE – Charge: 36 RELIEF VALVE – Load Sense (LSRV): SOLENOID ACTIVATED DIRECTIONAL
53
Reservoir Capacity 76 L (20 U.S. gal) 3000 kPa (30 bar) (435 psi) 24000 kPa (240 bar) (3480 psi) CONTROL VALVE – MOTOR
System Capacity 135 L (35.7 U.S. gal) DISPLACEMENT CONTROL SPOOL
20 RELIEF/REPLENISHING VALVE - HIGH
2 FILTER - Hydraulic PRESSURE (2): 65000 kPa (650 bar) (9428 psi) 37 LOAD SENSE ACTIVATION VALVE 54 SHUTTLE VALVE - Drain
3 SPRING LOADED FILTER BYPASS 21 VARIABLE CAPACITY DISPLACEMENT 38 ACCUMULATOR: 1,4 L (1,5 qt) - Dealer Copy -- Not for Resale
55 FLUSHING VALVE
VALVE: 250 kPa (2,5 bar) (36 psi) BIDIRECTIONAL HYDROSTATIC PUMP 1500 kPa (15 bar) (218 psi)
4 CHECK VALVE 22 39 CHECK VALVE 56 VARIABLE CAPACITY DISPLACEMENT

CHARGE PUMP:
BIDIRECTIONAL HYDROSTATIC MOTOR
32 L/min (8.5 U.S. gpm) @ High Engine Idle
40 PRESSURE SWITCH: 1600 kPa(16 bar) (232 psi)
5 CHECK VALVE - With 50 kPa (0,5 bar) 57
23 SERVO PISTON - Swash Plate SERVO PISTON - Swash Plate
(7 psi) Spring
41 RELIEF VALVE: 25000 kPa (250 bar) (3626 psi)
58 TOW VALVE
6 BOOM CYLINDER LOCK VALVE - Lock 24 HYDRAULIC PUMP - Gear type:
Pressure: 37500 kPa (375 bar) (4641 psi) 36 L/min (9.5 U.S. gpm) @ High Engine Idle 42 HYDRAULIC PUMP - Gear type:
9 L/min (2.38 U.S. gpm) @ High Engine Idle 59 ACCUMULATOR: 0,5 L (0,53 qt) -
7 ORIFICE 25 HYDRAULIC PUMP - Gear type: 7200 kPa (72 bar) (1044 psi)
37 L/min (9.8 U.S. gpm) @ High Engine Idle 43 SOLENOID ACTIVATED DIRECTIONAL 60 CHECK VALVE - With 350 kPa (3,5 bar)
8 TILT CYLINDER LOCK VALVE: CONTROL VALVE – Boom Cylinder Lowering (43 psi) Spring
24500 kPa (245 bar) (3552 psi) 26 PRIORITY VALVE
44 SOLENOID ACTIVATED DIRECTIONAL 61 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
9 SELF LEVELING CYLINDER LOCK VALVE:
25000 kPa (250 bar) (3625 psi) 27 CHECK VALVE CONTROL VALVE – Extension Cylinder Retract
62 CHECK VALVE – Anti-cavitation
10 EXTENSION CYLINDER BASE PILOT VALVE: 28 SHUTTLE VALVE 45 SOLENOID ACTIVATED DIRECTIONAL
25000 kPa (250 bar) (3625 psi) CONTROL VALVE – Bucket Position Cylinder 63 SOLENOID ACTIVATED DIRECTIONAL
29 LOAD CHECK CONTROL VALVE – Fan Reversing
11 EXTENSION CYLINDER ROD PILOT VALVE: 46 SOLENOID ACTIVATED DIRECTIONAL
25000 kPa (250 bar) (3625 psi) CONTROL VALVE – Boom Cylinder 64 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30 ANTICAVITATION/WORK PORT RELIEF
12 NOT USED FOR THIS MODEL VALVE: 22000 kPa (220 bar) (3191 psi)
47 SOLENOID ACTIVATED DIRECTIONAL 65 PRESSURE SWITCH:
ANTICAVITATION/WORK PORT RELIEF CONTROL VALVE – Stabiliser Cylinder 10000 kPa(100 bar) (1450 psi)
13 FRAME LEVELING CYLINDER LOCK 31
VALVE: 28000 kPa (280 bar) (4061 psi) VALVE (2): 21000 kPa (210 bar) (3045 psi)
48 SOLENOID ACTIVATED DIRECTIONAL 66 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Stabiliser CONTROL VALVE – With Two Speed Fan
14 STABILISER CYLINDER LOCK VALVE: 32 LOAD COMPENSATING VALVE:
28000 kPa (280 bar) (4061 psi) 750 kPa (7,5 bar) (109 psi) Motor (Optional)
49 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Stabiliser Cylinder
15 STABILISER CYLINDER LOCK VALVE: 33
21000 kPa (210 bar) (3046 psi) PRESSURE REDUCING VALVE:
2000 kPa (20 bar) (290 psi) 50 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
16 SOLENOID - Reverse Drive
34 PILOT RELIEF VALVE: NOTE: Unless otherwise specified
3000 kPa (30 bar) (435 psi) 51 RELIEF VALVE (2):
17 SOLENOID - Forward Drive springs have NO significant
22000 kPa (220 bar) (3191 psi)
pressure value.
35 BALANCE VALVE:
18 ORIFICE - 1,3 mm (0.051 in) 52 SHUTTLE VALVE - Drive Pressure
850 kPa (8,5 bar) (135 psi)
Printed in Belgium 6927504-A (1-12-12)
73 of 895
COUPLER
FEMALE
2ND AUX
VALVE
ENGINE
EV51
FORWARD
COUPLER
17
MALE
HYDROSTATIC
13 HYDRAULIC
2 PUMP
13
QUICKTACH
18
M2 M5 M4 M1
COOLE A
R 21
3 23
HYDRAULIC CONTROL VALVE
CW REVERSE 16
LX
FRAME LEVELING CYLINDER

28
B2 S
B5
62 61 66 19
B1
B C
4 22 M3
A5 EV58
27 T 5
10 A L1
EVP5 WITH TWO HYDRAULIC
11 FAN MOTOR
FILTER 1
SPEED FAN
28
63
MOTOR
(OPTIONAL) L2
B A
B4 20
B A
EV52
FAN
60 26
A4
REVERSING
27 BLOCK 24
EXTENSION CYLINDER CF
EVP4 IN
EF
T P
25
IN
28 HYDRAULIC
9 B3 64 RESERVOIR
C2 OUT LS
GEAR PUMP
PIL A3
V2
EVP3
32
28
SELF LEVELLING CYLINDER B2
M2 M4 L1 L2
B
31
M3
A2
REAR AXLE
FRONT AXLE 56 57
8 58
EVP2 EV8
Vg min 55
32 53 TOW STEERING
16 l/min VALVE VALVE
31 T3
28 52
B1 EV7
P2
A
30 54
P1
P
TILT CYLINDER
XB XA
A1
P1
T
A
M1 B
P2
EV6
29 EVP1
TRAVEL MOTOR
32
7 6 33
P
35 36
34 STEERING UNIT
T
BOOM CYLINDER
M LS R
51 L
ACCUMULATOR
CHARGING
VALVE
65
P LS T
EV3
LS SHUT 37 SERVICE S
OFF VALVE BRAKE VALVE
15 A
F MA
49
B P T SOLENOID VALVE
BLOCK
A 40 P T T LS P
14 A1 58
46
STABILISER CYLINDER EV21 EV22
PARK BRAKE 38 50
B EV56
48 T VALVE
A
A2
T
45
EV19 EV48
B 47
15 B2
X
P
A 44
EV49
39 HYDRAULIC SCHEMATIC
P
EV18 EV17
T
Pem Printable Version Click Here T40140 (S/N A8GA11001 AND ABOVE)
EV50
STABILIZER BLOCK 43
T40140 (S/N A8GC11001 AND ABOVE)
B1
14 T40170 (S/N A8GB11001 AND ABOVE)
74 of 895 42 41
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS T40170 (S/N A8GD11001 AND ABOVE)
STABILISER CYLINDER COMPONENTS
GEAR PUMP
(PRINTED JANUARY 2011)
Printed in Belgium 6927504-A
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
mc-2340
20-10-1 T40140, T40170 Service Manual

75 of 895
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340-2

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340-3

Troubleshooting Chart
The following troubleshooting chart is provided for

WARNING
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 authorised Bobcat Service Personnel
adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic fluid temperature warning light comes ON when hydraulics are 1, 2
operating.
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Section SPEC-01.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

Tightening Procedures
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
To tighten the hydraulic fittings, tubelines etc. (See

HYDRAULIC CONNECTION SPECIFICATIONS on Page
SPEC-40-1.) for the correct procedure and torque.
WARNING

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


LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1 1
S4645
Use a strap and a hoist (Item 1) [Figure 20-20-3] to

S7431 support the lift cylinder and bucket positioning cylinder.
Remove the pivot pin snap ring (Item 2) [Figure 20-20-3]

Lower the boom onto adequate stands or blocks as from the rod end.
shown in [Figure 20-20-1].

Figure 20-20-4
Figure 20-20-2
S4644
S4500
Remove the upper pivot pin using a pin removal tool

Remove the rear cover (Item 1) [Figure 20-20-2] from (Item 1) [Figure 20-20-4].
the machine.
NOTE: If a nut must be welded onto the pin for
removal the following three steps must be
performed:
1. Rotate the battery disconnect switch to the right to

disconnect the power supply from the battery.
2. The side window and frame opening must be

protected from sparks.
3. The cylinder rod must be wrapped with a damp

welding blanket to prevent damage.

LIFT CYLINDER (CONT'D) Figure 20-20-7
Removal And Installation (Cont'd)

1
Figure 20-20-5
S4570
Remove the two hoses (Item 1) [Figure 20-20-7] from

S4573 the lift lock on the bucket positioning cylinder.
NOTE: Mark all hoses for correct installation.

After the upper pivot pin has been removed, the rod end
of the cylinders should be lowered onto a wood block,

positioned as shown [Figure 20-20-5].
Figure 20-20-6 IMPORTANT

damage the system.
1 I-2003-0888
Figure 20-20-8
S4571
Remove the two hoses (Item 1) [Figure 20-20-6] from 1

the lift lock on the lift cylinder.
S4572
Remove the bolt (Item 1) [Figure 20-20-8] from the lift

cylinder and bucket positioning cylinder.

Figure 20-20-9
S4526
Remove the base end pivot pin (Item 1) [Figure 20-20-

S4574 11].
Lift and remove the lift cylinder from the machine.

Remove the base end pivot pin snap ring (Item 1)
[Figure 20-20-9].

Figure 20-20-10
P-50975
Lift and support the base end of the cylinders as shown

in [Figure 20-20-10].

LIFT CYLINDER (CONT'D)
Parts Identification
1. Cylinder body
6913683
2. Inner ring
3. Bush
4. Grease nipple
5. Cap grease nipple
6. Cylinder head
7. Piston
8. Screw
5
9. Rod 3 4
10. Set of seals 2
2
3

1
6913683
7
3
2 9
2 10
3
5
S4703

Disassembly
Figure 20-20-12
P-29905
Carefully peen the lock ring from the head gland [Figure
P-29903 20-20-14].
Figure 20-20-15
Use the following tools to disassemble the cylinders:

MEL1354-Spanner Wrench
MEL1076-Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-12].
Figure 20-20-13
1
2
P-29906
Use a spanner wrench to loosen the head gland [Figure

20-20-15].
P-29904
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-13].

LIFT CYLINDER (CONT'D)
Assembly
Use the following tools to assemble the cylinders:
MEL1033-Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

compressed air.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic fluid during

installation. Always use new O-rings and seals.
Clean off any old residue, and apply LOCTITE 242 or

equivalent to the threads on the rod (Item 9) (See “Parts
Identification” on page 20-20-4.)

BUCKET POSITIONING CYLINDER
Perform all steps for the removal of the lift cylinder. (See
Removal And Installation on Page 20-20-1.)
Instead of removing the lift cylinder, remove the bucket

positioning cylinder from the machine.

BUCKET POSITIONING CYLINDER (CONT'D)
97803.1
1. Cylinder assy
2. Cylinder
3. Bush
4. Grease nipple
5. Rod
6. Cylinder head
7. Piston
8. Screw 1
4
9. Seals kit

2
5
8
97803.1
7
3
6
4
S4704
SPC003019

BUCKET POSITIONING CYLINDER (CONT'D) Assembly
Disassembly Use the following tools to assemble the cylinder:
Use the following tools to disassemble the cylinder: MEL1354-Spanner Wrench

MEL1033-Rod Seal Installation Tool.
Figure 20-30-1 compressed air.


installation.
Always use new O-rings and seals.
Apply LOCTITE 242 or equivalent to the threads on the

rod (Item 5) (See “Parts Identification” on page 20-30-2.)
Apply LOCTITE 242 or equivalent to the set screw

(Item 8) (See “Parts Identification” on page 20-30-2.)
P-29868

Carefully peen the lock ring from the head gland
[Figure 20-30-1].
Figure 20-30-2
P-29869
Use a spanner wrench to remove the head gland

[Figure 20-30-2].


EXTENSION CYLINDER Figure 20-40-3
Cylinder Group Removal And Installation
Figure 20-40-1
S4555
Disconnect the two tubelines (Item 1) [Figure 20-40-3]

S4527 from the fittings.

Start the engine and raise the boom until the boom is in
the horizontal position [Figure 20-40-1]. Make sure that
the booms are retracted.

Figure 20-40-2
IMPORTANT
damage the system.
I-2003-0888
1
Figure 20-40-4
S4500
Remove the rear cover (Item 1) [Figure 20-40-2] from 1

the machine.
S4556
Remove the valve block (Item 1) from the extension

cylinder by removing the four screws (Item 2) [Figure 20-
40-4].

EXTENSION CYLINDER (CONT’D) Figure 20-40-7
Cylinder Group Removal And Installation (Cont’d)
Figure 20-40-5
1
1
S3566
Remove the support blocks. [Figure 20-40-7].

S4557
Remove the four attachment screws from the cylinder
body.
Remove the four bolts and nuts (Item 1) [Figure 20-40-5]
and pull the tubelines back. Figure 20-40-8
Figure 20-40-6

1
S4628
S4558
Lift and remove the cylinder out of the boom [Figure 20-
40-8].
Remove the attachment screws (Item 1) [Figure 20-40-6]
from both sides of the cylinder head.

EXTENSION CYLINDER (CONT’D)
Cylinder Group Removal And Installation (Cont’d)
Figure 20-40-9
S4629
Remove the skid that enables the telescoping cylinder

shaft to be held on the caisson by removing the two bolts
(Item 1) [Figure 20-40-9].

EXTENSION CYLINDER (CONT'D)
1. Cylinder
2. Cylinder
3. Plug
4. Rod
5. Cylinder head
6. Stop
7. Ring
8. Piston
9. Screw
10. Plug
11. Seal kit
1

2
4 8
7
3
6
10
5
11
EM5099

EXTENSION CYLINDER (CONT'D) Assembly
Disassembly Use the following tools to disassemble the cylinder:
Use the following tools to disassemble the cylinder: Spanner Wrench
Spanner Wrench Cylinder Wrench
Cylinder Wrench Rod Seal Installation Tool
Figure 20-40-10 Wash the cylinder parts in solvent and dry with
compressed air.


1 installation. Always use new O-rings and seals.

equivalent to the threads on the piston (Item 8) (See
Parts Identification on Page 20-40-4.)

S3658
Carefully peen the lock ring (Item 1) [Figure 20-40-10]

up and out of the lock groove.
Figure 20-40-11
1
S3650
Use the spanner wrench to loosen the head gland (Item

1) [Figure 20-40-11].


TILT CYLINDER Figure 20-50-3
Figure 20-50-1
2
1
1
S3625
Install a lifting eye (Item 1) on the top of the tilt cylinder,

then connect the eye with a lifting chain (Item 2) [Figure
S3577
20-50-3].
Disconnect the four hydraulic hoses (Item 1) [Figure 20- Figure 20-50-4
50-1] at the front of the boom.
NOTE: Mark the hoses for correct installation.

2
1
IMPORTANT
S4510
damage the system.
I-2003-0888
Remove the upper pivot pin snap ring (Item 1) [Figure
Figure 20-50-2 20-50-4] at both sides of the pivot pin.
1 Remove the upper pivot pin washer (Item 2) [Figure 20-

50-4] at both sides of the pivot pin.
S3624
Disconnect the two connectors (Item 1) [Figure 20-50-2]

at the front of the boom (If Equipped).

TILT CYLINDER (CONT’D) Figure 20-50-7
Removal And Installation (Cont’d)
Figure 20-50-5
1
S4674
Remove the lower pivot pin (Item 1) [Figure 20-50-7].

S4600
Figure 20-50-8
Remove the upper pivot pin (Item 1) [Figure 20-50-5].
Figure 20-50-6

1
S3631
1
Carefully lift and remove the tilt cylinder (Item 1) [Figure
20-50-8].
S4509
Remove the pivot pin retainer bolt (Item 1) [Figure 20-50-

6].

TILT CYLINDER (CONT’D)
6914552
1. Cylinder assy
2. Rod
3. Bushing
4. Grease nipple
5. Cap grease nipple
1
6. Piston 6914552
7. Screw
8. Cylinder body
9. Cylinder head
10. Nut
3 12 4 5
11. Lock valve
12. Inner ring
13 Seals kit
12 3

11
8
7
3
10
13
4
3
5
S4705

TILT CYLINDER (CONT'D) Figure 20-50-11
Disassembly
Use the following tool to disassemble the cylinder:
MEL1075-Adjustable Gland Wrench

1
Put the cylinder in a vise.
Figure 20-50-9
S3632
1
Loosen the head gland (Item 1) [Figure 20-50-11].
Assembly
1 Use the following tool to assemble the cylinder:

1
MEL1075-Adjustable Gland Nut Wrench

P-32031
compressed air.
the cylinder. Inspect the cylinder parts for damage. Replace any
damaged parts.
Figure 20-50-10

equivalent to the threads on the rod (Item 2) (See Parts
Identification on Page 20-50-3.)
Apply LOCTITE 242 or equivalent to the set screw (Item

7) (See Parts Identification on Page 20-50-3.)
1
P-32032
Remove the relief cartridge (Item 1) [Figure 20-50-10].

STEERING CYLINDER (FRONT) Figure 20-60-3
Removal And Installation 1
NOTE: It is not necessary to remove the front axle for

the removal of the steering cylinder. In this
2
procedure images are shown after removal of
the front axle to give a better view.
Figure 20-60-1
1
S4565
Remove the two bolts (Item 1) and remove the centreing

sensor (Item 2) [Figure 20-60-3] from the front steering
cylinder.
Installation: tighten the bolts (Item 2) [Figure 20-60-3]

to 5 - 6 N•m (3.7 - 4.4 ft-lb) torque.

S4548
Figure 20-60-4
Disconnect the hydraulic tubeline (Item 1) [Figure 20-60-

1] from the steering cylinder.
Figure 20-60-2
1
1
S4610
Remove the cotter pin (Item 1) [Figure 20-60-4].
S4561 Installation: Use new cotter pins.

2] from the bottom of the steering cylinder.

STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-7
Figure 20-60-5 2
1
S4609
Disconnect the left and right steering bars (Item 1) from

S4610 the piston (Item 2) [Figure 20-60-7].
Installation: Apply Loctite® 243 to the thread and

Remove the nut (Item 1) [Figure 20-60-5]. connect the steering bars by screwing the terminals onto
the piston stem, apply a torque of 240 - 270 N•m (177 -

Figure 20-60-6 200 ft-lb).
Figure 20-60-8
1
2
S4637
1
S2651
Remove the tie rod end (Item 1) [Figure 20-60-6] by
means of a puller.
Remove the securing screws (Item 1) from the steering
Installation: Insert the pins (Item 1) [Figure 20-60-6] in cylinder (Item 2) [Figure 20-60-8].
the steering case and lock into position of 260 - 290 N•m
(192 - 214 ft-lb) torque. Installation: Tighten the bolts (Item 1) [Figure 20-60-8]
to 116 - 128 N•m (85 - 95 ft-lb) torque.
Extract the cylinder using a plastic hammer.
NOTE: For cylinder disassembly (See Disassembly

on Page 20-60-3.)

Disassembly
Figure 20-60-9 2
2
S1518
With the help of a drift, apply pressure to the stop ring

S1516
(Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-60-11] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-60-9]. Figure 20-60-12

Figure 20-60-10
1
1
3
2
S1519
S1517 Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-60-12] using a plastic hammer.
With the help of a plastic hammer, push the head Continue hammering until the head (Item 2) is ejected
(Item 1) inside the cylinder (Item 2) [Figure 20-60-10]. from the cylinder (Item 3) [Figure 20-60-12].
NOTE: The head should line up with the edge of the

cylinder.

STEERING CYLINDER (FRONT) (CONT’D) Assembly
Disassembly (Cont’d) Figure 20-60-14
Figure 20-60-13
1 2 3
1
S1521
S1517
After applying grease, install the sealing ring (Item 1) on

the shaft, the anti-extrusion ring (Item 2) and the scraper
Disassemble the cylinder unit (Item 1) by extracting first ring (Item 3) [Figure 20-60-14] inside the cylinder
the head (Item 2) then the piston (Item 3) [Figure 20- (Item 3) [Figure 20-60-12].

60-13].
NOTE: Thoroughly check that positioning of the anti-
NOTE: Note down the assembly side of the piston extrusion ring (Item 2) [Figure 20-60-14] is
(Item 3) bevelled part “A” of the piston is correct.
oriented towards the head (Item 2) [Figure 20-
60-13]. Figure 20-60-15
Remove all seals, anti-extrusion rings and scraper rings

from head, cylinder and piston.
3 2 1
NOTE: 1) All seals must be replaced every time the
unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.
S1522

ring (Item 3) [Figure 20-60-15] in the head
(Item 2) [Figure 20-60-12].

extrusion ring (Item 2) [Figure 20-60-15] is
correct.

Assembly (Cont’d)
Figure 20-60-16 T18

2
S1525
Apply tool T18 to the shaft on the opposite side of the

S1523 head (Item 2) and centre it on the cylinder (Item 1) so
that it fits into the piston (Item 2) [Figure 20-60-18].
Fit the seal (Item 1) [Figure 20-60-16] onto the outside NOTE: Apply a little grease to seals and cylinder.
of the head (Item 2) [Figure 20-60-12].

Figure 20-60-19
NOTE: In order to facilitate assembly, apply grease to
the outer surface of the piston. Do not roll the
seal (Item 1) [Figure 20-60-16]
Figure 20-60-17
1
5 3 2
2
4
S1526
Push the piston (Item 1) into the cylinder (Item 2) [Figure

20-60-19] for 100 mm (4 in) using a plastic hammer.
S1524
Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring (Item 4)
and the seal (Item 5) [Figure 20-60-17].
NOTE: In order to facilitate assembly, apply grease.

Assembly (Cont’d)
1
Figure 20-60-20
T18 1
S1529
Insert the stop ring (Item 1) ensuring that it fits into the
S1527 seat of the cylinder (Item 2) [Figure 20-60-22].
Figure 20-60-23
Remove tool T18 and apply it to the opposite side of the
piston (Item 1) [Figure 20-60-20]

Figure 20-60-21
T18
1
S1530
2
Apply pressure to the head using two screwdrivers or
S1528
levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-60-23].
Apply grease to the head (Item 1) seals, fit the head onto
the piston and push it onto the cylinder (Item 2) [Figure
20-60-21].

STEERING CYLINDER (FRONT) (CONT’D)
Assembly (Cont’d)
Figure 20-60-24
S1531
Fit the snap ring (Item 1) on the head (Item 2) [Figure

20-60-24].

NOTE: Make sure that the snap ring (Item 1) [Figure
20-60-24] is securely fastened in its seat. If
necessary, force it into its seat using a drift
and a hammer.


STEERING CYLINDER (REAR) Figure 20-61-3
Removal
Figure 20-61-1
2
1
1 2
3
S2515
Remove the bolt (Item 1) for access for removing the nut
S2513
(Item 2) [Figure 20-61-3].
Figure 20-61-4
Remove the two bolts (Item 1) and remove the centreing
sensor (Item 2) from the steering cylinder (Item

3) [Figure 20-61-1].
Figure 20-61-2 1
1
S2516
Remove the nut (Item 1) [Figure 20-61-4].
S2514
Remove the cotter pin (Item 1) [Figure 20-61-2].

STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-7
Removal (Cont’d)
Figure 20-61-5
2
1
1
S2519
Remove the securing screws (Item 1) from the steering

S2517
cylinder (Item 2) [Figure 20-61-7].
Figure 20-61-8
Remove the tie rod end (Item 1) [Figure 20-61-5] by
means of a puller.

Figure 20-61-6
1
2
1
S2520
Extract the cylinder (Item 1) [Figure 20-61-8] using a

S2518
plastic hammer.
NOTE: For cylinder disassembly (See Disassembly

Disconnect the left and right steering bars (Item 1) from on Page 20-61-4.)
the piston (Item 2) [Figure 20-61-6].

Installation
Figure 20-61-9
S2523
Apply Loctite 242 to the thread and connect the steering

S2521
bars by screwing the terminals onto the piston stem,
tighten to 240 - 270 N•m (170 - 200 ft-lb) torque [Figure
20-61-11].
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-61-9] into its seat. Figure 20-61-12

Figure 20-61-10
1
1
S2524
S2522
Insert the pins (Item 1) in the steering case

(Item 2) [Figure 20-61-12] and tighten to 260 - 290 N•m
Tighten the bolts (Item 1) [Figure 20-61-10] to 116 - 128 (192 - 214 ft-lb) torque.
N•m (85 - 95 ft-lb) torque.
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (Item 3) [Figure 20-
61-12] further.
NOTE: Check that the rubber guards [Figure 20-61-12]

are intact.

STEERING CYLINDER (REAR) (CONT’D) Disassembly
Installation (Cont’d) Figure 20-61-15
Figure 20-61-13
1
1 S1516
S2525
Remove the snap ring (Item 1) from the cylinder head

(Item 2) [Figure 20-61-15],
Insert the cotter pins (Item 1) [Figure 20-61-13] and
bend the ends. Figure 20-61-16

NOTE: Use new cotter pins.
Figure 20-61-14
2
2 1
S1517
With the help of a plastic hammer, push the head (Item 1)

S2526
inside the cylinder (Item 2) [Figure 20-61-16],
NOTE: The head should line up with the edge of the

Install the centreing sensor (Item 1) for checking piston cylinder.
centreing and tighten the bolts (Item 2) [Figure 20-61-
14] to 5 - 6 N•m (3.7 - 4.4 ft-lb) torque.
After the axle has been reinstalled on the machine,

perform the axle toe-in procedure. (See AXLE TOE-IN on
Page 40-40-1.)

Disassembly (Cont’d)
Figure 20-61-17
3
2
2 1
1 A
S1520
Disassemble the cylinder unit (Item 1) by extracting first

S1518
the head (Item 2) then the piston (Item 3) [Figure 20-
61-19].
With the help of a drift, apply pressure to the stop ring NOTE: Note down the assembly side of the piston
(Item 1) that is placed inside the cylinder (Item 3). The bevelled part “A” of the piston is

(Item 2) [Figure 20-61-17] and extract the ring using a oriented towards the head (Item 2) [Figure 20-
screwdriver. 61-19].
Figure 20-61-18 Remove all seals, anti-extrusion rings and scraper rings
from head, cylinder and piston.
NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.
1
3
2
S1519
Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-61-18] using a plastic hammer.
Continue hammering until the head (Item 2) is ejected

from the cylinder (Item 3) [Figure 20-61-18].

Assembly
1
Figure 20-61-20
1 2 3
S1523
Fit the seal (Item 1) [Figure 20-61-22] onto the outside

S1521
of the head (Item 2) [Figure 20-61-18].
NOTE: In order to facilitate assembly, apply grease to

After applying grease, install the sealing ring (Item 1) on the outer surface of the piston. Do not roll the
the shaft, the anti-extrusion ring (Item 2) and the scraper seal (Item 1) [Figure 20-61-22]

ring (Item 3) [Figure 20-61-20] inside the cylinder
(Item 3) [Figure 20-61-18]. Figure 20-61-23

5 3 2
correct.
Figure 20-61-21 1
4
3 2 1
S1524
Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring
(Item 4) and the seal (Item 5) [Figure 20-61-23].
S1522
NOTE: In order to facilitate assembly, apply grease.

ring (Item 3) [Figure 20-61-21] in the head
(Item 2) [Figure 20-61-18].

correct.

Assembly (Cont’d)
Figure 20-61-24
T18 1
T18
2
1
S1527
Remove tool T18 and apply it to the opposite side of the

S1525
piston (Item 1) [Figure 20-61-26]
Figure 20-61-27
Apply tool T18 to the shaft on the opposite side of the
head (Item 2) and centre it on the cylinder (Item 1) so

that it fits into the piston (Item 2) [Figure 20-61-24].
NOTE: Apply a little grease to seals and cylinder. 1
Figure 20-61-25 T18
3
1 2
S1528
Apply grease to the head (Item 1) seals, fit the head onto
the piston and push it onto the cylinder (Item 3) [Figure
2
20-61-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2) [Figure

20-61-25] for 100 mm (4 in) using a plastic hammer.

Assembly (Cont’d)
2
Figure 20-61-28
S1531
2 Fit the snap ring (Item 1) on the head (Item 2) [Figure

S1529
20-61-30].
NOTE: Make sure that the snap ring (Item 1) [Figure

Insert the stop ring (Item 1) ensuring that it fits into the 20-61-30] is securely fastened in its seat. If
seat of the cylinder (Item 2) [Figure 20-61-28]. necessary, force it into its seat using a drift

and a hammer.
Figure 20-61-29
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-61-29].

DRIVE BOX
Figure 20-70-1
5
1. Gear
4
2. Snap ring 3
3. Ball bearing 2
1
4. Snap ring
5. Vent
6. Ring nut 27
26
7. Bearing
9
8. Ring 8
9. Plug 7
6
10. Seal
11. Ball bearing

12. Gear
24 25
10
23
11
12
13
14 13. Snap ring
15 14. Ball bearing
22
15. Seal
16. Plug
17. Spring washer
18. Hexagon bolt
20 17 16
21 19. Magnet plug
19 18
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Screw
25. Cover
26. Shim
27. Bearing
S2500

DRIVE BOX (CONT’D) Figure 20-70-4
Disassembly 1
Remove the front axle. (See Removal on Page 40-30-1.)
Remove the drive motor. (See Removal And Installation

on Page 30-30-1.)
Figure 20-70-2
S4685
Take off the drive side flange cover (Item 1) [Figure 20-
70-4] by alternatively forcing a screwdriver into the
appropriate slots.
1
NOTE: Look out not to damage the surfaces.

S4683 Figure 20-70-5
Loosen the securing bolts (Item 1) [Figure 20-70-2] only

so that later when you pry the drive side flange cover
loose, it does not fall.
Figure 20-70-3 1
S4686
1
Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-70-5].
S4684
Loosen the drive side flange cover (Item 1) [Figure 20-

70-3] using a plastic hammer.

Figure 20-70-6
1
S2488
Using two levers, remove the flange sealing ring (Item 1)

S4687 [Figure 20-70-8].
Figure 20-70-9
To remove the drive side shaft (Item 1), hook off the snap
ring (Item 2) [Figure 20-70-6].
1

Figure 20-70-7
S2432
Remove the snap ring (Item 1) [Figure 20-70-9].

S4688
Using two levers, remove the drive side shaft (Item 1)

[Figure 20-70-7].

1
Figure 20-70-10
S2490
1 Remove the secondary gear wheel (Item 1) [Figure 20-

70-12] using two levers.
S2433
Figure 20-70-13
With a puller, remove the bearing (Item 1) from the input
shaft (Item 2) [Figure 20-70-10].

Figure 20-70-11
2
1
S2435

1
S2489
With a puller, remove the bearing (Item 1) from the flange

shaft (Item 2) [Figure 20-70-11].

Figure 20-70-14
S2493
1
Pull out the cup of the sealing ring (Item 1) by using drift
(Item 2) [Figure 20-70-16].
S2491
Remove the flange (Item 1) [Figure 20-70-14] by means

of a plastic hammer.

Figure 20-70-15
S2492
Remove the internal bearing (Item 1) [Figure 20-70-15].

Assembly
Figure 20-70-17
S2494
T27
Fit the flange (Item 1) [Figure 20-70-19] and fasten it.
S4689
For keying the flange (Item 1) [Figure 20-70-19], use a
plastic hammer if necessary.
Insert the sealing ring using tool T27 [Figure 20-70-17].
Figure 20-70-20

NOTE: Bring the sealing ring just to the end stop,
apply grease to the sealing lips.
Figure 20-70-18
1 S2495
Insert the bearing (Item 1) [Figure 20-70-20].

S2436
Insert the sealing ring (Item 1) [Figure 20-70-18] with a

normal tool.
NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

Assembly (Cont’d)
Figure 20-70-21
1 S2437 / S2438
Using a normal tool insert the bearing (Item 1) [Figure

20-70-23].
S2496
Figure 20-70-24
Using a normal tool insert the bearing (Item 1) [Figure
20-70-21] and snap ring.

Figure 20-70-22
2
1
S2439 / S2440
Insert the snap ring (Item 1) and using a normal tool

S2497 insert the bearing (Item 2) [Figure 20-70-24].
Install the secondary gear wheel (Item 1) [Figure 20-70-

22] with a plastic hammer.

Assembly (Cont’d)
Figure 20-70-25
1
1
S4686
Install drive side flange cover (Item 1) [Figure 20-70-27],

apply LOCTITE 510 to the short screws.
S2441
Figure 20-70-28
Fix the bearing with the snap ring (Item 1) [Figure 20-70-
25].

Figure 20-70-26
S4690
Tighten the bolts [Figure 20-70-28] of 80 - 90 N•m

(60 -66 ft-lb) torque.
S2498
Hold the drive side shaft (Item 1) [Figure 20-70-26] using

a paler and install the drive side shaft with a plastic
hammer.

DRIVE BOX (CONT’D)
Special Tools
TOOL IMAGE DESCRIPTION BOBCAT PN
T27 Pinion tail seal 6912202


MAIN RELIEF VALVE Figure 20-80-3
Testing S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW
The following tool will be needed to do the following

procedure:
MEL10003-Hydraulic Tester
Figure 20-80-1
3
1
4
1
2
S4616

Connect the inlet hose (Item 1) from the tester to the front
coupler (Item 2) [Figure 20-80-1].
S4613
Connect the outlet hose (Item 3) from the tester to the

rear coupler (Item 4) [Figure 20-80-1].
Start the engine, lower the restraint bar (if equipped) and
run at low idle RPM. Push the detent rocker switch (Item
1) and front auxiliary rocker switch (Item 2) [Figure 20-
80-3]. Make sure the tester is connected correctly. If no
IMPORTANT flow is indicated on the tester, the hoses are connected
wrong. with the hoses connected correctly, increase the
Always keep the same size tires on the same side of engine speed to 2200 RPM.
the skid steer loader to avoid damage to the loader.
Rotate tires according to the procedure given in the Warm the fluid to 60 °C (140 °F) by turning the restrictor
manual. control on the tester to about 6,9 MPa (69 bar) (1000 psi).
I-2004-1285 DO NOT exceed system relief pressure. Open the
restrictor control knob and record the free flow (GPM) at
2200 RPM.
Figure 20-80-2
S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE There should be 55 L/min (13 U.S. gpm) free flow. Turn
the restrictor control on the tester until the main relief
opens. The correct pressure should be 25,5 MPa (255
bar) (3700 psi).
If adjustment is needed (See Adjustment on Page 20-80-

2.)
2 1
P-97008

MAIN RELIEF VALVE (CONT’D) Removal and Installation
Adjustment
Remove the rear cover.
Figure 20-80-4
IMPORTANT
damage the system.
I-2003-0888
Figure 20-80-6
S4606

Locate the main relief valve on the upper left side of the
control valve [Figure 20-80-4].
Figure 20-80-5
1
S4500
Remove the rear cover (Item 1) [Figure 20-80-6].
Locate the main relief valve on the upper left side of the
control valve.
Clean the area around the control valve.
S4612
Take off the plastic plug (Item 1) [Figure 20-80-5] and

turn the adjustment screw clockwise to increase the
pressure or anticlockwise to decrease the pressure.
NOTE: One full turn = 10 MPa (100 Bar) (1500 psi).
Retest the main relief valve after adjustment.

MAIN RELIEF VALVE (CONT’D) Figure 20-80-9
Figure 20-80-7
3
1
2
1
S4282
Remove the main relief valve plug (Item 1), the spring
S4612 (Item 2) and the pin (Item 3) [Figure 20-80-9] out of the
valve block.
Remove the plastic plug (Item 1) [Figure 20-80-7]. Installation: Tighten the main relief valve plug to 45 N•m
(33 ft-lb) torque.

Figure 20-80-8
S4281


QUICK-TACH CYLINDER Figure 20-90-3
Figure 20-90-1
S3645
Remove the end bushing (Item 1) [Figure 20-90-3].

S3643
Figure 20-90-4

the cylinder.

IMPORTANT 1

S3646
damage the system. Remove the roll pin (Item 1) [Figure 20-90-4].
I-2003-0888
Figure 20-90-2
S3644
Remove the bolt (Item 1) [Figure 20-90-2] from each

side of the cylinder.

QUICK-TACH CYLINDER (CONT’D) Figure 20-90-7
Figure 20-90-5
S3649
Remove the cylinder (Item 1) [Figure 20-90-7].

2 1
S3647
Remove the washer (Item 1) and spring (Item 2) [Figure

20-90-5] from the cylinder rod extension.
Figure 20-90-6

1
S3648
Remove the roll pin (Item 1) and remove the extension

rod (Item 2) [Figure 20-90-6] from the cylinder rod.

QUICK-TACH CYLINDER (CONT’D)
1. Quick-tach cylinder
2. Cylinder
3. Spindle
4. Nut
5. Seal kit

2
S4706

QUICK-TACH CYLINDER (CONT’D) Figure 20-90-10
Disassembly
Use the following tool to disassemble the cylinder:
Figure 20-90-8
P-32173
Use the cylinder wrench to loosen the head gland

[Figure 20-90-10].
Assembly
Use the following tool to assemble the cylinder:

P-32169

Place the cylinder in a vise [Figure 20-90-8].

1 Lubricate all O-rings and seals with hydraulic fluid during

installation.
Always use new O-rings and seals.
P-32170
Remove the two fittings (Item 1) [Figure 20-90-9].

FRAME LEVELING CYLINDER Figure 20-100-2
Remove the front weight from the machine.
WARNING
physician familiar with this injury is not received S4551
immediately.
W-2145-0290
Support the frame leveling cylinder with a bar as shown
in [Figure 20-100-2].
Figure 20-100-3
IMPORTANT

1
damage the system.
I-2003-0888
Figure 20-100-1
S4624
1
Remove the bolt and nut (Item 1) [Figure 20-100-3] from
the lower pivot pin.
S4549
Remove the two hoses (Item 1) [Figure 20-100-1].
Install caps and plugs.

FRAME LEVELLING CYLINDER (CONT’D) Figure 20-100-6
Figure 20-100-4
S4554
1
Remove the pivot pin as shown in [Figure 20-100-6].
S4626
Carefully remove the bar and lower the frame leveling
cylinder.
Remove the lower pivot pin (Item 1) [Figure 20-100-4]
from the machine. Remove the frame leveling cylinder.

Figure 20-100-5
S4625
Remove the bolt and nut (Item 1) [Figure 20-100-5] from

the pivot pin.
NOTE: Make sure the frame leveling cylinder is

supported well.

FRAME LEVELING CYLINDER (CONT’D)
1. Relief Cartridge
2. Housing
3. Wear Ring
4. Seal
5. Set Screw
6. Piston
7. O-ring
8. Sleeve
9. Head Gland
10. Wiper
11. Bushing
12. Rod
13. Grease Fitting

2 4
5
1
3
6
7
1 8
7
4
10
13
7
9
3
11
12
B-19814

FRAME LEVELING CYLINDER (CONT’D) Assembly
Disassembly Use the following tools to assemble the cylinder ((See

“Parts Identification” on page 20-100-3.)):
Use the following tools to disassemble the cylinder:
MEL1353 - Cylinder Gland Nut Wrench
MEL1353 - Cylinder Gland Nut Wrench

1
Always use new O-rings and seals. Lubricate all O-rings
and seals with hydraulic fluid during installation.
2 Clean the threads and apply LOCTITE® 243 or

equivalent to the threads on the rod (Item 12) (See “Parts
Identification” on page 20-100-3.)
Apply LOCTITE® 243 or equivalent to the set screw

(Item 5) ((See “Parts Identification” on page 20-100-3.)
S4678

Remove the two relief cartridges (Item 1) and two fittings
(Item 2) [Figure 20-100-7].
Put the cylinder in a vise.
Figure 20-100-8
P-40489
Remove the cylinder head gland with a cylinder gland nut

wrench as shown in [Figure 20-100-8].
Disassemble the frame leveling cylinder.

STEERING MODE VALVE BLOCK Figure 20-110-2
WARNING
1
and possible death if proper medical treatment by a 2 1
immediately.
W-2145-0290 S4681
Figure 20-110-1 Remove the four mounting bolts (Item 1) [Figure 20-110-
2].
NOTE: Mark the location of the valve on the block.
1 Remove the valve (Item 2) [Figure 20-110-2] from the

block.
1
IMPORTANT
S4604 clean the work area before disassembly and keep all
Relieve hydraulic pressure. damage the system.
I-2003-0888
Remove the retainer screw (Item 1) [Figure 20-110-1]
from the two solenoids.
Remove the wire connectors from the two solenoids.
NOTE: Mark the location of the wire connectors for

correct installation.

STEERING MODE VALVE BLOCK (CONT’D)
Figure 20-110-3
1 S4682
Remove the four hoses (Item 1) [Figure 20-110-3].

NOTE: Mark the location of the hoses.
Figure 20-110-4
S4682
Remove the four mounting bolts (Item 1) [Figure 20-110-

4] and remove the block.

STEERING MODE VALVE BLOCK (CONT’D)
1
1. Nut
2. O-Ring
3. Solenoid
4. Shaft 2
5. Pin
6. Spring
7. Retainer 3
8. Spool
9. Housing
10. Bolt 4
11. Washer 2
12. Elbow 5
13. Adapter
14. Housing 6
7

10
11
8
9
3
2
2
1
12 13
*
* 10
* * 12
14
13
* Supplied with fitting. MS1152

STEERING MODE VALVE BLOCK (CONT'D)
Disassembly
Mark the location of the solenoids to the housing for

IMPORTANT
correct assembly.
Figure 20-110-5 clean the work area before disassembly and keep all
damage the system.
1 I-2003-0888
Figure 20-110-7
1 1
P-42291

Remove the four O-rings (Item 1) [Figure 20-110-5] from
the housing.
Figure 20-110-6 P-42294
Remove the solenoids (Item 1) [Figure 20-110-7] from

the solenoid shafts.
Figure 20-110-8
1
1 1
P-42292
Remove the nut (Item 1) [Figure 20-110-6] from each

solenoid.
NOTE: Mark the location of the solenoids. P-42295
Remove the O-ring (Item 1) [Figure 20-110-8] from both

shafts.

STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-11
Disassembly (Cont'd)
Figure 20-110-9
1 1
P-42299
Remove the O-ring (Item 1) [Figure 20-110-11] from

P-42296 each shaft.
Figure 20-110-12
Loosen the shafts (Item 1) [Figure 20-110-9].

Figure 20-110-10
5
1
4
2
1
3
P-42300
P-42297 Carefully remove the spool (Item 1) [Figure 20-110-12]

from the housing.
Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-10]. (Both Sides)

STEERING MODE VALVE BLOCK (CONT'D) Assembly
Solenoid Testing Clean all components with solvent and dry with
compressed air.
Figure 20-110-13
Check all components for wear or damage. Replace any
worn or damaged components.
Always use new O-rings.
Lightly oil all parts.
Figure 20-110-14
1
P-42301
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-13], there

must be continuity. If there is no continuity, replace the
solenoid.
P-42300
Carefully install the spool (Item 1) [Figure 20-110-14].
Figure 20-110-15
P-42299
Install a new O-ring (Item 1) [Figure 20-110-15] on each

shaft.

Assembly (Cont'd)
1
Figure 20-110-16
5
2
1
3 P-42295
4
Install an O-ring (Item 1) [Figure 20-110-18] on each
P-42297 shaft.
Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5) [Figure Figure 20-110-19

20-110-16]. (Both Sides)
Figure 20-110-17
1
1 1
P-42293
P-42296 Install the O-ring (Item 1) [Figure 20-110-19] on the two

solenoids.
Tighten each shaft (Item 1) [Figure 20-110-17].

Assembly (Cont'd)
Figure 20-110-20 1
2
1
P-42291
2
Install the four O-rings (Item 1) [Figure 20-110-22] on the

P-42294 housing.
Install the solenoids (Item 1) on the shafts (Item 2)

[Figure 20-110-20].

Figure 20-110-21
1 1
P-42292
Install the nuts (Item 1) [Figure 20-110-21] on each shaft

and hand tighten.
NOTE: Do not overtighten the nuts.

BRAKE VALVE Figure 20-120-2
S/N A8GA12999 & Below, S/N A8GB12999 & Below:
Remove the dashboard / steering column cover.

(See Removal And Installation on Page 50-140-1.) 1
S/N A8GA13000 & Above, S/N A8GB13000 & Above:

(See Removal And Installation on Page 50-141-1.)
2
Figure 10-151-1
P-25249
Remove the accelerator cable (Item 1) from the pedal

and mounting bracket (Item 2) [Figure 20-120-2].
Figure 20-120-3

1
P-52341
Disconnect the connector (Item 1) [Figure 10-151-1]

from the brake light switch.
1
Figure 20-120-1
P-25638
1 Remove the three hoses (Item 1) [Figure 20-120-3] from

the brake valve.
NOTE: Mark hoses for correct installation.
IMPORTANT
P-42865
Disconnect the connector (Item 1) [Figure 20-120-1] tubelines and ports to keep dirt out. Dirt can quickly
from the inching switch. damage the system.
I-2003-0888

BRAKE VALVE (CONT’D) Disassembly And Assembly
Removal and Installation (Cont’d) Figure 20-120-5
Figure 20-120-4
1 2
P-42869
1 P-25637
Remove the bolt (Item 1) and spring (Item 2) [Figure 20-
120-5].
Remove the mounting bolts (Item 1) [Figure 20-120-4].
Figure 20-120-6

Remove the pedal assembly.
P-42870
Remove the roll pin (Item 1) and pedal (Item 2) [Figure

20-120-6].

BRAKE VALVE (CONT’D) Figure 20-120-9
Disassembly And Assembly (Cont’d)

1
Figure 20-120-7
1
1
1
P-42874
Remove the three bolts (Item 1) [Figure 20-120-9] from

P-42871 both bearing flanges.
Figure 20-120-10
Assembly: Align the hole (Item 1) in the pedal with the
hole (Item 2) [Figure 20-120-7] in the shaft.

Figure 20-120-8
P-42875
Remove the shaft and bearing assembly [Figure 20-120-

P-42872 10].
Loosen the two set screws (Item 1) [Figure 20-120-8] on

the two bearings.

BRAKE VALVE (CONT’D) Figure 20-120-13
Figure 20-120-11
1 2 1
2
P-42877
2 Remove the four bolts (Item 1) spacers (Item 2) [Figure

P-42876 20-120-13] and nuts from the brake valve.
Figure 20-120-14
Remove the flanges (Item 1) and bearings (Item 2)
[Figure 20-120-11].

Figure 20-120-12
P-42879
Remove the brake valve (Item 1) [Figure 20-120-14]

P-42878
Remove the three fittings (Item 1) [Figure 20-120-12]

from the brake valve.

GEAR PUMP Figure 20-130-2
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Stop the engine.
Relieve the hydraulic pressure. Drain the hydraulic 1

reservoir. (See Removing And Replacing Hydraulic Fluid 2
on Page 10-100-2.)
WARNING P-56477
Hydraulic fluid escaping under pressure can have Remove the four bolts (Item 1) and remove the hose
sufficient force to enter a person’s body by (Item 2) [Figure 20-130-2] from the hydrostatic pump.
and possible death if proper medical treatment by a Figure 20-130-3
immediately.

W-2145-0290
1
IMPORTANT
damage the system. P-56478
I-2003-0888
Remove the hose (Item 1) [Figure 20-130-3] from the

Figure 20-130-1 backside of the gear pump.
1
1
P-56463
Remove the three hoses (Item 1) [Figure 20-130-1] from

the backside of the pump.

GEAR PUMP (CONT'D) Figure 20-130-6
Figure 20-130-4
1 P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 20-130-6].
Figure 20-130-7
Remove the hose (Item 1) [Figure 20-130-4].

Figure 20-130-5
1 P-56482
P-56468 Install a chain hoist and lifting strap to lift and support the
gear pump [Figure 20-130-7].
Loosen the hose clamp (Item 1) [Figure 20-130-5] and Remove the two mounting bolts (Item 1) [Figure 20-130-
remove the hose. 7] from the gear pump.
Installation: Tighten the mounting bolts to 50 - 80 N•m

(52 - 59 ft-lb) torque.

GEAR PUMP (CONT'D)
Figure 20-130-8
P-56483
Remove the gear pump [Figure 20-130-8].

NOTE: It can be necessary to reposition any hose or
wires.

GEAR PUMP (CONT’D)
1. Fitting
2. O-ring 1
3. Spring
4. Spring Seat 2
5. Spool 3
6. Screen 8
4
7. Orifice Spool
8. Bolt 5
9. Housing 6
10. Plug 7
11. Bolt 14
12. Washer
13. Cover 9 16
14. Seal Ring 17
15. Housing
16. Back-up Ring 18
19
17. Seal Ring

18. Holder 2 18
10
19. Gear 17
20. Drive Shaft 16
21. Mount Plate
22. Thrust Plate 13
15
23. Mount Plate
24. Seal 14
25. Snap ring 14
12
11
15
14
21 19
22
17
16
20
25 2
24
23
8 17
16
22
MS1423

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
P-56449
Figure 20-130-9
Remove the flow divider from the housing [Figure 20-
130-11].
1
Figure 20-130-12
1
6

2 1
5 4 3
1
1
P-56447
Mark the pump housing for correct assembly and remove

the fittings (Item 1) [Figure 20-130-9].
P-25293
Figure 20-130-10
Remove the fitting (Item 1), O-ring (Item 2), spring (Item
3), spring seat (Item 4) and spool (Item 5) from the
1 1 housing (Item 6) [Figure 20-130-12].
NOTE: Always use new O-rings.
1 1
P-56448
Remove the four bolts (Item 1) [Figure 20-130-10].
Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.

Disassembly And Assembly (Cont'd)
Figure 20-130-13
2
1
P-25296
To remove the orifice assembly (Item 1) [Figure 20-130-

P-25294 15] from the spool, make a holding fixture from a 19 mm
thick x 38 mm wide x 50 mm long (0.750 in thick x 1.500
in wide x 2.0 in long) piece of hardwood. Drill a 14 mm
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- (0.550 in) hole in the centre of the hardwood block. Cut
130-13] from the housing. the block lengthwise [Figure 20-130-14].

Figure 20-130-14 Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-15].
Cut
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.
Figure 20-130-16
14 mm 50 mm (2.0”)
(0.550”) dia.
1 2
19 mm
38 mm (1.500”) (0.750”)
B-14674
P-25295
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-130-16] and clean.

Figure 20-130-17 1
2 1 3
1
2
1 1
P-56451
Remove the housing (Item 1) from the gear assembly

P-56450 (Item 2) [Figure 20-130-19].
Assembly: The position of the small opening (Item 3) on

Remove the four bolts (Item 1) and cover (Item 2) [Figure the gear holders will point towards the large port (Item 4)
20-130-17]. [Figure 20-130-19] on the housing.

Figure 20-130-18 Figure 20-130-20
1
1
P-56454 P-56452
Remove the housing / gear assembly (Item 1) [Figure Remove both O-rings (Item 1) [Figure 20-130-20] from
20-130-18] from the main housing. the housing.

Figure 20-130-21 1 1
1 1
2
P-25304
1
Remove the four bolts (Item 1) and drive shaft (Item 2)

P-56453 [Figure 20-130-23].
Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.

Remove the backup ring (Item 1) and seal ring (Item 2)
[Figure 20-130-21] from the gear holder. Figure 20-130-24

Assembly: The seal ring (Item 2) [Figure 20-130-21] is
installed onto the gear holder first followed by the back-
up ring.
Figure 20-130-22
P-25305
Turn the housing over and remove the mount plate

[Figure 20-130-24].
P-25322
Remove and discard the O-ring (Item 1) [Figure 20-130-

22] from the flange.

Disassembly And Assembly (Cont'd) 2
Figure 20-130-25
1
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

P-25306 [Figure 20-130-27] from the housing.
Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-130-25]. thrust plate must point towards the larger port (Item 4)
[Figure 20-130-27] on the housing.

Figure 20-130-26
Figure 20-130-28
1
2
2
3 3
P-25307
1 1
P-25313
Remove the shaft seal (Item 1) [Figure 20-130-26].

Remove the two thrust plates (Item 1), seal ring (Item 2)
and back-up ring (Item 3) [Figure 20-130-28] from the
gears.
Assembly: The seal ring (Item 2) will be installed on the

thrust plate (Item 1) first followed by the backup ring (Item
3) [Figure 20-130-28].


FAN MOTOR Figure 20-140-2
Removal And Installation 4 4
IMPORTANT 5
3
damage the system.
I-2003-0888 2 1
S6837
Drain the radiator. (See Removing And Replacing The

Coolant on Page 10-70-1.) Remove the mounting bolt (Item 1) and nut (Item 2).
Remove the radiator support (Item 3) [Figure 20-140-2].
Figure 20-140-1
Loosen the two hose clamps (Item 4) and remove the
intercooler hose (Item 5) [Figure 20-140-2].
1

2 Figure 20-140-3
1
S6834
Loosen the two hose clamps (Item 1) and remove the

radiator hose (Item 2) [Figure 20-140-1].
S6835
Mark the location of the hood latch (Item 1). Remove the
two mounting bolts (Item 2) [Figure 20-140-3]. Remove
the hood latch.

FAN MOTOR (CONT’D) Figure 20-140-6
Figure 20-140-4 2
1
P-53264
Loosen the screw (Item 1) and disconnect the connector

S6836 (Item 2) [Figure 20-140-6].
Figure 20-140-7
Remove the top hose (Item 1) [Figure 20-140-4] from the
fan motor. 1

Figure 20-140-5
1 S6845
Remove the two bolts (Item 1) [Figure 20-140-7] (both

S6848 sides) from the fan guard.
Tilt the cooler forward and carefully remove the fan

Remove the three hoses (Item 1) [Figure 20-140-5] from assembly.
the bottom of the fan motor.

Figure 20-140-8 2
1 2
1
1
1
1 P-53270
Remove the four fan guard mount bolts (Item 1) and

P-53269 remove the fan guard (Item 2) [Figure 20-140-10].
Figure 20-140-11
Remove the four bolts (Item 1) and remove the blade
assembly (Item 2) [Figure 20-140-8] from the fan motor.

NOTE: Mark the direction of the fan for correct
assembly.
1
Figure 20-140-9
1 P-53272
Remove the nut and lock washer (Item 1) [Figure 20-

140-11].
P-53271
Mark the location of the fan motor to the fan guard for
correct assembly (Item 1) [Figure 20-140-9].

FAN MOTOR (CONT’D)
Figure 20-140-12
P-53273
Remove the fan blade mounting flange (Item 1) [Figure

20-140-12] from the fan motor.

FAN MOTOR (CONT’D)

3
1. Seal
2. Valve
3. Housing
4. Gear assembly
S2754

IMPORTANT
4
parts clean. Always use caps and plugs on hoses, 3
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888 1
P-53276
Figure 20-140-13
Remove the plug (Item 1), spring (Item 2) and check
valve (Item 3) from the housing (Item 4) [Figure 20-140-
2 1 15].
Figure 20-140-16

P-53274
1
Remove the nut (Item 1) and solenoid (Item 2) [Figure
20-140-13].
Mark the housing for correct assembly. P-53277
Figure 20-140-14
Remove the O-ring (Item 1) [Figure 20-140-16] from the
plug. Replace as needed.
2
1
P-53275
Remove the solenoid stem (Item 1) and three fittings

(Item 2) [Figure 20-140-14].

Figure 20-140-17
1
1
1 1 P-53281
Remove the quad ring (Item 1) [Figure 20-140-19] from

P-53278 the housing.
Figure 20-140-20
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2

Assembly: Tighten bolts to 43 - 47 N•m (32 - 35 ft-lb) 1
torque.
Figure 20-140-18
P-53282
Remove the gear assembly (Item 1) from the housing

(Item 2) [Figure 20-140-20].
P-53279
Remove the end cover (Item 1) from the main housing

(Item 2) [Figure 20-140-18].

Figure 20-140-21
P-53285
1
Inspect the gears (Item 1) [Figure 20-140-23] for
P-53283 damage or wear
Remove the back-up ring / seal (Item 1) [Figure 20-140-

21] from the gear holder.

Figure 20-140-22
P-53256
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-140-22].
Assembly: The open part of the seal goes into the

housing first.

HYDRAULIC FLUID RESERVOIR Figure 20-150-3
Remove the engine / hydrostat assembly. (See Removal

And Installation on Page 70-90-1.)
Figure 20-150-1
1 S6856

tubeline.
Remove the mounting bolt (Item 2) [Figure 20-150-3].

P-56462
Figure 20-150-4

Remove the two bolts (Item 1) [Figure 20-150-1]. 1
Figure 20-150-2
1
2
S6857
Loosen the nut (Item 1) [Figure 20-150-4] on the

S6855 tubeline.
Remove the tubeline.

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-
150-2]. Remove the two hoses (Item 2) [Figure 20-150-4] from
the filter.

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-150-6
Figure 20-150-5
P-55220
Figure 20-150-7
P-55217

tank.

1
S6858
Remove the two tank mounting bolts (Item 1) [Figure 20-

150-6] and [Figure 20-150-7].
Remove the hydraulic reservoir.

STEERING VALVE Figure 20-160-2
S/N A8GA12999 & Below, S/N A8GB12999 & Below: 1

Remove the dashboard / steering column cover. 1

Figure 20-160-1
P-42863
1 Remove the four bolts (Item 1) [Figure 20-160-2] and

remove the steering valve.

P-42863
Remove the five hoses (Item 1) [Figure 20-160-1] from

the steering valve.
IMPORTANT
damage the system.
I-2003-0888

STEERING VALVE (CONT'D)
1. Bolt 13. Springs

2. End Cap 14. Pin
3. Spacer 15. Check Ball (.250”)
4. O-ring 16. Spring
5. Wear Ring 17. Pin
6. Gerotor assembly 18. Check Ball (.187”)
7. Drive Shaft 19. O-ring
8. O-ring 20. Housing
9. Spacer Plate 21. Thrust Washer
10. Spool 22. Thrust Bearing
11. Sleeve 23. Seal
12. Drive Pin 24. Gland Bushing
25. Seal
S4721

STEERING VALVE (CONT'D) Figure 20-160-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
S0200
Remove the hydraulic fittings from the steering valve.

Remove the gerotor assembly (Item 1) [Figure 20-160-5]
Figure 20-160-3 and the O-ring beneath.
Figure 20-160-6

1
S4962
Remove the seven end cap bolts [Figure 20-160-3]. S0202
Figure 20-160-4
Remove the spacer plate (Item 1) [Figure 20-160-6].
2 3 1
S0198
Remove the O-ring (Item 1), spacer (Item 2) and wear

ring (Item 3) [Figure 20-160-4].

1
Figure 20-160-7
1 2
S4728
Tip the housing onto the port face and remove the spool
S0203 and sleeve assembly (Item 1) [Figure 20-160-9].
NOTE: Do not bind spool and sleeve in housing.

Remove the O-ring (Item 1) [Figure 20-160-7]. Rotate spool and sleeve assembly slowly
when removing it from housing.

Remove the drive shaft (Item 2) [Figure 20-160-7], while
holding the steering valve upright. Figure 20-160-10
Figure 20-160-8
4
3
1
4
2
1 2
S4726
S4722
Remove the two bearing washers (Item 1) and thrust
bearing (Item 2) [Figure 20-160-10].
Carefully remove the two springs (Item 1), two pins (Item
2), pin (Item 3) and balls (Item 4) [Figure 20-160-8] from
each port.

Figure 20-160-11 1
2 1
S4731
1
The housing valves (Item 1) [Figure 20-160-13] are
S5361
factory adjusted and are not to be changed. The housing
with specified valve pressure settings, the mating spool
and sleeve are not practical replacement parts.
Remove the pin (Item 1), then remove the six springs
(Item 2) by partially sliding out the spool. [Figure 20-160- Figure 20-160-14

11].
Figure 20-160-12
3 1
S4731
2
3 Remove the seals (Items 1 and 2) [Figure 20-160-14]
S5360
from the gland bushing.
Remove the control spool (Item 1) from the sleeve NOTE: Gland bushing removal requires a special 4-
(Item 2) [Figure 20-160-12]. pin tool. Do not attempt to remove without
this tool as damage to the bushing could
Check the condition of the six (two sets of three) springs occur.
(Item 3) [Figure 20-160-12]. It is not required to remove the bushing for
seal replacement.

STEERING VALVE (CONT'D) Assembly
Inspection Figure 20-160-17
Figure 20-160-15
2 S4738
S4738
Assemble the spool (Item 1) and sleeve (Item 2) [Figure
20-160-17] carefully so that spring slots line up at the
Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20- same end. Rotate the spool while sliding parts together.
160-15] for any damage or wear. Replace as needed.

NOTE: Test for free rotation. The spool should rotate
Figure 20-160-16 smoothly in the sleeve with fingertip force
applied at splined end.
Figure 20-160-18
1
S4737
Inspect the drive shaft (Item 1) [Figure 20-160-16] for

S5360
any damage or wear. Replace as needed.
Install the six springs (Item 1) [Figure 20-160-18] onto

the spool and sleeve.
Centre spring set in spring slots. Seat springs down
evenly and flush with upper surface of spool and sleeve.
NOTE: There are six springs and should be

positioned three per side and back to back.

Assembly (Cont’d)
Figure 20-160-19
S4731
1
Install the seal (Item 1) [Figure 20-160-21] in the gland
bushing, with smooth side of the seal facing towards
S5361
bushing.
Insert pin (Item 1) [Figure 20-160-19] through the spool Figure 20-160-22
and sleeve assembly until the pin is flush at both sides of

the sleeve.
Figure 20-160-20
1
1
3
S4731
Install the seal (Item 1) [Figure 20-160-22] in the gland

2 bushing.
S4726
Install the big diameter bearing washer (Item 1) [Figure

20-160-20] with the chamfered side towards the sleeve.
Install the thrust bearing (Item 2) [Figure 20-160-20].
Install the small diameter bearing washer (Item 3)

[Figure 20-160-20] with the chamfered side facing the
outside of the bearing assembly.

STEERING VALVE (CONT'D) Assembly (Cont’d)
Assembly (Cont’d) Figure 20-160-25
Figure 20-160-23
5
2
1
4 6
1
3
S4728
Put some clean oil on the spool and sleeve assembly

(Item 1) and fully insert it into the housing (Item 2)

[Figure 20-160-23] such that the splined end of the spool
S4732
enters the housing first. Mind the correct position of the
bearing and washers inside the housing.
Install the two .187” balls (Item 1), .250” ball (Item 2), pin
NOTE: To prevent the cross pin from dropping into (Item 3), two pins (Item 4) and springs (Item 5) [Figure
the discharge groove of the housing, do not 20-160-25] in the holes as shown.
pull the spool assembly beyond this point.
With the spool assembly in this flush position, Install the spacer plate (Item 6) [Figure 20-160-25]. Align
check for free rotation within housing by the bolt holes in the spacer plate with tapped holes in the
turning assembly with fingertip force at the housing.
splined end.
Figure 20-160-26
Figure 20-160-24
2
S4733
S4742
Rotate the spool and sleeve assembly until the pin (Item
Install the O-ring (Item 1) [Figure 20-160-24] into the 1) is parallel with the port face (Item 2) [Figure 20-160-
housing. 26].
Install the drive (Item 3) [Figure 20-160-26] making sure
the drive is engaged with the pin.
Mark the drive according to the parallel line.

Assembly (Cont’d)
Figure 20-160-27 1
2 3
1
S0198
Install the O-ring (Item 1), spacer (Item 2) and wear ring
S4734 (Item 3) [Figure 20-160-29].
Figure 20-160-30
Install the O-ring (Item 1) [Figure 20-160-27] in the
gerotor (on the spacer plate side).

Figure 20-160-28
S4962
2
Install the seven end cap bolts [Figure 20-160-30].
Pretighten to 17 N•m (12.5 ft-lb), then torque screws to
26 - 30 N•m (19 - 22 in-lb).
S4735
Align the star valleys (Items 1) (Reference A) to the

marked drive (Item 2) (Reference B) [Figure 20-160-28].
This way the valleys are aligned with the pin.
NOTE: Keep in mind the parallel relationship of

reference lines A, B, C, and D in [Figure 20-
160-28].


HYDRAULIC CONTROL VALVE Valve Section Troubleshooting (Auxiliary Section
Example)
Checking Drain Pressure
NOTE: This procedure is the same for all the valve
Figure 20-170-1 sections and should be performed for every
valve section. As an example the Auxiliary
Valve Troubleshooting is described.
See below [Figure 20-170-3] for an overview of
the section functions.
1 Figure 20-170-3
S4717
1. Remove the hose (Item 1) [Figure 20-170-1] from the

inlet section of the control valve and install a tee

fitting.
Figure 20-170-2
1 2 3 4 5
S7419
Lifting Valve Section (Item 1), Tilting Valve Section (Item

2), Telescoping Valve Section (Item 3), Auxiliary Valve
Section (Item 4), Frame Leveling Valve Section (Item 5),
[Figure 20-170-3].
Record the serial number of the machine, control valve

and control module.
The following procedure must be done with the control

valve in the machine.
P-52913 With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure.
2. Install a 3500 kPa (35 bar) (500 psi) gauge on the tee
fitting [Figure 20-170-2]. Remove the rear cover from machine.
3. Start the engine, lower the restraint bar (if equipped)

and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 150
kPa (1,5 bar) (22 psi) maximum.
4. Remove the gauge.

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-6
Valve Section Troubleshooting (Auxiliary Section

Example) (Cont’d)
Figure 20-170-4 1
S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW
S4718

2
S4752
5. With the engine OFF, the key in the run position,

S4613
check that the battery voltage (PIN 3: +12V) on the
controller connector (Item 1) [Figure 20-170-6] is at
least 12 volt or higher.
Figure 20-170-5
S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE
P-97008
The hydraulic control function switch (Item 1) must be ON

(light is on) for all testing procedures and the front
auxiliary hydraulics ON / OFF switch (Item 2) [Figure 20-
170-4] and [Figure 20-170-5] must be on (top position)
(only for auxiliary valve troubleshooting procedure).

Valve Section Troubleshooting (Auxiliary Section

Example) (Cont’d)
1
Figure 20-170-7
m
Maximu
l
Neutra
1
m
Minimu
S4720
9. With adequate room in front of the machine, start the

engine, lower the restraint bar (if equipped) and run
the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-8] forward and back to
S4719 see if this function works. Stop the engine.

Figure 20-170-9
6. With the auxiliary function switch (Item 1) [Figure 20-
170-7] in the minimum (back) position check that the
SIGNAL voltage on the controller connector (Item 1)
[Figure 20-170-6] is 3 volt. If the voltage drops below
1
3 volt the controller will interpret this as a failure.

170-7] in the neutral (middle) position check that the
SIGNAL voltage on the controller connector (Item 1)
[Figure 20-170-6] is 6 volt.

170-7] in the maximum (forward) position check that
the SIGNAL voltage on the controller connector (Item
1) [Figure 20-170-6] is 9 volt. S4718
If one of the three voltage readings in Steps 2, 3 and 4 is

not correct, replace the joystick handle. (See Removal 10. If the auxiliary function does not work with the engine
And Installation on Page 20-200-1.) running, disconnect the controller connector (Item 1)
[Figure 20-170-9] and reconnect it.
If all voltage readings in Steps 2, 3 and 4 are correct go
to step 7.
Perform the following procedure to make sure the

required pressures are present:
(See Checking Drain Pressure on Page 20-170-1.)

HYDRAULIC CONTROL VALVE (CONT’D) Removal And Installation
Valve Section Troubleshooting (Auxiliary Section Relieve hydraulic pressure. Drain the hydraulic reservoir.
Example) (Cont’d) (See Removing And Replacing Hydraulic Fluid on Page
10-100-2.)
Figure 20-170-10
WARNING
immediately.
1 W-2145-0290
S4751
11. If the auxiliary function does not work, operate the IMPORTANT

spool manually by using a key to rotate the hexagonal
axle (Item 1) [Figure 20-170-10].
12. Start the engine, lower the restraint bar (if equipped)
and run the engine at 2200 RPM.
damage the system.
13. Manually push and pull the spool to test the I-2003-0888
movement of the auxiliary function in both directions.
NOTE: If by manually operating the spool the auxiliary Figure 20-170-11

function is working, the controller must be
replaced.
S4500

Figure 20-170-12
1
1
S4504
1
Remove the four bolts (Item 1) [Figure 20-170-14] by
S4501 which the hydraulic control valve is mounted to its
support frame.
Disconnect the wire connector (Item 1) [Figure 20-170- Figure 20-170-15

12].

Figure 20-170-13
1 S4505
Install a hoist and lifting strap (Item 1) [Figure 20-170-

P-50943 15] on the control valve and remove it from the machine.
Note down the position of the five electrical connectors

(Item 1) [Figure 20-170-13] (each wire is marked with a
unique code) and disconnect them.
NOTE: Mark all hoses and tubelines for correct

installation.
Mark and remove the 14 hoses from the hydraulic control

valve.

HYDRAULIC CONTROL VALVE (CONT’D)
1. Control Valve 13. Hose 25. Adapter

2. Support 14. Adapter 26. Hose
3. Washer 15. Hose 27. Block
4. Screw 16. Elbow 28. Valve
5. Nut 17. Adapter 29. Seals Kit
6. Washer 18. Hose 30. Coil
7. Screw 19. Pressure Switch 31. Nut
8. Screw 20. Adapter
9. Valve 21. Hose
10. Washer 22. Adapter
11. Nut 23. T-union
12. Elbow 24. Reducer
S4710

Parts Identification (Cont’d)
1. Control Valve
2. Lifting Element
3. Tilting Element
4. Telescope Element
5. Auxiliary
Hydraulics Element
6. Frame Levelling
Element
7. End Plate
8. Pressure Switch
9. Seal Kit
10. End Plate
11. Tie Rod Set
12. Washer
13. Bolt
S4711

1. Control Valve
2. Controller Assembly
3. Seal Kit
4. Valve Section
5. Spool
6. Port Relief Valve
8. O-ring
9. Control Box
10. Seal Kit
S4712

1. Control Valve
3. Seal Kit
4. Valve Section
5. Spool
8. O-ring
9. Control Box
10. Seal Kit
S4713

1. Control Valve
3. Seal Kit
4. Valve Section
5. Spool
6. Control Box
7. Seal Kit
S4714

1. Control Valve
3. Seal Kit
4. Valve Section
5. Spool
6. Control Box
7. Seal Kit
S4715

1. Control Valve
3. Seal Kit
4. Valve Section
5. Distributor Slide
6. Control Box
7. Seal Kit
S4716

Section Removal
IMPORTANT 1
damage the system.
I-2003-0888
S36281
Figure 20-170-16 Unscrew the three nuts (Item 1) [Figure 20-170-17] from
the tie rod bolts and remove the bolts.
Assembly: Tighten the nuts to 35 N•m (26 ft-lb) torque.
Section Disassembly And Assembly
Control Box

Figure 20-170-18
1 7
2 3 4 5 6
S36280
Mark the valve sections for ease of assembly: Inlet-Outlet

Valve Section (Item 1), Lifting Valve Section (Item 2),
Tilting Valve Section (Item 3), Telescoping Valve Section
(Item 4), Auxiliary Valve Section (Item 5), Frame Leveling 1
Valve Section (Item 6), and End Housing Valve Section 1
(Item 7) [Figure 20-170-16].
2
S36282
Loosen the four screws (Item 1) and remove the control

box (Item 2) [Figure 20-170-18].

HYDRAULIC CONTROL VALVE (CONT’D) Controller Assembly
Section Disassembly And Assembly (Cont’d) Figure 20-170-21
Control Box (Cont’d)
Figure 20-170-19
2 1 1
2
S36285
1
S36283
Loosen the four screws (Item 1) (two visible, two on the
other side) and remove the controller assembly from the
section valve (Item 2) [Figure 20-170-21].

Remove the seals (Item 1). Remove the plug (Item 2)
[Figure 20-170-19] from the control box. Figure 20-170-22
Figure 20-170-20
1
1
S36286
S36284
Remove the five O-rings (Item 1) [Figure 20-170-22]
from the controller assembly.
plug.

Section Disassembly And Assembly (Cont’d)

1 1
Controller Assembly (Cont’d)
Figure 20-170-23
S36289
3 Remove both valve cartridges (Item 1) [Figure 20-170-

25].
1 2
S36287 Figure 20-170-26

Remove the screen (Item 1), the cylindric part (Item 2)
and ring (Item 3) [Figure 20-170-23] from the controller
assembly.
Loosen the two screws (Item 4) [Figure 20-170-23].
Figure 20-170-24
22
1 1
S36290
1
2
Remove the two O-rings (Item 1) and the two backup
3
rings (Item 2) [Figure 20-170-26].
S36288
Remove the plunger (Item 1) [Figure 20-170-24] from

the controller assembly.
Loosen the screw (Item 2) and remove the cover (Item 3)

[Figure 20-170-24] from the controller assembly.

Section Valve
Figure 20-170-27
S36293
1
Use a wrench to remove the adapter (Item 1) [Figure 20-

170-29] from the spool.
S36291 Figure 20-170-30

Remove the spool (Item 1) [Figure 20-170-27] from the
element.
Figure 20-170-28
4
3
1 2
1
S36294
Remove the O-rings (Item 1), the spring retainer (Item 2),
the spring (Item 3) and the other spring retainer (Item 4)
[Figure 20-170-30] from the spool.
S36292
Loosen the screw (Item 1) [Figure 20-170-28] on top of

the spool.


Lifting valve section:
Section Valve (Cont’d)
Figure 20-170-31
1
1
1 2
3 3
S36296
Tilting valve section:
S36295

Remove both port relief valve plugs (Item 1) [Figure 20-
170-31] from the valve section (lifting and tilting valve 1 2
sections only).
3 3
S36297
Lifting valve section: Remove the port relief valve (Item 1)

and the check valve (Item 2), and their corresponding
springs (Items 3) [Figure 20-170-32] from the valve
section.
Tilting valve section: Remove both port relief valves

(Items 1 and 2), and their corresponding springs (Items
3) [Figure 20-170-32] from the valve section.

Inlet Section Disassembly And Assembly
Figure 20-170-33
S4251
Remove the cap (Item 1) [Figure 20-170-35] from the

S4266 inlet section.
Figure 20-170-36
Remove the plug (Item 1) [Figure 20-170-33] from the
inlet section.

Figure 20-170-34
4
3
2
1
5
1 2
3
S4282
Remove the snap ring (Item 1), the plug (Item 2), the
S4246 spring (Item 3) and the pin (Item 4) [Figure 20-170-36]
from the inlet section.

plug.

Inlet Section Disassembly And Assembly (Cont’d)
Figure 20-170-37
S4283
1
Remove the plug (Item 1), the spool (Item 2) and the
S4286 spring (Item 3) [Figure 20-170-39] from the inlet section.
Figure 20-170-40
Press the pin (Item 1) [Figure 20-170-37] out such that it
no longer blocks the valve.

Figure 20-170-38
S4256
Installation: Use a hydraulic press to carefully install the

S4290 spring, spool and plug in the hole and reinstall the pin
(Item 1) [Figure 20-170-40] to keep the assembly in its
place.
If the valve cannot be removed by hand, install a bolt in
the threaded hole and carefully pull the plug (Item 1)
[Figure 20-170-39] out with nut and washer as shown in
[Figure 20-170-38].


PORT RELIEF VALVES
IMPORTANT
damage the system.
I-2003-0888
Remove the hydraulic control valve from the back of the

machine. (See Removal And Installation on Page 20-
170-4.)
Remove the lift and tilt sections from the hydraulic control
valve. (See Section Removal on Page 20-170-13.)

Figure 20-180-1
3 3
3 3
1 2
S36280
Only the tilting (Item 1) and lifting (Item 2) valve sections

have port relief valves (Items 3) [Figure 20-180-1].
(See Section Disassembly And Assembly on Page 20-

170-13.) for disassembly of the port relief valves.


FLOW CONTROL VALVE Figure 20-190-2
Figure 20-190-1
1
S36298

S4500 upper left side of the hydraulic control valve and remove
the flow control valve.
Remove the rear cover (Item 1) [Figure 20-190-1]. Installation: Tighten the flow control valve plug to 20
N•m (15 ft-lb) torque.


PARKING BRAKE Figure 20-210-2
Parking Brake Valve Removal And Installation
Figure 20-210-1
2
2
1
S4519
Remove the three hoses (Item 1). Disconnect the

P-50821 electrical connector (Item 2) [Figure 20-210-2].
Figure 20-210-3
Relieve the hydraulic pressure.
1

Remove the three screws (Item 1) from the access panel
(Item 2) [Figure 20-210-1].
Remove the access panel.
WARNING
penetrating the skin. This can cause serious injury S4519
immediately. Remove the two screws (Item 1) [Figure 20-210-3] in
W-2145-0290 order to loosen the parking brake lever.
IMPORTANT
damage the system.
I-2003-0888
Mark all hoses and electrical connectors for correct

installation.

PARKING BRAKE (CONT’D) Parking Brake Valve Disassembly And Assembly
Parking Brake Valve Removal And Installation (Cont’d) Figure 20-210-5
Figure 20-210-4
S2756
S4519
Remove the fittings (Item 1) [Figure 20-210-5].
Lift the parking brake lever and valve (Item 1) [Figure 20- Figure 20-210-6
210-4] out the frame.

1
P-44439
Loosen the collar (Item 1) [Figure 20-210-6].
NOTE: Use care removing the collar. The collar is

under spring pressure.

PARKING BRAKE (CONT’D) Figure 20-210-9
Parking Brake Valve Disassembly And Assembly

(Cont’d)
Figure 20-210-7
1
P-44442
Remove the electrical connector (Item 1) [Figure 20-210-

9] from the housing.
P-44440
Remove the collar (Item 1), spring (Item 2) and shaft

(Item 3) [Figure 20-210-7] from the housing.
Figure 20-210-8
P-44441
Remove the washer (Item 1) [Figure 20-210-8] from the

housing


PRESSURE REDUCING VALVE Figure 20-220-3
Testing
Figure 20-220-1
S4694
1
Install a 7 MPa (70 Bar) (1000 psi) gauge on the test
fitting [Figure 20-220-3].
Start the engine, lower the restraint bar (if equipped) and
S4500 run engine at 2200 rpm.

Record the pressure. The pressure at the gauge should
Remove the rear cover (Item 1) [Figure 20-220-1]. be 3,31 MPa (33,10 bar) (480 psi).
Figure 20-220-2 The pressure reducing valve is not adjustable. If the

pressure is incorrect, replace the pressure reducing
valve. (See Removal And Installation on Page 20-220-2.)
S4693
Locate the test fitting (Item 1) [Figure 20-220-2] below

the control valve and remove the cap.

PRESSURE REDUCING VALVE (CONT’D) Figure 20-220-6
Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Removing And Replacing Hydraulic Fluid on Page
10-100-2.) 1
Figure 20-220-4
S4695
1 Remove the plug (Item 1) [Figure 20-220-6].
Figure 20-220-7
S4500

Figure 20-220-5
1 1
2
3
S4246
Remove the spring (Item 1), the bolt (Item 2) and the
cylinder (Item 3) [Figure 20-220-7] out of the valve block.
S4692
Locate the pressure reducing valve (Item 1) [Figure 20-

220-5] at the upper side of the left valve block.

ACCUMULATOR Figure 20-230-2
The accumulator is located below the boom, and can be

seen through an access hole on top of the frame.
WARNING
immediately.
W-2145-0290
IMPORTANT

damage the system. S4613
I-2003-0888
With the engine off, relieve the hydraulic pressure by

Figure 20-230-1 pressing the bottom of the button (Item 1) [Figure 20-
S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE 230-1] and [Figure 20-230-2].
Figure 20-230-3
1
P-97008
2 1
S4523
Remove the accumulator (Item 1) from the manifold (Item

2) [Figure 20-230-3].


TOW VALVE Figure 20-240-2
Figure 20-240-1
S6839
Mark the hoses for correct installation. Remove the two

hoses (Item 1) [Figure 20-240-2].
S6838 Figure 20-240-3

Position the tow valve to towing position to relieve
hydraulic pressure [Figure 20-240-1].
2
WARNING 3
Hydraulic fluid escaping under pressure can have 1

immediately.
W-2145-0290
Remove the two bolts, nuts (Item 1) and strap (Item 2).
Remove the tow valve (Item 3) [Figure 20-240-3].
IMPORTANT
damage the system.
I-2003-0888

TOW VALVE (CONT’D) Figure 20-240-6
Clean the outside of the tow valve before disassembly.
Mark the outside of the tow valve for ease of assembly.
Figure 20-240-4
1
P-46750
Remove the retainer (Item 1) and stop plate (Item 2)

2 [Figure 20-240-6].
NOTE: Record the position of the stop plate for

1 proper assembly.
P-46747

Figure 20-240-7
Remove the screw (Item 1) and washer (Item 2) [Figure

20-240-4].
Figure 20-240-5
1
1 1
P-46752
Remove the two fittings (Item 1) [Figure 20-240-7].
P-46749
Remove the handle (Item 1) [Figure 20-240-5].

Figure 20-240-8 1
P-46755
1

P-46753 adapters.

fittings.

Figure 20-240-9
1 1
P-46754
Remove the two adapters (Item 1) [Figure 20-240-9].

Figure 20-240-11
1
P-46759
Figure 20-240-14
P-46756
Figure 20-240-12
1

2
1
P-46760
Assembly: Align the slot (Item 1) [Figure 20-240-13]

P-46758 with the notch (Item 1) [Figure 20-240-14] in the shaft.
Remove the seal (Item 1) [Figure 20-240-11] from the

valve (Both sides).
Assembly: The concave side of the seal (Item 1) [Figure

20-240-11] fits over the ball (Item 2) [Figure 20-240-12].
Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-240-12] are in the position shown. Remove
the ball.
Assembly: Record the position of the shaft and ball for

proper assembly.

Figure 20-240-15
1
1
P-46762
Remove the seal (Item 1) [Figure 20-240-17] from the

P-46763 housing.
Clean all parts in solvent and dry with compressed air.

Remove the shaft (Item 1) [Figure 20-240-15] by
pressing the shaft into the housing. Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Figure 20-240-16
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
P-46761

shaft.


STABILISER CYLINDER Figure 20-250-3
Figure 20-250-1
S4647
Remove the pivot pin retainer bolt (Item 1) [Figure 20-

S7431
250-3].
Figure 20-250-4
Extend and support the boom on adequate stands
[Figure 20-250-1].

IMPORTANT 1 2

damage the system.
I-2003-0888
S4648
Figure 20-250-2
Support the cylinder by using a lifting strap (Item 1)
[Figure 20-250-4].
1 Remove the pin (Item 2) [Figure 20-250-4].
S4646
Disconnect both hoses (Item 1) [Figure 20-250-2] and

put caps on the connections to prevent bleeding the
hydraulic tank.

STABILISER CYLINDER (CONT’D) Figure 20-250-7
Figure 20-250-5
1
S4651
Remove the stabiliser cylinder from the front of the

S4649
machine [Figure 20-250-7].
Remove the nut and washer (Item 1) [Figure 20-250-5]

on one side of the pivot pin.

Figure 20-250-6
2
1
S4650
Remove the nut and washer (Item 1) [Figure 20-250-6]

on the other side of the pivot pin.
Remove the pivot pin (Item 2) [Figure 20-250-6] from the

stabiliser cylinder.

STABILISER CYLINDER (CONT’D)
1 7
10
12
1. Cylinder Ref. 2 to 14 5
2. Rod 8
3. Piston torque: 900 ± 180 N•m (664 ± 133 ft-lb)
4. Screw torque: 20 N•m (14.7 ft-lb)
5. Bush
6. Grease nipple
7. Cap
8. Inner ring

9. Cylinder
10. Grease nipple
11. Cylinder head torque: 450 - 500 N•m (332 - 369 ft-lb)
12. Valve torque: 45 - 50 N•m (33 - 37 ft-lb) 9
13. Valve 13
14. Seals kit 8
5
14
7
6
11
5
8 4
8
5
S2821

STABILISER CYLINDER (CONT’D) Figure 20-250-10
Disassembly
Figure 20-250-8
1
S3230
Carefully peen the lock ring (Item 1) [Figure 20-250-10]

S3229 from the head gland.
Figure 20-250-11
Figure 20-250-9

1
1 S2819
S3222 Loosen the head gland (Item 1) [Figure 20-250-11].
Remove both relief cartridges (Item 1) [Figure 20-250-9]

from the cylinder.

STABILISER CYLINDER (CONT’D)
Assembly
Use the following tool to assemble the cylinder:

MEL1075-Adjustable Gland Nut Wrench

compressed air.
Inspect the cylinder parts for damage. Replace any

damaged parts.

Clean off any old residue, and apply LOCTITE® 243 or

equivalent to the threads on the rod (Item 2). Install the
piston (Item 3) onto the rod and tighten. (See Parts
Identification on Page 20-250-3.)


STABILISER CONTROL VALVE
5
1. Selector valve
2. Block
3. Electro distributor
4. Control valve
5. Screw
6. Solenoid
7. Adapter
8. Drain plug
9. Adapter
10. Plug

11. Adapter 2 1
12. Pipe
13. Pipe 8
14. Support
15. Elbow
16. Elbow
11 10
12
13
14 9 7
12
15
13
16
55° 55°
S4707

STABILISER CONTROL VALVE (CONT’D) Figure 20-260-3
Removal
Figure 20-260-1
1
S4578
Disconnect the two hoses (Item 1) [Figure 20-260-3]

S4583 from the stabiliser control valve and cap them.
Figure 20-260-4
Remove the screw (Item 1) to remove the cover (Item 2)
[Figure 20-260-1].

Figure 20-260-2
1 1
S4580
Remove the four screws (Item 1) [Figure 20-260-4] from

1 S4577
the bottom of the stabiliser control valve.
Disconnect the five coils (Item 1) [Figure 20-260-2] by

loosening the screws and remove the coils.

Removal (Cont’d)
Figure 20-260-5
1 1
1
S4581
Disconnect the four hydraulic tubelines (Item 1) [Figure

S4658 20-260-7] from the plate and cap the hoses and the
couplings.
Remove the two bolts (Item 1) and remove the cover Figure 20-260-8
(Item 2) [Figure 20-260-5] from the front of the machine.

Figure 20-260-6
1
S4582
S4579 Tilt the stabiliser control valve back and disconnect the
hose (Item 1) [Figure 20-260-8] from the control valve.
Pull the plate with the hoses (Item 1) [Figure 20-260-6]

back from the front of the machine.

STABILISER CONTROL VALVE (CONT’D) Installation
Removal Figure 20-260-10
Figure 20-260-9
1
S4582
S4659
Place the valve block in its position in the stabiliser frame,
but do not yet secure the valve block to the frame.
Remove the stabiliser control valve from the front of the
machine [Figure 20-260-9]. Install the hose (Item 1) [Figure 20-260-10].

Figure 20-260-11
S4578
Connect the two hoses (Item 1) [Figure 20-260-11] on

the stabiliser control valve.

Installation (Cont’d)
Figure 20-260-12
1
S4658
1 1
Install the cover (Item 1) with the two bolts (Item 2)

S4581 [Figure 20-260-14] on the front of the machine.
Figure 20-260-15
Pull the valve block a bit forward in order to be able to
connect the four hoses / tubes (Item 1) [Figure 20-260- 1
12].

Figure 20-260-13
1
1
S4577
Install the five coils (Item 1) [Figure 20-260-15] and

tighten the screws.
S4580
Install the four screws (Item 1) [Figure 20-260-13] on the

bottom of the stabiliser control valve.

STABILISER CONTROL VALVE (CONT’D)
Figure 20-260-16
S4583
Install the cover (Item 1) and screw (Item 2) [Figure 20-

260-16].

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21


HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart

WARNING
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 authorised Bobcat Service Personnel
adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.

3. The tyres do not have the correct tyre pressure.
4. The tyres are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The telescopic handler is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

HYDROSTATIC SYSTEM INFORMATION (CONT’D) The functions of the replenishing valves are:
Replenishing Valve Function 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
Figure 30-10-1 because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].
Valve Moves For

Function 1 Charge Oil
Replacement

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804
IMPORTANT
damage the system.
I-2003-0888

OIL COOLER
Description
The oil cooler is a combined radiator / oil cooler. (See

Removal And Installation on Page 70-50-1.) for Radiator /
Oil Cooler Removal And Installation.


HYDROSTATIC DRIVE MOTOR
Remove the front axle. (See Removal on Page 40-30-1.)
Figure 30-30-1
1 1
P-22325

Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-1].

1] from the drive motor.
Installation: Tighten the mounting bolts to 190 - 210

Remove the hydrostatic drive motor from the axle

housing.

HYDROSTATIC DRIVE MOTOR (CONT'D)
1. Bolt
2. End Cap
3. Plug
4. O-ring
5. Seal
6. Servo Piston
7. Feed Back Lug
8. Nut
9. Adjuster
10. Rod
11. Set Screw
12. Spring seat
13. Spring
14 Spool
15. Orifice

16. Housing
17. Solenoid
B-18528

1. Valve Segment
2. Plate
3. Pins
4. Bearing
5. Cylinder
6. Pin
7. Synchronizing Shaft
8. Rollers
9. Bolt
10. Nut
11. Cap
12. Plug
13. O-ring
14 Ring
15. Piston

16. Spring Seat
17. Spring
18. Shaft
19. Bearing
20. Spacer
21. Nut
22. O-ring
23. Seal
24. Housing
B-15937


1. Nut
2. Solenoid
3. Solenoid Shaft
4. O-ring
5. Spring
6. Plug
7. Fitting
8. Bolt
9. Orifice
10. Housing
11. Spool
12. Adjustment Spool
13. End Nut
14 Nut
15. Spring Seat
16. Limiter
B-15939

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4
Disassembly 1
IMPORTANT
damage the system.
I-2003-0888
P-29653
Figure 30-30-2
Remove the solenoid nut (Item 1) [Figure 30-30-4].
Figure 30-30-5

P-29652
Place the hydrostatic drive motor on a work surface, mark

P-29654
the sections for correct assembly [Figure 30-30-2].
Figure 30-30-3 Remove the solenoid (Item 1) [Figure 30-30-5] from the
shaft.
P-29651
Remove the four bolts (Item 1) [Figure 30-30-3] and

remove the solenoid housing.

Disassembly (Cont'd) 1
Figure 30-30-6
2
1
P-29657
Remove the solenoid shaft (Item 1) and O-ring (Item 2)

P-29655 [Figure 30-30-8] from the housing.
Figure 30-30-9
Remove and discard the O-ring (Item 1) [Figure 30-30-6]
from the solenoid.

Figure 30-30-7 3
1 2
P-29659
Remove the O-ring (Item 1) and pin (Item 2) from the

P-29656 solenoid shaft (Item 3) [Figure 30-30-9].

housing.

Figure 30-30-10
P-29661
Remove the pin (Item 1) [Figure 30-30-12] from the

P-29660 housing.
Figure 30-30-13
housing.

Figure 30-30-11
1 1
P-29663
Remove the fitting (Item 1) [Figure 30-30-13].

P-29662

11] from the plug.

Figure 30-30-14
1 1
1
1 1
P-22345
Remove the eight bolts (Item 1) [Figure 30-30-16] from

P-29664 the end cap.
Figure 30-30-17
housing.

Figure 30-30-15
1
1
1
P-29667
1
Lift and remove the end cap (Item 1) [Figure 30-30-17]
P-29666 from the housing.
Remove and discard the seven O-rings (Item 1) [Figure

30-30-15] from the housing.

Figure 30-30-18
1
P-29664
Remove the orifice (Item 1) [Figure 30-30-20].

P-29668
NOTE: Mark the orifice location for correct assembly.
Remove the gasket (Item 1) [Figure 30-30-18] from the Figure 30-30-21
end cap.

Figure 30-30-19
P-29671
P-29669 Remove the spool (Item 1) [Figure 30-30-21].
Remove the plug (Item 1) [Figure 30-30-19].

Figure 30-30-22
1
P-29674
Remove the two orifices (Item 1) [Figure 30-30-24] from

P-29672 the spool.
NOTE: Mark the orifice location for correct assembly.

Remove the servo control spool (Item 1) [Figure 30-30-
22] from the housing. Figure 30-30-25

Figure 30-30-23
2
P-29675
P-29673
Remove the two spring seats and spring (Item 1) from the
servo spool hole (Item 2) [Figure 30-30-25].
Remove the two O-rings (Item 1) [Figure 30-30-23] from
the servo control spool.

Figure 30-30-26
1
P-29678

P-29676 28].
Figure 30-30-29
Loosen the large nut (Item 1) [Figure 30-30-26] on the
adjustment screw.
2

NOTE: Do not change the adjustment.
Figure 30-30-27
1 1
P-29679
Remove the four bolts (Item 1) and remove the end cap
(Item 2) [Figure 30-30-29].
P-29677
Remove the adjustment screw (Item 1) [Figure 30-30-27]

from the housing.

Figure 30-30-30
1 P-29682
Remove the inner set screw from the servo piston

P-29680 [Figure 30-30-32].
Figure 30-30-33
Remove the two O-rings (Item 1) [Figure 30-30-30].

Figure 30-30-31
P-29683
P-29681 Remove the feedback lug (Item 1) [Figure 30-30-33]

from the servo piston.
Remove the outer set screw from the servo piston

[Figure 30-30-31].

Figure 30-30-34
1 1
P-29686
Remove the two plugs (Item 1) [Figure 30-30-36] from

P-29684 the housing.
Figure 30-30-37
Remove the servo piston (Item 1) [Figure 30-30-34].

Figure 30-30-35
P-29687
P-29685 Remove the relief valve (Item 1) [Figure 30-30-37] from

the housing by loosening the larger nut.
Remove the two seals (Item 1) [Figure 30-30-35] from

the servo piston.

Figure 30-30-38
4
5 2
1 2 3 4 3
2
1
P-29690
Remove the plug (Item 1), spring (Item 2), spring seat
P-22501 (Item 3) and spool (Item 4) [Figure 30-30-40] from the
housing.
Remove the plug (Item 1), O-rings (Item 2), spring (Item Figure 30-30-41
3) and poppet (Item 4) from the relief valve housing (Item

5) [Figure 30-30-38].
Figure 30-30-39
1
P-29692
1
Loosen the plug (Item 1) [Figure 30-30-41].

P-29689
Loosen the plug (Item 1) [Figure 30-30-39].

Figure 30-30-42
3
2
1
P-29696

P-29693
Figure 30-30-45
Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-42] from the housing.

Figure 30-30-43
1
P-29697
P-29691 NOTE: Mark the location of the orifice for correct

assembly.

43] from the plug.

Figure 30-30-46
1
1
P-29698
Remove the valve segment (Item 1) [Figure 30-30-48]

P-29694 from the cylinder.
Figure 30-30-49

Figure 30-30-47 2 2
1 1
2
P-22386
P-29695 Remove and discard the O-ring (Item 1). Remove the
eight mounting bolts (Item 2) [Figure 30-30-49] from the
mounting plate.
NOTE: Mark the location of the orifice for correct

assembly.

Figure 30-30-50
2 1
P-22503
Remove the cylinder block (Item 1) and synchronizing

P-22504 shaft assembly (Item 2) [Figure 30-30-52] from the
housing.
Remove the mounting plate [Figure 30-30-50] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.

Figure 30-30-51 Figure 30-30-53
P-22449 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-51] Remove the bearing plate (Item 1) [Figure 30-30-53]
from the mounting plate. from the cylinder block.

Figure 30-30-54
P-22390
Press the piston / shaft assembly from the housing

P-22458 [Figure 30-30-56].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-54]. Figure 30-30-57

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-55
1 P-22505
Pry up the peened notch (Item 1) [Figure 30-30-57] in

the ring nut.
P-22388

housing.

Figure 30-30-58
1
P-22446
Using a clamp, compress the spring seat and spring, and

P-22506 drive the pin (Item 1) [Figure 30-30-60] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-58] from the Figure 30-30-61
shaft.

Figure 30-30-59
2 3
1
3
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-61] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3) [Figure
30-30-59] from the shaft.

HYDROSTATIC DRIVE MOTOR (CONT'D) Inspection
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-62 material can get into the system and cause damage.
Figure 30-30-63
1
2
1
P-22508 2
P-22461
Remove the piston rings (Item 1) [Figure 30-30-62] from
the pistons.

Inspect the running (bronze) surface of the bearing plate
NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-63]
or races must be replaced, the complete shaft / for wear. Replace if damaged or worn.
bearing assembly must be ordered. The only
serviceable part is the piston rings (Item 1) Figure 30-30-64
[Figure 30-30-62].
P-22462
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-64]
must not be worn.
If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.

Inspection (Cont'd)
Figure 30-30-65
B-15936
Inspect the valve segment for damage or wear on the

P-29685 sealing surface (Item 1) [Figure 30-30-67].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-65] for wear or segment by measuring distance "A" [Figure 30-30-67]. If
damage. this dimension is not within 34,5 to 34,7 mm (1.36 to 1.37

in) the assembly must be replaced.
Figure 30-30-66
P-22349
Inspect the swash plate running surface (Item 1) [Figure

30-30-66] in the end cap for wear or damage.

Assembly
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
P-22441
Clean and lightly oil all parts prior to assembly.

Install the pin (Item 1) [Figure 30-30-70] as shown.
Figure 30-30-68
NOTE: Clamp is removed for photo clarity.
3 Figure 30-30-71

1 2
2
P-22447
Install the spring (Item 1) and spring seat (Item 2) into the 1
shaft assembly (Item 3) [Figure 30-30-68]. P-22453
Figure 30-30-69
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-71] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
P-22446
Using a clamp, compress the spring and spring seat

[Figure 30-30-69].

Assembly (Cont'd)
Figure 30-30-72
P-22455
Press the piston / shaft assembly into the housing

P-22505 [Figure 30-30-74].
DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-72] onto the
shaft. Figure 30-30-75

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Figure 30-30-73
1
P-22455
Install a new seal (Item 1) [Figure 30-30-75] into the

mounting plate until it is fully seated.
P-22509
Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-73].

Assembly (Cont'd)
Figure 30-30-76
1
P-22386
Install a new O-ring (Item 1) [Figure 30-30-78] onto the

P-22388 mounting plate.
Figure 30-30-79
housing.

Figure 30-30-77 13,5 to 14,0 mm
(0.53 to 0.55”)
1 1
B-15933
1 Press a new bearing into the cylinder block until it is

1 located 3,5 to 14,0 mm (0.53 to 0.55 in) below the
P-22387 bearing plate surface [Figure 30-30-79].
Install the mounting plate onto the housing, install the

eight mounting bolts (Item 1) [Figure 30-30-77] and
tighten to 63 N•m (46 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-80 1
P-22459
Install the bearing plate (Item 1) [Figure 30-30-82] with

P-22440 the bronze surface facing up onto the cylinder block.
Figure 30-30-83
Figure 30-30-81
Piston End

2
P-22464
B-15935
Position the housing on end, tip the three pistons (Item 1)

Install new piston rings (Item 1) [Figure 30-30-80] onto [Figure 30-30-83] closest to the minimum angle stop out
the pistons, make sure the spherical surface (Item 1) toward the housing.
[Figure 30-30-81] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-80] and

[Figure 30-30-81] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.

Assembly (Cont'd) 1
Figure 30-30-84
B-15934
NOTE: The recess (Item 1) [Figure 30-30-86] on each

roller MUST face the synchronizing shaft.
P-22511
Figure 30-30-87
Install the synchronizing shaft support pin (Item 1)
[Figure 30-30-84] into the cylinder block and retain with

grease.
Figure 30-30-85
1
1
P-22512
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-87] into the motor shaft assembly and
retain with grease.
P-22499
Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-85] onto the synchronizing shaft and retain with
grease.

HYDROSTATIC DRIVE MOTOR (CONT'D) Lift the cylinder block slightly and guide the three
remaining pistons in position.
Assembly (Cont'd)
Figure 30-30-90
Figure 30-30-88
3
2
P-22500
P-22513
If the cylinder block (Item 1) [Figure 30-30-90] is properly

Install the synchronizing shaft and rollers (Item 1) installed, there should be very little rotational free-play
[Figure 30-30-88] into the motor shaft races. When between the block and the motor shaft.

properly installed the synchronizing shaft should move
freely in all directions. NOTE: A brass rod can be used to guide the pistons
into their bores.
NOTE: The motor shaft end of the synchronizing
shaft is smaller than the cylinder end. Lubricate the pistons and cylinder block bores with
hydraulic fluid.
Figure 30-30-89
Figure 30-30-91
2
1
4
1
3 3
2
1
P-22511
P-29698
When installing the cylinder block, the races (Item 1)

[Figure 30-30-89] in the cylinder block must be Install a new gasket (Item 1) [Figure 30-30-91] onto the
positioned so the synchronizing shaft rollers (Item 2) and housing.
pistons (Item 3) [Figure 30-30-88] and their bores (Item
2) [Figure 30-30-89] are aligned. Install the valve segment (Item 2) [Figure 30-30-91] onto
the cylinder block and retain with heavy grease.
Install the six pistons (Item 3) [Figure 30-30-88] into the
cylinder bores, tilt the block so the synchronizing shaft NOTE: The hole (Item 3) in the valve segment should
rollers enter their races in the block and the support pin be next to the minimum displacement
(Item 3) [Figure 30-30-89] enter the recess. adjustment screw (Item 4) [Figure 30-30-91].

Assembly (Cont'd)
Figure 30-30-92
P-29697
Install the orifice (Item 1) [Figure 30-30-94] and tighten

P-29695 to 5 N•m (4 ft-lb) torque.
Figure 30-30-95
Install the orifice (Item 1) [Figure 30-30-92] and tighten
to 5 N•m (4 ft-lb) torque.

Figure 30-30-93
P-29696
Install the plug (Item 1) [Figure 30-30-95] and tighten to

P-29694 5 N•m (4 ft-lb)) torque.

5 N•m (4 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-96
1
P-29691
Install a new O-ring (Item 1) [Figure 30-30-98] on the

P-29691 plug.
Figure 30-30-99
plug.

Figure 30-30-97
1
2
3
4
3
2
1
P-29693
Install the spring seat (Item 1), spring (Item 2) and plug
P-29690 (Item 3) [Figure 30-30-99] into the housing and tighten to
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 30-30-97] into the
housing and tighten to 41 N•m (30 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-100
1 1
3 4
5 4 2 1
P-29686
Install the two plugs (Item 1) [Figure 30-30-102] and

P-22501 tighten to 41 N•m (30 ft-lb) torque.
Assemble the poppet (Item 1) and spring (Item 2) into the Figure 30-30-103
relief valve housing (Item 3) using new O-rings (Item 4)
and plug (Item 5) [Figure 30-30-100].

Figure 30-30-101
P-29685
Install the two seals (Item 1) [Figure 30-30-103] onto the

servo piston.
P-29687
Install the relief valve (Item 1) [Figure 30-30-101] into the

housing and tighten to 52 N•m (38 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-104
P-29682
While holding the feedback lug, install the pointed set

P-29684 screw into the groove in the feedback lug [Figure 30-30-
106].
Install the servo piston (Item 1) into the housing, make Do not tighten at this time.
sure the hole (Item 2) [Figure 30-30-104] is in the

position shown when the piston is fully installed. Figure 30-30-107
Figure 30-30-105
1
P-29680
P-29683
Install the two O-rings (Item 1) [Figure 30-30-107].
Install the feed back lug (Item 1) [Figure 30-30-105] into

the servo piston.
NOTE: The position of the flat side of the feed back

lug (Item 2) [Figure 30-30-105].

Assembly (Cont'd)
Figure 30-30-108
1 1
P-29677
Install the adjustment rod (Item 1) [Figure 30-30-110]

P-29679 into the housing and through the feed back lug. Tighten
the large nut to 20 N•m (15 ft-lb) torque.
Install the end cap and tighten the four bolts (Item 1) Figure 30-30-111
[Figure 30-30-108] to 78 N•m (58 ft-lb) torque.

Figure 30-30-109
P-29682
P-29678 Tighten the pointed set screw at this time [Figure 30-30-
111].

adjustment rod.

Assembly (Cont'd)
Figure 30-30-112
1
P-29674
Install the two orifices (Item 1) [Figure 30-30-114] into

P-29681 the spool and tighten to 2 N•m (18 in-lb) torque.
Figure 30-30-115
Install the second set screw and tighten [Figure 30-30-
112].

Figure 30-30-113
1
P-29673
Install the two O-rings (Item 1) [Figure 30-30-115] onto

P-29675 the spool.
Install the two spring seats and spring (Item 1) into the
servo piston hole (Item 2) [Figure 30-30-113].
NOTE: Apply assembly lube to help hold into correct

position.

Assembly (Cont'd)
Figure 30-30-116
1
P-29664
Install the orifice (Item 1) [Figure 30-30-118] into the

P-29672 housing and tighten to 5 N•m (4 ft-lb) torque.
Figure 30-30-119
Install the servo control spool (Item 1) [Figure 30-30-
116] into the housing.

1
Figure 30-30-117
1
P-29669

P-29671 5 N•m (4 ft-lb) torque.
Install the inner spool (Item 1) [Figure 30-30-117].

Assembly (Cont'd)
Figure 30-30-120
1 1
1
1 1
P-22345
Install the end cap housing and tighten the eight bolts
P-29668 (Item 1) [Figure 30-30-122] to 115 N•m (85 ft-lb) torque.
Figure 30-30-123
Install a new gasket (Item 1) [Figure 30-30-120] onto the
end cap.

Figure 30-30-121 1
1
1
2 P-29666
Install the seven O-rings (Item 1) [Figure 30-30-123].

P-29667
Align the feed back lug (Item 1) and the valve segment
(Item 2) [Figure 30-30-121].

Assembly (Cont'd)
Figure 30-30-124
1
2
P-29661
Install the pin into the housing as shown [Figure 30-30-

P-29664 126].
Figure 30-30-127
Install the spool (Item 1) [Figure 30-30-124] into the
housing.

NOTE: The position of the groove (Item 2) [Figure 30- 1
30-124].
Figure 30-30-125
1 P-29662

plug.
P-29663
Install the fitting (Item 1) [Figure 30-30-125].

Assembly (Cont'd) 2
Figure 30-30-128
P-29657
Install a new O-ring (Item 1) and solenoid shaft assembly

P-29660 (Item 2) [Figure 30-30-130] into the housing.
Figure 30-30-131

Figure 30-30-129
1
P-29656
Install the spool (Item 1) [Figure 30-30-131] into the

P-29659 housing.

solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-129] and

install into the solenoid shaft.

Assembly (Cont'd) 1
Figure 30-30-132
P-29653
Install the solenoid nut (Item 1) [Figure 30-30-134] and

P-29655 hand tighten.
Figure 30-30-135
solenoid.
1

Figure 30-30-133 2
P-29651
Install the solenoid housing assembly (Item 1). Tighten

P-29654 the bolts (Item 2) [Figure 30-30-135] to 78 N•m (58 ft-lb)
torque.
Install the solenoid (Item 1) [Figure 30-30-133].

HYDROSTATIC PUMP Figure 30-40-2
Remove the gear pump. (See Removal And Installation

on Page 20-130-1.)
1
IMPORTANT
1
tubelines and ports to keep dirt out. Dirt can quickly S4697
damage the system.

I-2003-0888

1
S4696 S4698
Remove the hose (Item 1) [Figure 30-40-1] from the top Remove the tubeline (Item 1) [Figure 30-40-3].
of the hydrostatic pump.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-6
Figure 30-40-4
S4700
Remove the hoses on the right side of the hydrostatic

S4700 pump (Item 1) [Figure 30-40-6].
Figure 30-40-7
tubeline.

Figure 30-40-5
S4699
1
Install a chain hoist and lifting strap to lift and support the
S4698 pump.

Remove the four bolt flange hose (Item 1) [Figure 30-40- 7].
5] from the front of the pump.
Lift and remove the hydrostatic pump.
NOTE: It can be necessary to remove fittings from the

pump for complete removal.

HYDROSTATIC PUMP (CONT'D)
1. Multi-Function Valve Assembly

2. O-Ring
3. Plug
4. Plug
5. Nut
6. Charge Relief
7. O-Ring
8. Spring
9. Poppet
10. Plug
11. Control Filter Screen
12. Bolt
13. Lip Seal
14 Cover
15. O-Ring
16. Retainer Plate
B-15899

HYDROSTATIC PUMP (CONT’D)
1
2
3
4
5

8
6
12 7
1. Key
13
2. Charge Pump Shaft
3. Pin
4. Wear Plate 14
5. Gears
6. Coupling 11
7. Seal
8. Charge Pump Cover 9
9. Retaining Plate 15
10. Bolt 10
11. O-Ring
12. Flange Adapter
13. Washer
14. Bolt
15. O-Ring
B-23195

1. Valve Plate
2. Retaining Ring
3. Spring Retainer
4. Spring
5. Spring Seat
6. Cylinder
7. Bolt
8. Slipper Guide Bearing
9. Spacer
10. Slipper Guide
11. Piston
12. Bolt
13. Bolt
14. Block
15. Spring
16. Servo Arm
17. Pin

18. Washer
19. Swash Plate Guide
20. Pin
21. Housing
22. Swash Plate
23. Bearing Assembly
24. Pin
25. Housing
B-19856

1. Snap Ring
2. Spring Guide
3. Spring
4. Spring Guide

5. Bolt
6. Bolt
7. Servo Spring Housing
8. Nut
9. Screw
10. Servo Cylinder
11. O-Ring
12. O-Ring
13. Nut
14. Nut
15. Bearing
16. Spacer
17. Snap Ring
18. Shaft
19. Piston Ring
20. O-Ring
21. Block
22. Servo Piston
23. O-Ring
24. O-Ring
25. Bolt
26. End Cap
27. Shim
28. Spring
29. Spring Seat
30. Guide Post
31. Leveler
32. O-ring
33. Inserts
34. Side Cover
35. Bolt
36. Nut
37. Plug
B-19857

HYDROSTATIC PUMP (CONT'D) Remove the retainer plate (Item 2) [Figure 30-40-9] from
the pump housing.
Disassembly
Figure 30-40-10
IMPORTANT
damage the system.
I-2003-0888
Figure 30-40-8
P-18566
1 Remove the shaft and bearing assembly from the

housing [Figure 30-40-10].

NOTE: If the shaft or bearing assembly become stuck
2 in the housing, lightly tap on the shaft.
Figure 30-40-11
P-18550 1
Remove the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-8] from the shaft.
Figure 30-40-9
P-18567
2
1
Remove the shaft seal (Item 1) [Figure 30-40-11] from
the shaft.
P-18565
Remove the three screws (Item 1) [Figure 30-40-9].

HYDROSTATIC PUMP (CONT'D) Figure 30-40-14
Figure 30-40-12
1
1
2
P-18721
Remove the relief valve lock nut (Item 1) and the plug
P-18570 (Item 2) [Figure 30-40-14].
Figure 30-40-15
Remove the snap ring (Item 1) and spacer washer (Item
2) [Figure 30-40-12] from the shaft.

Figure 30-40-13
P-18722
Remove the spring and relief poppet from the charge

P-18572 pump housing [Figure 30-40-15].
Remove the bearing (Item 1) [Figure 30-40-13] from the

shaft.
Place the pump on the work surface with the charge

pump up.
Mark the pump housings for correct assembly.
Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.

Disassembly (Cont'd) 1
Figure 30-40-16
S4701
2
Lift and remove the charge pump (Item 1) [Figure 30-40-
P-18723 18] from the pump housing.
Figure 30-40-19
Remove the mounting bolt (Item 1) [Figure 30-40-16].

NOTE: Remove the lifting bracket (Item 2) [Figure 30- 1
40-16] from the pump.
Figure 30-40-17 1
1 1
1 2
1
P-18726
Remove the six bolts (Item 1) and remove the retaining

plate (Item 2) [Figure 30-40-19] from the charge pump.
P-18724

17] from the flange adapter.
Remove the flange adapter (Item 2) [Figure 30-40-17].

Figure 30-40-20 1
P-18728
Remove the coupler (Item 1) [Figure 30-40-22].

P-18727
Figure 30-40-23
Remove the charge pump cover (Item 1)

[Figure 30-40-20].

Figure 30-40-21 1
1 2
2 P-18729
Remove the charge pump shaft (Item 1) and key (Item 2)

[Figure 30-40-23] from the pump.
P-18558
Only if wear marks are present, remove the bushing (Item

1) from the charge pump cover (Item 2) [Figure 30-40-
21].

Figure 30-40-24 1
P-18732
Remove the charge pump wear plate (Item 1) [Figure 30-

P-18730 40-26].
Remove the O-ring (Item 2) [Figure 30-40-26].

Remove the charge pump gears (Item 1) [Figure 30-40-
24]. Figure 30-40-27

Figure 30-40-25
2 1 2
P-18585
P-18731
Remove the swash plate leveler spring shims (Item 1)
[Figure 30-40-27] from the spring pockets.
Remove the eccentric ring (Item 1) and alignment pin
(Item 2) [Figure 30-40-25] from the pump. Inspect the journal bearing (Item 2) [Figure 30-40-27].
Replace as needed.
Note the position of the alignment pin.

3 1
Figure 30-40-28
2
2
1
P-18586
Remove the gasket (Item 1) and the valve plate (Item 2)

P-18734 from the housing. Note the direction of the arrows (Item
3) [Figure 30-40-30] on the valve plate for proper
assembly.
For proper operation, if the plugs (Items 1 and 2) [Figure
30-40-28] are removed from the housing they must be Figure 30-40-31

returned to their original position.
Installation: Tighten the servo relief valve plug (Item 1) 1

to 12 N•m (9 ft-lb) torque. Tighten the rotation pipe plugs
(Item 2) [Figure 30-40-28] to 5,4 N•m (4 ft-lb) torque.
Figure 30-40-29
1
P-18588
1
Remove the two leveler springs (Item 1)
[Figure 30-40-31].
1
P-18735
Remove the multi-function valve assemblies (Item 1)

[Figure 30-40-29] from the housing.

Figure 30-40-32
1
1 1
1
P-18596
Remove the six bolts (Item 1) [Figure 30-40-34] from the

P-18589 side cover.
Figure 30-40-35
Remove both spring seats (Item 1) [Figure 30-40-32]
from the swash plate leveler.

Figure 30-40-33
1
P-18597
Remove the side cover / swash plate leveler assembly

P-18590 from the housing [Figure 30-40-35].
Remove the swash plate hold down spring (Item 1)

[Figure 30-40-33].
Mark the position of the side cover.

Figure 30-40-36 1
P-18609
1
Remove the cylinder block (Item 1) [Figure 30-40-38]
P-18598 through the housing end opening. The swash plate and
piston assembly will remain in the housing.
Remove and discard the O-ring (Item 1). Loosen and Figure 30-40-39
remove both guide posts (Item 2) [Figure 30-40-36].

Figure 30-40-37
1
P-18610
P-18599 Remove the swash plate / piston assembly (Item 1)

[Figure 30-40-39] from the pump housing.
Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-37] from the side cover.
Inspect the slide inserts for wear or damage.
Replace if needed.

Figure 30-40-40
P-18616
1 Remove the swash plate bearing races (Item 1) [Figure

P-18611 30-40-42] from the housing.
Figure 30-40-43
Remove the four slipper guide bearing retainer bolts
(Item 1) [Figure 30-40-40].

Figure 30-40-41
1
P-18617
Remove the bronze slider block (Item 1) [Figure 30-40-

P-18615 43] from the servo piston.
Mark the position of the servo end covers.

Remove the swash plate bearings (Item 1) [Figure 30-
40-41] from the housing.

Figure 30-40-44
1
P-18620
Measure and record the adjustment setting for

P-18777 approximate installation adjustment [Figure 30-40-46].
Figure 30-40-47
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-

40-44].
3 2
Figure 30-40-45
1
P-18622
Remove the servo piston (Item 1) from the housing (Item

2) [Figure 30-40-47].
P-18778
Remove and discard the O-ring (Item 3)
[Figure 30-40-47].
Remove the three screws (Item 1) [Figure 30-40-45] and
remove the servo adjustment cover.

Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of 1 1
material can get into the system and cause damage.
Figure 30-40-48
1 2
P-18628
Inspect the servo piston and seal rings (Item 1) [Figure

30-40-50] for wear. If worn, remove the seal rings and
expander O-rings from the piston.
Install new expander O-rings into the grooves in the

P-18769 servo piston. Carefully install the piston seal rings over

the expander rings. Do not overstretch the piston seal
rings.
Check the wear plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-48] for damage or wear. Figure 30-40-51
Figure 30-40-49
1
P-18622
P-18770
Lubricate the seal rings and carefully slide the servo
piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
Check the valve plate [Figure 30-40-49], the surface 51]. Allow the assembly to set for 5 minutes to allow the
must be smooth and free of scratches. If scratches can seal rings to return to their original size.
be felt with a finger nail, replace the part.

Inspection (Cont'd)
Figure 30-40-52
1
P-18739
Servo arm (Item 1) [Figure 30-40-54] alignment is critical

P-18736 for proper pump operation. For this reason, removal of
the servo arm from the swash plate is not recommended.
Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-52]. Remove the swash plate guide bolt (Item 2) and the

servo arm mounting bolt (Item 3) [Figure 30-40-54].
Figure 30-40-53
Installation: The servo arm (Item 1) [Figure 30-40-54]
must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.
Tighten the swash plate guide bolt and servo arm bolt to
Figure 30-40-55
1
P-18737
Inspect the swash plate guide (Item 1) [Figure 30-40-53]

for wear. Replace as needed.
Installation: Tighten the bolt to 32 N•m (24 ft-lb) torque.
P-18738
The threaded holes [Figure 30-40-55] in the swash plate

must be cleaned prior to assembly.

Inspection (Cont'd)
Figure 30-40-56
P-18773
1 Check the swash plate bearings [Figure 30-40-58] for

P-18739 wear and damage. Replace as needed.
Figure 30-40-59
Figure 30-40-57

2 1
P-18771
EM9353
Check each piston (Item 1) and piston shoe (Item 2)

If the headed roll pin and flat washer (Item 1) [Figure 30- [Figure 30-40-59] for wear or scratches.
40-56] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be 5,33 mm (0.21 in) [Figure 30-40-57].

Inspection (Cont'd)
Figure 30-40-60
1
P-18568
Inspect the shaft seal (Item 1) [Figure 30-40-62].

P-18772 Replace if needed.

Check the cylinder block bores for wear or scratches 62].
[Figure 30-40-60].

Figure 30-40-63
If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
Figure 30-40-61
P-18741
Inspect the multi-function valve cartridge for damage to

P-18712 parts or O-rings.
Replace O-rings as needed [Figure 30-40-63].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-61].
Check the bearing for correct operation. Remove the race

(Item 1) [Figure 30-40-61] from the shaft only if it is
necessary to replace the bearing.

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-18755
Clean and lightly oil all parts prior to assembly.

Lubricate the slipper running surface on the swash plate,
Figure 30-40-64 centre the piston and guide on the swash plate [Figure
30-40-65].
Figure 30-40-66

1
2
1
P-18754 1
3 2
Put the piston assemblies into the slipper guide [Figure 1 P-18611
30-40-64].
Apply LOCTITE #242 to four NEW retainer bolts (Item 1).

Install the slipper guide bearings (Item 2) and spacers
(Item 3) and bolts (Item 1) [Figure 30-40-66].
Tighten the four bolts to 13,5 N•m (10 ft-lb) torque.
NOTE: Always use NEW retainer bolts with proper

locking compound.
NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.

Assembly (Cont'd)
Figure 30-40-67
P-18615
Assemble and lubricate the bearing cage (Item 1)

P-18756 [Figure 30-40-69], and install it on the bearing races.
Lubricate the pistons and cylinder block bores. Install the

assembled swash plate and pistons into the cylinder Figure 30-40-70

block [Figure 30-40-67].
NOTE: The pistons and bores are not selectively

fitted.
1
Figure 30-40-68
P-18757
1
Install the bronze slider block (Item 1) [Figure 30-40-70]
on the swash plate servo arm.
P-18616
Install the swash plate bearing races (Item 1) [Figure 30-

40-68] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

Assembly (Cont'd)
Figure 30-40-71
P-18760
Lower the cylinder block and swash plate assembly until

P-18758 the swash plate is properly located on the bearings
[Figure 30-40-73].
Carefully lower the cylinder block and swash plate Figure 30-40-74
assembly into the housing [Figure 30-40-71].

Figure 30-40-72
1
1
P-18595
P-18759 Install new O-rings (Item 1) [Figure 30-40-74] on the

servo end cap.
Holding the cylinder block and swash plate assembly Lightly lubricate the O-rings and the inner surface of the
approximately 12 mm (0.5 in) above the bearings. end cap.
Position the servo piston (Item 1) on the bronze slider
block (Item 2) [Figure 30-40-72]. Take care not to wedge
the block, the parts should slide freely.

Assembly (Cont'd)
Figure 30-40-75
P-18762
Install the servo adjustment cover over the servo piston

P-18594 until the piston adjustment screw touches the cover.
Using a hex wrench, turn the adjustment screw
anticlockwise while holding the cover until it is in position
Hold the servo piston in position and install the servo end [Figure 30-40-77].
cap [Figure 30-40-75].

NOTE: Do not install the bolts at this time.
Figure 30-40-76
Figure 30-40-78
1
1
P-18761
P-18764
Install the three end cap mounting bolts (Item 1) [Figure

30-40-76]. Tighten to 13,5 N•m (10 ft-lb) torque. Push the swash plate assembly toward the servo piston
until the swash plate guide contacts the bearing races.
Lightly lubricate the O-rings and inner surface of the Check for clearance between the servo arm and the
adjustment cover. slider block [Figure 30-40-78]. If no clearance is present,
recheck the assembly of the bearing cage and races.

Assembly (Cont'd)
Figure 30-40-79
P-18742
2
1 Lift the swash plate leveler and install the side cover
P-18765 [Figure 30-40-81].
Figure 30-40-82
Position the two side cover inserts (Item 1) and swash
plate leveler (Item 2) on the side cover. Note the

orientation of the leveler and the notch (Item 3) [Figure
30-40-79] in the cover.
Figure 30-40-80
1 1 3
1 P-18743
Install the two side cover bolts (Item 1) [Figure 30-40-82]

2 finger tight.
P-18598 Apply a force of 22 - 44 N•m (5 - 10 ft-lb) to the swash

plate leveler to make sure both lever arms contact the
swash plate.
Install the two guide post bolts (Item 1) [Figure 30-40-80]
through the leveler and inserts. Install the sealing nuts Make sure the swash plate assembly is seated correctly
and tighten to 23 N•m (17 ft-lb) torque. on the bearings.

cover.

Assembly (Cont'd)
Figure 30-40-83
1 1
P-18743
After the zero angle position has been established,

P-18744 tighten the two side cover bolts (Item 1)
[Figure 30-40-85].
Use a depth micrometer to measure the distance from Figure 30-40-86

the end cap to the swash plate surface. Take a second

measurement at a point 90° (Item 1) [Figure 30-40-83]
from the first point of measurement. These
measurements must not vary more than 0,025 mm
(0.001 in). 1 1
Figure 30-40-84
2 2
P-18596
Install the four remaining side cover bolts, apply

LOCTITE #242 to the threads of the "thru" bolts (Item 1)
[Figure 30-40-86].
P-18745 First tighten the four side cover bolts (Item 2) to 32,5 N•m
(24 ft-lb) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-86] to 25 N•m (18.5 ft-lb)
Rotate the side cover [Figure 30-40-84] (which will also torque.
rotate the leveler and swash plate) until the zero angle
position is established, as determined by a second depth
measurement.

Assembly (Cont'd)
Figure 30-40-87
2
1
P-18748
Use a depth micrometer to measure the distance from

P-18746 the end cap to the swash plate surface [Figure 30-40-
89]. Take a second measurement at a point 180° from
the first point of measurement. These measurements
Install the three servo adjustment cover mounting screws must not vary more than 0,025 mm (0.001 in).
(Item 1) [Figure 30-40-87]. Tighten to 13,5 N•m (10 ft-lb)

torque. Figure 30-40-90
Figure 30-40-88
P-18749
P-18747
Without turning the servo adjustment screw, install the
sealed nut (Item 1) [Figure 30-40-90] and tighten.
Turn the adjustment screw on the servo, which will rotate
the swash plate assembly until a zero angle position is
established [Figure 30-40-88].

Assembly (Cont'd)
1
Figure 30-40-91
2
P-18588
Install both springs (Item 1) [Figure 30-40-93] on the

P-18590 leveler spring seats.
Lubricate the running surface of the cylinder (Item 2)

Install the spring (Item 1) [Figure 30-40-91] on the servo [Figure 30-40-93].
arm link.

Figure 30-40-94
Figure 30-40-92
1
2
1
P-18587
P-18589
Install the valve plate (Item 1) [Figure 30-40-94] on the

Install the spring seats (Item 1) [Figure 30-40-92] on the alignment pins.
leveler arms.
NOTE: Ensure the direction of the arrow cut outs
(Item 2) [Figure 30-40-94] in the valve plate are
positioned as shown.

Assembly (Cont'd)
Figure 30-40-95
1
1
P-18750
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-

P-18586 97] and install into the charge pump housing, in the
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.
Install a new gasket (Item 1) [Figure 30-40-95] on the
housing. Install a new O-ring (Item 2) [Figure 30-40-97].

Figure 30-40-96 Figure 30-40-98
1
2
1
1
P-18585 P-18751
Lubricate the end cap journal bearing (Item 1). Install the Lubricate both sides of the wear plate (Item 1) and install
hardened shims (Item 2) [Figure 30-40-96] in the charge in the charge pump. Align the wear plate with the
pump pockets for the swash plate leveler springs. Retain alignment pin (Item 2) [Figure 30-40-98].
the shims with assembly lube.
Turn the charge pump housing over.

Assembly (Cont'd)
Figure 30-40-99
1
P-18728
Install the coupler (Item 1) [Figure 30-40-101].

P-18731
Figure 30-40-102
Install the eccentric ring (Item 1) in the charge pump and

align with the alignment pin (Item 2) [Figure 30-40-99].

Figure 30-40-100 1
3 P-18727
Install the charge pump cover (Item 1)

[Figure 30-40-102].
P-18729
Rotate until pin hole in cover aligns with the pin.
Apply assembly lube and install the charge pump gears

(Item 1), charge pump shaft (Item 2) and key (Item 3)
[Figure 30-40-100] into the pump.

Assembly (Cont'd)
1
Figure 30-40-103
2 2
2 2 2
P-18724
1
Install the flange adapter (Item 1) and four bolts (Item 2)
P-18726 [Figure 30-40-105]. Tighten the bolts to 122 N•m (90 ft-
lb) torque.
Install the retaining plate cover (Item 1) and six bolts Figure 30-40-106
(Item 2) [Figure 30-40-103]. Tighten the bolts to 13,5

Figure 30-40-104
2
P-18723
Install the mounting bolt (Item 1) [Figure 30-40-106] and

S4702 tighten to 38 N•m (28 ft-lb) torque.
NOTE: Install the lifting bracket (Item 2)

Lower the charge pump onto the pump housing while [Figure 30-40-106].
positioning the three springs in their pockets [Figure 30-
40-104].
When properly installed, the charge pump will engage

the alignment pins, but the springs will hold the charge
pump housing 3 to 8 mm (0.1 to 0.3 in) away from the
pump housing.

Assembly (Cont'd)
Figure 30-40-107
1 1
P-18753
Lightly lubricate and install both multi-function valve

P-18722 assemblies (Item 1) [Figure 30-40-109] in the charge
pump. Tighten to 89 N•m (66 ft-lb) torque.
Install the spring and relief poppet into the charge pump
[Figure 30-40-107].

Figure 30-40-110
Figure 30-40-108
1
1
P-18570
P-18721
Install the bearing (Item 1), the spacer washer (Item 2)

Install the plug with lock nut (Item 1) [Figure 30-40-108], and the snap ring (Item 3) [Figure 30-40-110] on the
align the marks made at disassembly. Tighten the lock drive shaft.
nut to 52 N•m (38 ft-lb) torque.
Position the pump on the charge pump end.

Assembly (Cont'd)
Figure 30-40-111
2 2
P-18768
Install the retainer plate (Item 1) and three screws (Item

P-18766 2) [Figure 30-40-113]. Tighten the screws in a
sequenced pattern to 16 N•m (12 ft-lb) torque.
Install the shaft and bearing assembly, aligning the shaft Figure 30-40-114
spline with the cylinder block spline. Continue to lower

the shaft and align with the charge pump journal bearing
and charge pump coupler [Figure 30-40-111].
3
Figure 30-40-112 2 1
1,59 mm
(0.0625”) P-18550
Install the coupler gear (Item 1) on the shaft and install

the bolt (Item 2) [Figure 30-40-114].
P-18767
Install a new O-ring (Item 1) [Figure 30-40-112].
Lubricate the seal with assembly lube and install the seal
assembly on the drive shaft and in the housing [Figure
30-40-111].

HYDROSTATIC PUMP (CONT'D)
Assembly (Cont'd)
Figure 30-40-115
1.59 mm
(0.0625”)
B-15045
NOTE: When installing the coupler, maintain a 8,56

mm (0.337 in) gap from the pump mount

flange to the coupler [Figure 30-40-114] and
[Figure 30-40-115].
Remove the case plug (Item 3) [Figure 30-40-114] and

fill with clean hydraulic fluid prior to start up. Rotate the
pump shaft with a torque wrench to assure correct
assembly. The torque required to turn the shaft (after
"break away") should be within:
Minimum Maximum
5,4 N•m (4 ft-lb) 12,2 N•m (9 ft-lb)

DRIVE SYSTEM
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake System Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-18
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-24
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-27
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-36
Brake System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-41
Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-47

Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-49
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-56
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential And Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-15
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-18
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-26
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-31
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-38
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1


TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorised Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Machine intensively operated or overloaded
20. Wheel loose
21. Beam housing bent


AXLE AND DIFFERENTIAL (FRONT)
General Information
For photo clarity, the following axle procedures are done • Front Axle removal. (See Removal on Page 40-30-1.),
with the complete axle assembly removed from the Front steering cylinder removal. (See Removal And
machine, although the planetary carrier, wheel hub, Installation on Page 20-60-1.)
steering knuckle and drive axle procedures can be done
with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear

8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Snap ring
19. Stud
S2668

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) Figure 40-20-3
Planetary Carrier Disassembly
Figure 40-20-1 1
1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-20-3].
Figure 40-20-4
so that later when you pry the planet gear carrier loose, is
does not fall.

1
Figure 40-20-2
1 2
S2466
S2464A
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-20-2] by alternatively forcing a
screwdriver into the appropriate slots.

Planetary Carrier Disassembly (Cont’d)
Figure 40-20-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-20-7] by acting on the stud bolts.
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].

Figure 40-20-6 1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-20-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-20-6].
points.

Figure 40-20-9
1
1
1 1
S2473A
Remove the snap rings (Item 1) [Figure 40-20-11].

S2470A
Figure 40-20-12
Remove the external bearing (Item 1) [Figure 40-20-9].
Figure 40-20-10

1
S2474A
With the help of a puller, remove the planet wheel gears

S2471A
(Item 1) [Figure 40-20-12].
NOTE: Mark the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-20-
10] by hand.


1
Figure 40-20-13
1 S2477A
Remove the sealing ring Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-20-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-20-16
[Figure 40-20-13].
1
Figure 40-20-14

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-20-16].
Remove the ring gear support (Item 1) [Figure 40-20-

14].

AXLE AND DIFFERENTIAL (FRONT) (CONT’D)
Figure 40-20-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-20-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Joint
8. Thrust bushing
9. Thrust bushing
10. Plug
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
20. Plug

21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Articulation
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-20-18 1 2
1
3
S2429B
2
1
Using two levers, remove the top tie rod (Item 1)
complete with front sealing ring (Item 2) and shims
S2591
(Item 3) [Figure 40-20-20].
Figure 40-20-21
Loosen and remove the fitting bolts (Item 1) from the tie
rod (Item 2) [Figure 40-20-18].

Figure 40-20-19 2
1
3
2
UPPER TIE ROD BOTTOM TIE ROD

S1393
1 Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the bottom tie rod (Item 3) [Figure 40-20-
S2427
21].
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-20-
19].

Steering Knuckle Disassembly (Cont’d) 1
Figure 40-20-22
1 2
3
4
S1387
Use a puller to remove the centreing ring (Item 1), the

S2539 sealing ring (Item 2) and the bearing (Item 3) from the
steering case (Item 4) [Figure 40-20-23].
Remove the complete steering case (Item 1) [Figure 40-
20-22]. NOTE: Mark the orientation of both centreing and
sealing ring.

Drive Axle Disassembly
Figure 40-20-24
1
2
1 S1402
Remove the snap ring (Item 1) from the bushing unit

S2592 (Item 2) [Figure 40-20-26].
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24].
1

Figure 40-20-25
S1403
Position the entire drive axle (Item 1) under a press and

remove the complete bush (Item 2) [Figure 40-20-27].
S2593
Remove the entire drive axle (Item 1) [Figure 40-20-25].
NOTE: To remove the drive axle use, if necessary, a

plastic hammer or a lever.

Drive Axle Disassembly (Cont’d)
Figure 40-20-28
2
1
2 1
S1404
Use a puller to remove the bearing (Item 1), the sealing

S3567 ring (Item 2) [Figure 40-20-29] and the O-ring.
Remove the snap ring (Item 1) from the bearing (Item 2)

[Figure 40-20-28].

Brake System Parts Identification
1. Spacer
2. Spring
3. Piston
4. O-ring
5. O-ring
6. Back-up ring
7. Plug
8. Bleed fitting
9. Bolt
10. Seal washer
11. Cover
12. O-ring
13. Back-up ring

14. Piston
15. Intermediate brake
disc
16. Spring
17. Adjusting bolt
18. Adjusting bolt
19. Spring
20. Bolt
21. Nut
22. Lock washer
23. Shim
24. Spacer
25. Intermediate brake
disc
26. Brake disc
S2672

Brake System Disassembly 2
Figure 40-20-30
S2615
1
Remove the adjusting bolts (Item 1) from the

S2595 intermediate brake disc (Item 2) [Figure 40-20-32].
Figure 40-20-33
Sling the arms to be removed and connect it to a hoist.
Loosen and remove the bolts (Item 1) that fix the arm
(Item 2) to the central body (Item 3) [Figure 40-20-30].

Figure 40-20-31
2
1 1
S2616
Remove the pin bolts (Item 1) guiding the intermediate

2 brake disc (Item 2) [Figure 40-20-33].
S2596
If the bolts are to be replaced, mark down the
different colours for the different brake gaps.
Remove arm (Item 1) together with the pack of the
braking discs (Item 2) [Figure 40-20-31]. Place the arm
on a bench.

Brake System Disassembly (Cont’d)
Figure 40-20-34
S2620
1 Remove the cover (Item 1) [Figure 40-20-36].

S2617
Figure 40-20-37
Remove the intermediate brake disc (Item 1) [Figure 40-
20-34].

Figure 40-20-35
1
1
S2621
1
Remove the Belleville washers (Item 1) [Figure 40-20-
37] and note down direction of assembly.
S2618
Loose the four studs (Item 1) [Figure 40-20-35].

Figure 40-20-38
1 S2624
Slowly introduce low-pressure compressed air through

S2622 the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-40].
Slowly introduce low-pressure compressed air through Figure 40-20-41

the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-38].

Figure 40-20-39
S2625
Remove the braking discs (Item 1) [Figure 40-20-41],

S2623 noting down direction of assembly.
NOTE: If disks are not to be replaced, avoid changing

Mark down the order of assembly and remove negative their position
piston. Mark the position [Figure 40-20-39].

Figure 40-20-42
S2626
Remove the braking discs, noting down direction of

assembly (Item 1) [Figure 40-20-42].

NOTE: If disks are not to be replaced, avoid changing
their position.

Differential Parts Identification
1. Lock nut
2. Cylinder bolt
3. Taper roller bearing
4. Cylinder bolt
5. Bolt
6. Pin
7. Snap ring
8. Snap ring
9. Friction washer
10. Differential pinion
11. Ring and Pinion
Gear Set
12. Differential side
gear

13. Differential carrier
14. Limited slip discs
S2673

Differential Disassembly
Figure 40-20-43
T13
2
1
S1409
Apply tool T13 and remove the ring nuts [Figure 40-20-
S2597 45].
Figure 40-20-46
Mark the position of the ring nut (Item 1). Remove the
cylinder bolts (Item 2) [Figure 40-20-43] from the ring
nut. 1 2

Figure 40-20-44
S2600
Remove the fitting bolts (Item 1) from the middle cover

(Item 2) [Figure 40-20-46].
S2598
Uniformly heat the ring nuts (Item 1) [Figure 40-20-44]

up to a temperature of 80°C (176°F).

Differential Disassembly (Cont’d)
Figure 40-20-47
2 1
S2675

S2601
Figure 40-20-50
Insert a screwdriver in the opposing slots then force and

remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-20-47].

Figure 40-20-48
4
2
1
S2676
3 1
5 Remove the plug (Item 1) [Figure 40-20-50].
S1412
If the bearings need replacing, extract the bearing race

(Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-20-48].
NOTE: Check for damaged O-rings (Item 5) [Figure

40-20-48].


1
Figure 40-20-51
2
S1416
Remove the shim washer (Item 1) and the planetary gear

S1414 (Item 2) [Figure 40-20-53].
Figure 40-20-54
Remove the fitting bolts (Item 1) from the crown (Item 2)
[Figure 40-20-51].

Figure 40-20-52
1
1
2
S1417
If the bearing needs to be replaced, extract the bearing

S1415 (Item 1) from the differential carrier (Item 2) [Figure 40-
20-54].

(Item 1) and remove the crown (Item 2) [Figure 40-20-
52].

Differential Disassembly (Cont’d) 3

2
Figure 40-20-55
3
1
2
1
S1421
2
Place the differential carrier (Item 1) under a press,

S1418 position a bushing (Item 2) and insert a pin (Item 3)
[Figure 40-20-57]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-20-56].
Remove the snap rings (Item 1) from the four pins
(Item 2) [Figure 40-20-55] of the planet wheel gears. Figure 40-20-58

Figure 40-20-56
T
2 1 2
1
S1422
S1419
Remove pinion and bush [Figure 40-20-58].
Insert a tool T between two planet wheel gears (Item 1) NOTE: In this condition the tool contains the pin.
[Figure 40-20-56].
NOTE: Make sure that the tool is perfectly lined up

with the pins (Item 2) [Figure 40-20-56] when
locked.


1
Figure 40-20-59
2
S1425
Remove the tool T and remove the planet wheel gears

S1423 (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-61].
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-59].

Figure 40-20-60
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

40-20-60] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

2nd planet wheel gear (Item 2) [Figure 40-20-60].
Repeat the operations for the two remaining pins.

Bevel Pinion Parts Identification
1. Cover
2. Gear
3. Snap ring
4. Ball bearing
5. Snap ring
6. Ring and Pinion
Gear Set
8. Shim
9. Shim
10. Spacer
11. Lock nut
12. Seal

13. Ball bearing
14. Gear
15. Snap ring
16. Ball bearing
17. Seal
18. Plug
19. Spring washer
20. Hexagon bolt
21. Magnet plug
22. Dowel
23. Plug
24. Flange
25. O-ring
26. Cylinder bolt
S1568

Bevel Pinion Disassembly
Figure 40-20-62
S2605
Place two levers into the appropriate slots [Figure 40-20-

S2603 64].
NOTE: Look out not to damage the surfaces.

Remove cylinder bolts (Item 1) [Figure 40-20-62] of the
drive side flange cover. Figure 40-20-65

Figure 40-20-63
S2606
2604
Lift off the cover (Item 1) [Figure 40-20-65].
Make the drive side flange cover loose using a plastic

hammer [Figure 40-20-63].

Bevel Pinion Disassembly (Cont’d)
Figure 40-20-66
1 1
S2733
Extract the pinion (Item 1) [Figure 40-20-68] complete

S2607 with the internal bearing, the distance piece and shims.
NOTE: The bearing races of the bearings remain in

Remove the sealing ring (Item 1) [Figure 40-20-66]. the central body (Item 2) [Figure 40-20-68].
Figure 40-20-67 Figure 40-20-69

T20
S2602 S2473
Position tool T20A (or T20B), so as to avoid pinion Remove the pinion, shims and distance piece [Figure
rotation. Loosen and remove the nut. Also remove the O- 40-20-69].
ring [Figure 40-20-67].

Figure 40-20-70
1 1
S2575
Insert a drift in the appropriate holes and remove the

S1565 bearing race (Item 1) as well as the shim
washers (Item 2) [Figure 40-20-72].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-20-70].

Figure 40-20-71
S2574
Remove the bearing race (Item 1) [Figure 40-20-71].

Bevel Pinion Assembly
Figure 40-20-73
T25C
DG
T24 1
T25A
S2576
Partially insert the bearing race (Item 1) [Figure 40-20-

S1569 75].
Figure 40-20-76
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.189 in]) [Figure 40-20-

73].
T25B T24 T25C T25A
Preset the indicator to approx. 2 mm (0.078 in).
Figure 40-20-74
2 S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race (Item 1) [Figure 40-
20-76].
S1570
Bring the internal bearing (Item 1), complete with its

bearing race, under the indicator (Item 2) [Figure 40-20-
74].
Determine overall thickness “D” of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the centre and take

several measurements while rotating the
bearing race.

Bevel Pinion Assembly (Cont’d)
Figure 40-20-77 1
GB
GB
S1575
1
Fit a depth gauge with long stem into a perfectly flat bar
S2577 (Item 1) [Figure 40-20-79]; when the bar rests on two
gauge blocks “GB” of 57 mm (2,24 in), reset the indicator.
Connect the tension rod to the press and move the Preset the indicator to approx.2 mm (0.078 in) and reset.
bearing race (Item 1) [Figure 40-20-77] into its seat.
Disconnect the press and remove the tension rod. Figure 40-20-80

NOTE: Before starting the next stage, make sure that
the bearing race has been completely inserted
into its seat.
Figure 40-20-78
T26 (2)
1
T26 (2) T26 (1)
T24
1
S2579
Lay the bar (Item 1) [Figure 40-20-80] on tool T26 and

take the size “A” at about 57 mm (2,24 in) corresponding
to the maximum diameter of arms centring.
S2578
See [Figure 40-20-81] for a sectional view.

Assemble the different parts of tool T26 complete with
external bearing (Item 1) [Figure 40-20-78],
measurement ring T24.
Tighten manually.

Figure 40-20-81
T24 T26 (2)
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
under the bearing race [Figure 40-20-83].
Calculate size “B” which will be the first useful value for Figure 40-20-84
calculating the size of the shims that are to be inserted
1

Figure 40-20-82
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-20-
84] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-20-82] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-20-85
T26 (2)
1 2 T26 (1)
S2582
2 Position tool T26 complete with tapered bearings

S2580 (Items 1 and 2) [Figure 40-20-87]; manually tighten until
a rolling torque has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-20-88
internal bearing (Item 2) [Figure 40-20-85] in the central
body.

1
Figure 40-20-86
S2583
T25C
Insert the stem of a depth gauge (Item 1) [Figure 40-20-
S2581 88] in either side hole of tool T26(1); reset the indicator
with a presetting of approx. 3 mm (0.118 in).
Connect the tension rod to the press, fasten the bearing

race and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.


1 S1
Figure 40-20-89
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0.12-

S1585 0,13 mm [0.0047 - 0.0051 in], so as to obtain the size of
shim “S1” (Item 1) [Figure 40-20-91] which will be
inserted between the external bearing (Item 1) [Figure
Remove the indicator and release tools and bearings 40-20-90] and the distance piece (Item 1) [Figure 40-
from the central body. 20-89] and subsequently, to determine the preload for the
bearings.

Re-install all and insert the distance piece (Item 1)
between both bearings (Items 2 and 3) [Figure 40-20- Figure 40-20-92
89]; manually tighten the whole pack.
Figure 40-20-90
H
DDG
T26 (2)
2
1
1
T26 (1)
S1588
S1586 Position the internal bearing (Item 1) and the pinion

(Item 2) [Figure 40-20-92] under a press. Force the
bearing onto the pinion.
Insert depth gauge into tool T26 and measure variation
“H” in relation to the zero setting performed in [Figure 40-
20-90].

Figure 40-20-93
1
4 1 3
S2585
Connect the pinion (Item 1) [Figure 40-20-95] to the tie

S2584 rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Fit the pinion (Item 1), shim “S1” (Item 2) and the Figure 40-20-96
distance piece (Item 3) in the main body
(Item 4) [Figure 40-20-93].

NOTE: If multiple shims are used, always position the
thinner shims in between the thicker shims. 1
Figure 40-20-94
1
S1592
Apply Loctite® #242 to the thread of the ring nut

(Item 1) [Figure 40-20-96] and screw the nut onto the
pinion.
S1590
Insert the external bearing (Item 1) [Figure 40-20-94] in

the central body in order to complete the pack arranged
as in the figure.

Figure 40-20-97
T19
T21
S2609
T22
The rolling torque of the pinion shaft must be checked.

S2608 Using a dial indicator torque wrench, measure the rolling
torque. The correct torque is 1,20 - 1,70 N•m (0.88 - 1.25
ft-lb) [Figure 40-20-98].
Apply special wrench T22 to the ring nut and bar-hold
T21 to the pinion [Figure 40-20-97]. NOTE: If torque exceeds the maximum value, then
the size of shim “S1” between the bearing and

Lock the wrench T22 and tighten the pinion to minimum the distance piece needs to be increased.
NOTE: If torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
570 N•m (420 ft-lb) (see the step under [Figure
40-20-97]).
NOTE: If torque does not reach the minimum value,

then the size of shim “S1” needs to be
reduced.
NOTE:When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0.01 mm (0.00039 in) corresponds
to a variation of 60 N•m (0.44 ft-lb) in the
torque of the pinion.

Figure 40-20-99
S2461
T27
2
Tighten the bolts (Item 1) [Figure 40-20-101] of the drive
S2610 side flange cover.
Lubricate the outer surface of the new sealing ring

(Item 1) and fit it onto the central body (Item 2) [Figure
40-20-99] using tool T27.

NOTE: Check that it is properly oriented.
Figure 40-20-100
S2606
Install the drive side flange cover (Item 1) [Figure 40-20-

100].


2
Figure 40-20-102
1
2
S1534
With the help of a bar, position the second planet wheel

S1532 gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-20-104].
Insert the thrust washer (Item 1) and the planetary gear Figure 40-20-105
(Item 2) in the differential carrier (Item 3) [Figure 40-20-
102].

Figure 40-20-103
1
1
3
S1535
Insert a tool between the two planetary gears and line up

S1533 the entire unit by pushing the bar (Item 1) [Figure 40-20-
105] all the way down until it is ejected.
Position the thrust washer (Item 1) and the first planet

wheel gear (Item 2). Temporarily hold them in position
using a bar (Item 3) [Figure 40-20-103].

Differential Assembly 2
1
Figure 40-20-106
2
1
1
S1538
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-20-108].
Lock tool (Item 2) behind the planet wheel gears Figure 40-20-109
(Item 1) [Figure 40-20-106].

Figure 40-20-107
2
1
S1539
S1537 Put a tool pin on top of the planet wheel pin

(Item 1) [Figure 40-20-109].
Fit the snap rings (Item 1) onto the pins (Item 2) [Figure
40-20-107].

Differential Assembly (Cont’d)
Figure 40-20-110
1
1
S1542
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-20-112].
Figure 40-20-113
Press the pin all the way down (Item 1) [Figure 40-20-
110]

Figure 40-20-111 1
2
S1543
Position the thrust washer (Item 1) on the crown

S1541 (Item 2) [Figure 40-20-113].
NOTE: In order to hold the shim washer in position,

Remove the tool pin, bushing and fit the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-20-111].
NOTE: Make sure that the snap ring centres the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-20-114
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races in the middle cover (Item 1) [Figure 40-20-116]
and in the central body.
Position the crown (Item 1) on the differential carrier Figure 40-20-117

(Item 2) and lock the bolts (Item 3) [Figure 40-20-114]
with Loctite® #242.
3

Tighten the bolts to 128 - 142 N•m (95 - 105 ft-lb) torque. 1
2
NOTE: Secure the bolts using the cross tightening
method.
Figure 40-20-115
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and fit the middle cover
(Item 2) [Figure 40-20-117].
NOTE: Thoroughly check the state of the O-ring

(Item 3) [Figure 40-20-117] and make sure
S1545 that the cover is fitted with the hole (see arrow
on [Figure 40-20-117]) in the lower position.
Install the bearing races (Items 1 and 2) [Figure 40-20-

115] using tool T17.

Figure 40-20-118
T19
S1550
Pre-set the bearings by means of the ring nut situated on

S2613 the opposite side of the crown, so as to increase pinion
torque up to 1,40 - 2,10 N•m (1.0 - 1.55 ft-lb) [Figure 40-
20-120].
Lock the middle cover (Item 1) with bolts
(Item 2) [Figure 40-20-118]. NOTE: If bearings are not new, check the static
torque. If bearings are new, check the

continuous torque.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.5 ft-lb)
torque. Figure 40-20-121
Figure 40-20-119
A
2
T13
S2667
S2614
Introduce a dial indicator with rotary key “A” through the
plug hole (Item 1). Position the indicator on the centre of
NOTE: If the ring nuts [Figure 40-20-119] are one of the teeth of the crown (Item 2) [Figure 40-20-
removed, apply some Loctite® #242 to them. 121] and pre-set it to 1 mm (0.039 in) and reset it.
Tighten ring nuts on the crown side until
clearance between pinion and crown is zero,
then lock the crown. Go back 90° - 180° .

Figure 40-20-122
1
A
1
S2682
Apply Loctite® #242 to the bolts (Item 1) [Figure 40-20-

S2667 124], fit them into one of the two holes and tighten.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)

Manually move the crown (Item 1) [Figure 40-20-122] in torque.
both directions in order to check the existing backlash
between the pinion and the crown. Fit the plug in the hole (Item 1) [Figure 40-20-121 on

Page 39] after applying flexible gasket compound for
Figure 40-20-123 seals to the rims.
T13
S2614
Adjust the backlash between the pinion and the crown by

unloosing one of the ring nuts [Figure 40-20-123] and
tightening the opposite to compensate.
Normal backlash: see table
CLEARANCE
RATIO
MIN. MAX.
14 – 32 0.18 mm 0.23 mm
(0.007 in) (0.009 in)
NOTE: Difference between MIN and MAX clearance

for whole circumference should not exceed
0,09 mm (0.0035 in).

Brake System Assembly
Figure 40-20-125

Y = Brake gap
Y = 0,75 mm (0.029 in)
S40033

Brake System Assembly (Cont’d)
Figure 40-20-126
1
S2629
Fit O-rings (Item 1) [Figure 40-20-128] onto the piston.

S2627 Lubricate the piston and the O-rings and install the unit
into the cylinder.
Fit O-rings (Item 1) [Figure 40-20-126] onto the piston. Figure 40-20-129
Lubricate the piston and the O-rings and install the unit
into the cylinder.

Figure 40-20-127
2
1
1 S2631
Using a plastic hammer, tap the piston (Item 1) into the

S2628 cylinder (Item 2) [Figure 40-20-129].
NOTE: Lightly hammer all around the edge in an

Using a plastic hammer, tap the piston (Item 1) into the alternate sequence.
cylinder (Item 2) [Figure 40-20-127].
NOTE: Lightly hammer all around the edge in an

alternate sequence.

Figure 40-20-130
S2634
1
Install the O-ring (Item 1) [Figure 40-20-132].
S2632
Figure 40-20-133
Clean and grease the surface, position one Belleville

washer (Item 1) [Figure 40-20-130] with the concave
side onto the cylinder. See [Figure 40-20-125 on Page

41] for a sectional view.
Figure 40-20-131
S2620
1
Engage the cylinder while holding the Belleville washers
into their position (Item 1) [Figure 40-20-133].
NOTE: Check the relative centring of the washers.

S2633
Position the second Belleville washer (Item 1) [Figure

40-20-131] with the concave side onto the other cylinder.
See [Figure 40-20-125 on Page 41] for a sectional view.

Figure 40-20-134
1
1
1
S2636
Insert the stroke automatic regulation springs (Item 1)

S2619 [Figure 40-20-136], place them in line with the piston.
Figure 40-20-137
Tighten the studs (Item 1) [Figure 40-20-134] to 30 - 45

Figure 40-20-135
1
S2612
1
Insert the intermediate disk (Item 1) [Figure 40-20-137].
S2635
Connect an external pump to the negative brake (Item 1)

[Figure 40-20-135] and introduce pressure to 1,5 - 3
MPa (15 - 30 bar) (217 - 435 psi). Always use Bobcat
hydraulic fluid.

Figure 40-20-138
S2638 / S2639
2 3
Take measure from the surface of the intermediate disk
S2637 to the cover sealing surface with 3 MPa (30 bar) (435 psi)
of pressure introduced. (example: 25,4 mm (1 in) [Figure
40-20-140].
Install the six springs (Item 1) and the bolts (Item 2) into
the piston (Item 3) [Figure 40-20-138]. Figure 40-20-141

Figure 40-20-139
S2640
S2615
Put the brake disc pack including the shim under a press,
load with 100 kg (220 lb) and take the measure “V”.
Fit the pin bolts making sure that they are all of the same (example: 40 mm (1.5 in) [Figure 40-20-141].
colour [Figure 40-20-139].
Apply Loctite® #270 to the thread.
Tighten the bolts to 5 - 7 N•m (3.7 - 5.2 ft-lb) torque.

Figure 40-20-142
S2596
Check integrity and position of the arms’ O-ring (Item 1)

S2642 [Figure 40-20-144], install the complete arm.
NOTE: To assist axle shaft centring, slightly move

S = 68 mm (2.6 in) - (x + y + v) = Thickness of shims to the wheel hub.
insert under the shim washer.
Figure 40-20-145

See [Figure 40-20-125 on Page 41] for a sectional view
showing these dimensions.
Figure 40-20-143
1
3
1
1 4
2
S2645
Install the four washer (Item 1) and nuts (Item 2), tighten
S2643 nuts to 200N•m (150 ft-lb) torque. Install the twelve
washer (Item 3) and bolts (Item 4) [Figure 40-20-145],
tighten the bolts to 283 N•m (209 ft-lb).
Slightly lubricate the braking disks with Bobcat hydraulic
fluid and fit them in the arm following the correct NOTE: Tighten using the criss-cross method.
sequence. Orient them so that the oil circulation holes
and the holes (Item 1) [Figure 40-20-143] are perfectly
lined up.

Drive Axle Assembly
Figure 40-20-146
1
T5 T6
1 2 S1399
3
3 Heat the bush in oil at an approx. temperature of 100°C
S1397 (212°F) and fit the entire bush (Item 1) on the drive axle
(Item 2) [Figure 40-20-148].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-149
and the bearing (Item 2) in the bush (Item 3) [Figure 40-
20-146].

NOTE: Carefully check the assembly side of the
sealing ring. 3
Figure 40-20-147
2
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-149].
S1398
Fit the snap ring (Item 1) on the bearing (Item 2) [Figure

40-20-147].

Drive Axle Assembly (Cont’d)

1
Figure 40-20-150 2 1
2
S1507
Screw the check nuts (Item 1) of the dowels

S2592 (Item 2) [Figure 40-20-151] and lock them using a
torque wrench: 122 N•m (90 ft-lb).
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-150]. Tighten to max.

NOTE: Centre the point of the check dowels in the
slot.

Steering Knuckle Assembly
Figure 40-20-152
T7
1
1
S1496
Lubricate the terminal of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-20-154].
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-20-152], using tool T7. Figure 40-20-155

Figure 40-20-153
2
1 2
1
T8
S40021
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper pin (Item 2) [Figure
Lubricate the outer surface of the sealing ring (Item 1) 40-20-155].
and centreing ring (Item 2) [Figure 40-20-153]. Fit them
into their seat using tool T8.

Steering Knuckle Assembly (Cont’d)
Figure 40-20-156
1
3
3
2
2 1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S40022 orientated as shown in the inset. Lubricate the pivot pin
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)
and the six bolts (Item 2) [Figure 40-20-158]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
orientated as shown in the inset. Lubricate the pivot pin torque.
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)

and the six bolts (Item 2) [Figure 40-20-156]. (Bolts not Figure 40-20-159
shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
torque.
Figure 40-20-157
S40023
Tighten the fitting bolts (Item 1) [Figure 40-20-159] of

S1499 the bottom tie rod in sequence using the cross tightening
method, to 140 N•m (103 ft-lb) torque.
Lubricate the group with grease and mount it in the


Figure 40-20-160
S40024
Check the torque of the pins, which has to be 30 -

S2568 60 N•m (22 - 44 ft-lb). If the preliminary measured value
is too high, the shims have to be increased [Figure 40-
20-161].
Install a magnetic based dial indicator on the steering
housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-20-
160].

Planetary Carrier Assembly
Figure 40-20-162
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-164] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-165
of the external bearing (Item 1) [Figure 40-20-162]
under the press.

Figure 40-20-163
2
1
S2587
T9A Fit the bearing (Item 1) [Figure 40-20-165] into the

S2586 bearing race.
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-20-163] (wide side up).
NOTE: Check that the bearing race is correctly

oriented.

Planetary Carrier Assembly (Cont’d)
Figure 40-20-166
1
T10
3
S1456
1
Insert the snap ring (Item 1) in order to fix the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-20-168].
NOTE: Make sure the snap ring is firmly seated in the

Position tool T10 and press the sealing ring groove.
(Item 1) [Figure 40-20-166] into its seat.
Figure 40-20-169

Figure 40-20-167
DOWN
T11
1
1
2 2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-20-169].
40-20-167].
Accurately check the orientation.

Figure 40-20-170
S2470A
Install the external bearing (Item 1) [Figure 40-20-172].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-20-170]. edge.
Figure 40-20-171 Figure 40-20-173

1 1
S2471A S2646
Install the hub (Item 1) [Figure 40-20-171]. Fit the complete crown flange (Item 1) [Figure 40-20-
173].
NOTE: In order to fasten the flange, use a plastic

hammer and alternatively hammer on several
equidistant points.

Figure 40-20-174 2
3
1
2
1
S2465A
Fit the planetary carrier cover (Item 1) onto the hub

S2467 (Item 2) [Figure 40-20-176].
NOTE: Check that the O-ring (Item 3) [Figure 40-20-

Apply silicone-based grease to the surface of the flange 176] is in good condition and in position.
(Item 1) which touches the crown flange (Item 2) [Figure
40-20-174]. Figure 40-20-177

Fit the flange (Item 1) [Figure 40-20-174].
Figure 40-20-175 1
2 2
S2648
Lock the planetary carrier cover (Item 1) by tightening the

S2647 bolts (Item 2) [Figure 40-20-177]. Tighten the bolts to 40
- 50 N•m (30 - 37 ft-lb) torque.
Apply silicone based grease to the surface of the flange

(Item 1) which touches the crown flange (Item 2) [Figure
40-20-175].
Cross tighten the nuts (Item 1) [Figure 40-20-175] in two

stages.
Initial torque: 120 N•m (89 ft-lb)

Final torque: 255 - 285 N•m (188 - 210 ft-lb)

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
DIFFERENTIAL BEARING

6912196 T17
INNER RINGS
T19
6912197 PINION RING NUT T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

AXLE AND DIFFERENTIAL (REAR)
General Information
For photo clarity, the following axle procedures are done with the axle assembly installed in the machine. For
with the complete axle assembly removed from the complete axle repair, the following must be done.
machine, although the planetary carrier, wheel hub, • Rear Axle removal. (See Removal And Installation on
steering knuckle and drive axle procedures can be done Page 40-90-1.)
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear

8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Snap ring
19. Stud
S2668

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Figure 40-21-1
1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-21-3].
Figure 40-21-4
so that later when you pry the planet gear carrier loose, is
does not fall.

Figure 40-21-2 1
2
1
S2466
S2464A
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-21-2] by alternatively forcing a
screwdriver into the appropriate slots.

Figure 40-21-5 1
1 2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B
[Figure 40-21-7] by acting on the stud bolts.
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].
Figure 40-21-6 1

1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-21-8]

S2467
using a plastic hammer.
Remove the locking plate (Item 1) [Figure 40-21-6] NOTE: Alternately hammer on several equidistant
points.

Figure 40-21-9
1
1
1
1
1
S2473A
Remove the snap rings (Item 1) [Figure 40-21-11].

S2470A
Figure 40-21-12
Remove the external bearing (Item 1) [Figure 40-21-9].
Figure 40-21-10

1
S2474A
With the help of a puller, remove the planet wheel gears

S2471A (Item 1) [Figure 40-21-12].
NOTE: Note the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-21-
10] by hand.

Figure 40-21-13 1
1 S2477A
Remove the sealing ring (Item 1) from the wheel hub

S2475
(Item 2) [Figure 40-21-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-21-16
[Figure 40-21-13].
Figure 40-21-14
1

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-21-16].
Remove the ring gear support (Item 1) [Figure 40-21-

14].

AXLE AND DIFFERENTIAL (REAR) (CONT’D)
Figure 40-21-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-21-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Joint
8. Thrust bushing
9. Thrust bushing
10. Plug
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
20. Plug

21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Articulation
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-21-18
2
1
1
3
2
2 S2429B
1
Using two levers, remove the top tie rod (Item 1)
complete with front seal (Item 2) and shims (Item 3)
S2591
[Figure 40-21-20].
Figure 40-21-21
Loosen and remove the fitting bolts (Item 1) from the tie
rod (Item 2) [Figure 40-21-18].
Figure 40-21-19

2
1
3
2
UPPER TIE ROD BOTTOM TIE ROD

S1393
Configuration of the upper (Item 1) tie rod with shims

1
(Item 2) and the lower tie rod (Item 3) [Figure 40-21-21].
S2427A
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-21-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-21-22
1 1
S2540
Remove the entire drive axle (Item 1) [Figure 40-21-24].

S2539
NOTE: To remove the drive axle use, if necessary, a

Remove the complete steering case (Item 1) [Figure 40- plastic hammer or a lever.
21-22].
Figure 40-21-23

1
3
1 2 3
4
S1387
Use a puller to remove the centring ring (Item 1), the

sealing ring (Item 2) and the bearing (Item 3) from the
NOTE: Mark the orientation of both centring and

sealing ring.

Differential And Bevel Pinion Parts Identification

1. Cylinder bolt
2. Shim
3. Taper roller bearing 10. Differential pinion
4. Bolt 11. Washer
5. Bevel gear set 12. Differential side
6. Circlip gear
7. Friction washer 13. Differential carrier
8. Snap ring 14. Differential
9. Pin 15. Taper roller bearing

16. Shim
18. Shim
19. Shim
20. Spacer
21. Ring nut
22. Seal
23. Gear assembly
24. Flange
25. O-ring
26. Pinion
S2670

Differential Disassembly
Figure 40-21-25
S2543
Pull out the differential (Item 1) [Figure 40-21-27].

S2541
Figure 40-21-28
Loose the nuts (Item 1) [Figure 40-21-25].
Figure 40-21-26

1
S2544
1 Remove the snap ring (Item 1) [Figure 40-21-28].

S2542
Remove the complete arm (Item 1) [Figure 40-21-26].

Figure 40-21-29
1
1
S1415

S2545
(Item 1) and remove the crown (Item 2) [Figure 40-21-
31].
Remove the top plug (Item 1) [Figure 40-21-29]. Figure 40-21-32
Figure 40-21-30

1
2
1
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-21-32].
Remove the fitting bolts (Item 1) from the crown (Item 2)
[Figure 40-21-30].

Figure 40-21-33 T
2 1 1 2
2
S1419
Insert a tool T between two planet wheel gears (Item 1)

S1417
[Figure 40-21-35].
NOTE: Make sure that the tool is perfectly lined up

If the bearing needs to be replaced, extract the bearing with the pins (Item 2) [Figure 40-21-35] when
(Item 1) from the differential carrier (Item 2) [Figure 40- locked.
21-33].

Figure 40-21-36
Figure 40-21-34
3
2
3
1
2
1
2
S1421
S1418
Place the differential carrier (Item 1) under a press,

Remove the snap rings (Item 1) from the four pins position a bushing (Item 2) and insert a pin (Item 3)
(Item 2) [Figure 40-21-34] of the planet wheel gears. [Figure 40-21-36]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-21-36].

Figure 40-21-37
1
2
S1424
Leave the released planet wheel gear (Item 1)

S1422
[Figure 40-21-39] in position and again lock the tool.
Remove the pin and bushing [Figure 40-21-37]. Repeat the operations for the extraction of the pin of the
2nd planet wheel gear (Item 2) [Figure 40-21-39].
NOTE: In this condition the tool contains the pin.

Repeat the operations for the two remaining pins.
Figure 40-21-38
Figure 40-21-40
S1423
S1425
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-21-38]. Remove the tool T and remove the planet wheel gears
(Item 1) and the relative shim washers (Item 2) from the

Bevel Pinion Disassembly
Figure 40-21-41
1
1
S2547
2
Remove the flange (Item 1) [Figure 40-21-43] complete
S2546
with guard by means of a puller.
Figure 40-21-44
If disassembly is awkward, heat the check nut (Item 1) of
the flange (Item 2) [Figure 40-21-41] at 80°C (176°F).
NOTE: Heating is meant to loosen the setting of

Loctite® on the nut. Always be careful with 1
hot parts.
Figure 40-21-42
S2548
1
Remove the swinging support (Item 1) [Figure 40-21-
44].
2
S2571
Remove the nut (Item 1) and remove the O-ring (Item 2)

[Figure 40-21-42].

Figure 40-21-45
2
1
S2551
Extract the pinion (Item 1) [Figure 40-21-47] complete

S2549
with the internal bearing, the distance piece and shims.
NOTE: The bearing races remain in the central body

Remove the sealing ring (Item 1) [Figure 40-21-45]. (Item 2) [Figure 40-21-47].
Figure 40-21-46 Figure 40-21-48

T21 1
1
T22
S2550
S1564
Position wrench T22 onto the ring nut (Item 1) [Figure Remove the pinion (Item 1) [Figure 40-21-48], shims
40-21-46] and apply bar hold T21 to the pinion (Item 1) and distance piece.
[Figure 40-21-47].
Stop wrench T22 and rotate the pinion so as to release

and remove the ring nut (Item 1) [Figure 40-21-46].
NOTE: If disassembly proves awkward, heat the ring

nut to approx. 80°C (176°F).

Figure 40-21-49
1 1
S1567
Insert a drift in the appropriate holes and remove the

S1565
bearing race (Item 1) as well as the shim washers
(Item 2) [Figure 40-21-51].
Using a puller and a press, remove the inner bearing
(Item 1) from the pinion (Item 2) [Figure 40-21-49].
Figure 40-21-50

1
S1566
Remove the bearing race of the external bearing (Item 1)

[Figure 40-21-50].

Bevel Pinion Assembly
Figure 40-21-52
DG
T25C
T24
T25A S1571
Partially insert the bearing race (Item 1) [Figure 40-21-

S1569
54].
Figure 40-21-55
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.189 in]) [Figure 40-21-
52].

T25B T24 T25C T25A
Preset the indicator to approx. 2mm.
Figure 40-21-53
DG S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race of the external
bearing (Item 1) [Figure 40-21-55].
1
S1570
Bring the internal bearing (Item 1) [Figure 40-21-53],

complete with its bearing race, under the indicator.
Determine overall thickness “D” of the bearing checking

the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the centre and take

several measurements while rotating the
bearing race.

Figure 40-21-56 DG1

1
GB
GB
S1575
Fit a depth gauge with long stem into a perfectly flat bar
S2556
(Item 1) [Figure 40-21-58]; when the bar rests on two
size-blocks “GB” of 57 mm (2,24 in), reset the indicator.
Connect the tension rod to the press and move the Preset the indicator to approx.2 mm (0.078 in) and reset.
bearing race [Figure 40-21-56] into its seat.
Figure 40-21-59
Disconnect the press and remove the tension rod.

NOTE: Before starting the next stage, make sure that
the bearing race has been completely inserted
into its seat.
Figure 40-21-57 T26 (1)
T26 (2) T24 T26 (1) S1576
1
Lay bar (Item 1) [Figure 40-21-59] on tool T26(1) and
take the size “A” at about 57 mm (2,24 in) corresponding
to the maximum diameter of arms centring.
S1574
Insert both parts of tool T26 complete with external

bearing (Item 1) [Figure 40-21-57], measurement ring
T24.
Tighten manually.

Figure 40-21-60
T26 (2)
T24
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577
calculating the size of the shims “S” that are to be placed
Calculate size “B” which will be the first useful value for Figure 40-21-63
calculating the size of the shims that are to be inserted
1

Figure 40-21-61
1
X
Y S
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578
to obtain the size “S” of the shim (Item 1) [Figure 40-21-
63] that will go under the bearing race.
Check the nominal size (X) marked on the pinion
(Item 1) [Figure 40-21-61] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-21-64
T26 (2)
1 2
T26 (1)
S2561
2 Position tools T26C and T26B complete with tapered

S2559
bearings (Items 1 and 2) [Figure 40-21-66]; manually
tighten until a rolling has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-21-67
internal bearing (Item 2) [Figure 40-21-64] in the central
body.

Figure 40-21-65 DDG
S2562
T25A
Insert the stem of a depth dial indicator in either side hole
T25C
T25C S2560
of tool T26C; reset the indicator with a presetting of
approx. 3 mm (0.118 in) [Figure 40-21-67].
Position tool T25A and tension rod T25C [Figure 40-21-
65].
Connect the tension rod to the press, fasten the bearing

race and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.


1 S1
Figure 40-21-68
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12-

S1585
0,13 mm [0.0047 - 0.0051 in], so as to obtain the size of
shim “S1” (Item 1) [Figure 40-21-70] which will be
inserted between the external bearing (Item 1) [Figure
Remove the indicator and release tools and bearings
40-21-69] and the distance piece (Item 1) [Figure 40-
from the central body.
21-68] and subsequently, to determine the preload for the
Re-install all and insert the distance piece (Item 1) bearings.

between both bearings (Items 2 and 3) [Figure 40-21-
Figure 40-21-71
68]; manually tighten the whole pack.
Figure 40-21-69
H
DDG
T26 (2) 2
1
1
1
T26 (1)
S1588
S1586
Position the internal bearing (Item 1) and the pinion
(Item 2) [Figure 40-21-71] under a press. Force the
Insert depth dial indicator into tool T26B-T26C and bearing onto the pinion.
measure variation “H” in relation to the zero setting
performed in [Figure 40-21-69].

Figure 40-21-72
4
1 3
S2564
2 Connect the pinion (Item 1) [Figure 40-21-74] to the tie

S2563
rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Fit the pinion (Item 1), shim “S1” (Item 2) and the Figure 40-21-75
distance piece (Item 3) in the main body (Item 4) [Figure
40-21-72].

NOTE: The finer shims must be placed in between
the thicker ones.
Figure 40-21-73
2 1
1
S2570
Apply Loctite® #242 to the thread of the ring nut

(Item 1) and screw the nut onto the pinion
(Item 2) [Figure 40-21-75].
S1590
Insert the external bearing (Item 1) [Figure 40-21-73] in

the central body in order to complete the pack arranged
as in the figure.

Figure 40-21-76
T19
T19
T22
S2566
The rolling torque of the pinion shaft must be checked.

S2565
Using a dial indicator torque wrench, measure the rolling
torque [Figure 40-21-77]. The correct torque is 1,20-
1,70 N•m (0.88 - 1.25 ft-lb).
Apply special wrench T22 to the ring nut and bar-hold
T19 to the pinion [Figure 40-21-76]. NOTE: If torque exceeds the maximum value, then
the size of shim “S1” between the bearing and
Lock the wrench T22 and rotate the pinion using a torque

the distance piece needs to be increased.
wrench, up to a minimum required torque of 500 N•m
(370 ft-lb) . NOTE: If torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
570 N•m (420 ft-lb).
NOTE: If torque does not reach the minimum value,

then the size of shim “S1” needs to be
reduced.
NOTE: When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0.01 mm (0.00039 in) corresponds
to a variation of 60 N•m (0.44 ft-lb) in the
torque of the pinion.

Figure 40-21-78
2
T27
1
S1597
Fit the flange (Item 1) complete with the guard

S2567
(Item 2) [Figure 40-21-80] and fasten it. For aligning the
flange, use a plastic hammer if necessary.
Lubricate the outer surface of the new sealing ring and fit NOTE: Make sure that the guard is securely fastened
it onto the central body (Item 1) [Figure 40-21-78] using onto the flange and that it is not deformed.
tool T27.

Figure 40-21-81
Figure 40-21-79
1
S2571
S2548
Apply Loctite® #242 to the threads on the pinion shaft.

Install the swinging support (Item 1) [Figure 40-21-79].
NOTE: Check that it is properly oriented. Install the O-ring (Item 1) and nut (Item 2) [Figure 40-21-
81] on the pinion shaft.
Tighten the bolt to 280 - 310 N•m (207 - 229 ft-lb) torque.

Differential Assembly
2
Figure 40-21-82
1
2
S1534
With the help of a bar, position the second planet wheel

S1532
gear (Item 1) and the relative shim washer
(Item 2) [Figure 40-21-84].
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-85
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
82].

Figure 40-21-83
1
1
3
S1535
Insert a tool between the two planetary gears and. Line

S1533
up the entire unit by pushing the bar (Item 1) [Figure 40-
21-85] all the way down until it is ejected.
Position the shim washer (Item 1) and the first planet
wheel gear (Item 2). Hold them in position using a bar
(Item 3) [Figure 40-21-83].

Differential Assembly (Cont’d) 2

1
Figure 40-21-86
1
1
S1538
Place the differential carrier under the press, position

S1536
bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-21-88].
Lock the tool behind the planet wheel gears Figure 40-21-89
(Item 1) [Figure 40-21-86]. After locking, remove bar
T16C.

Figure 40-21-87
2
1
S1539
Put a tool pin on top of the planet wheel pin

S1537
(Item 1) [Figure 40-21-89].
Fit the snap rings (Item 1) onto the pins (Item 2) [Figure
40-21-87].

Figure 40-21-90
1
S1542
1
Position the second planetary gear (Item 1) in the

S1540
Figure 40-21-93
Press the pin all the way down (Item 1) [Figure 40-21-
90].
Figure 40-21-91

1
2
1
2
S1543
Position the shim washer (Item 1) on the crown

S1541
(Item 2) [Figure 40-21-93].
NOTE: In order to hold the shim washer in position,

Remove tool pin, bushing and fit the snap ring (Item 1) apply grease to it.
on the pin (Item 2) [Figure 40-21-91].
NOTE: Make sure that the snap ring centres the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-21-94
1
3 1 2
S1546
2
If the bearings are replaced, insert the external bearing
S1544
races (Item 1) in the central body (Item 2) [Figure 40-21-
96].
Position the crown (Item 1) on the differential carrier Figure 40-21-97
(Item 2) and lock the bolts (Item 3) [Figure 40-21-94]
with Loctite® #242.

Tighten the bolts to 128 - 142 N•m (94 - 105 ft-lb) torque.
1
NOTE: Secure the bolts using the cross tightening A
method.
Figure 40-21-95
2
T17
2 S1551
T17
1
Introduce a dial indicator with rotary key “A” through the
top plug hole (Item 1). Position the indicator on the centre
of one of the teeth of the crown (Item 2) [Figure 40-21-
97] and pre-set it to 1 mm and reset it.
S1545
Install the bearing races (Item 1 and 2) [Figure 40-21-

95] using tool T17.

Figure 40-21-98
A 1
S2542
Re-install the complete arms (Item 1) [Figure 40-21-99].

S1552
Manually move the crown (Item 1) [Figure 40-21-98] in

both directions in order to check the existing backlash
between the pinion and the crown.

NOTE: Difference between MIN and MAX clearance
for whole circumference should not exceed
0.09 mm (0.0035 in).

Steering Knuckle Assembly
Figure 40-21-100
T17
1
S1496
Lubricate the terminal of the drive axle and install the

S1447
Lubricate the bushing (Item 1) and the seat of the Pay due attention not to damage the dust cover rings and
steering case (Item 2). Install the bushing the sealing rings.
(Item 1) [Figure 40-21-100], using tool T17.

Figure 40-21-103
Figure 40-21-101
1 2
T8
1
S40021
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).

Lubricate the outer surface of the sealing ring
To be assembled under the upper pin (Item 2) [Figure
(Item 1) and centreing ring (Item 2) [Figure 40-21-101].
40-21-103].
Fit them into their seat using tool T8.

Figure 40-21-104
3 3
1 2
2
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Fit the unit (Item 1) in the steering case (Item 2) [Figure

S40022
40-21-106]. Position the new bolts and tighten.
Fit a new seal (Item 1) onto the top tie rod (Item 3). Check for the correct assembly side of the seal
Lubricate and install the unit in the steering case. Insert (Item 3) [Figure 40-21-106].
and tighten the 6 bolts (Item 2) [Figure 40-21-104] to

140 N•m (103 ft-lb) using the cross tightening method. Figure 40-21-107
Check the correct assembly side of the seal

(Item 1) [Figure 40-21-104].
Figure 40-21-105
S40023
Tighten the fitting bolts (Item 1) [Figure 40-21-107] of

the bottom tie rod in sequence using the cross tightening
method, to 140 N•m (103 ft-lb).
S1499
Lubricate the group with grease and mount it in the


Figure 40-21-108
S2569
Check the torque of the pins, which has to be between

S2568
30 - 60 N•m (22 - 44 ft-lb). If the preliminary measured
value is too high, the shims have to be increased
[Figure 40-21-109].
Install a magnetic based dial indicator on the steering
housing.Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the
width and reduce it by removing shims [Figure 40-21-

108].

Planetary Carrier Assembly
Figure 40-21-110
T10
T9B
S2588
Position tool T10 and press the sealing ring into its seat
S1451
[Figure 40-21-112].
Figure 40-21-113
Position the upper part of tool T9B and press the bearing
races into the hub (Item 1) [Figure 40-21-110] all the
way down.

Figure 40-21-111
1 2
S1455
Insert the flange (Item 1) in the crown (Item 2) [Figure

40-21-113].
S2587
Fit the bearing (Item 1) [Figure 40-21-111] into the

internal bearing race (wide side up).

Figure 40-21-114
3
S2473A
Install the four snap rings (Item 1) [Figure 40-21-116].

S1456
Figure 40-21-117
Insert the snap ring (Item 1) in order to fix the flange

(Item 2) in the crown (Item 3) [Figure 40-21-114].
NOTE: Carefully check that the ring is properly 2

inserted in the slot of the crown.
Figure 40-21-115
DOWN
1
T11 S2539
1
Fit the steering case (Item 1) onto the drive axle
2 (Item 2) [Figure 40-21-117] and install the tie rods.
Connect the steering bars.

S1457
With the help of tool T11, insert the planet wheel gears
(Item 1) into the cover (Item 2) [Figure 40-21-115].
Accurately check the orientation.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-118
1
S2646
Fit the complete crown flange (Item 1) [Figure 40-21-

S2471A
120].
NOTE: In order to fasten the flange, use a plastic

Install the hub (Item 1) [Figure 40-21-118]. hammer and alternatively hammer on several
equidistant points.
Figure 40-21-119

Figure 40-21-121
2
1
1
S2470A
S2467
Install the external bearing (Item 1) [Figure 40-21-119].

Apply silicone based grease to the surface of the flange
NOTE: Using a plastic hammer, drive the bearing to
(Item 1) which touches the crown flange (Item 2). Fit the
the limit stop by lightly hammering around the
flange (Item 1) [Figure 40-21-121].
edge.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-122
2
1
S1468
Lock the planetary carrier cover (Item 1) by tightening

S2647
the bolts (Item 2) [Figure 40-21-124]. Tighten the bolts
to 40 - 50 N•m (30 - 37 ft-lb).
Cross tighten the nuts (Item 1) [Figure 40-21-122] in two
stages.
Initial torque setting: 120 N•m (88 ft-lb) .

The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.
Figure 40-21-123
1
S2465
Fit the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-123] and install the snap ring.
NOTE: Check that the O-ring is in good condition and

in position.

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
DIFFERENTIAL BEARING

6912196 T17
INNER RINGS
T19
6912197 PINION RING NUT T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

FRONT AXLE Figure 40-30-3
Removal
Figure 40-30-1
S4634
Remove the eight lug nuts and washers [Figure 40-30-3]

S4516 from each front wheel.
Remove both front wheels.

Raise the boom and install the boom stop (Item 1)
[Figure 40-30-1]. Figure 40-30-4

Figure 40-30-2
S4636
S4635
remove the front fenders.
Lift the front of the machine until the front wheels are off
the ground and place jackstands under the frame as Raise the two stabilisers until they are horizontal so the
shown [Figure 40-30-2]. machine only supports on the rear wheels and the
jackstands.
Place a block in front and behind the rear wheel [Figure
40-30-2].

FRONT AXLE (CONT’D)
Removal (Cont’d)
IMPORTANT
Figure 40-30-5
damage the system.
I-2003-0888
1
Figure 40-30-7
S4587
Rotate the battery disconnect switch (Item 1) [Figure 40- 1

30-5] to the right, to disconnect the power supply from

the battery.
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-100-2.)
S4548
Figure 40-30-6
7] from the steering cylinder. Cap the tubeline.
Figure 40-30-8
1 1
S4560
Disconnect the parking brake and service brake hydraulic

tubelines (Item 1) [Figure 40-30-6] and cap them. Do this 1
S4562
at both sides of the machine.
NOTE: Mark all tubelines for correct installation. Disconnect the two hydraulic tubelines (Item 1) from the
hydrostatic motor by removing the four bolts. Also
disconnect the drain hydraulic tubeline on top of the
hydrostatic motor (Item 2) [Figure 40-30-8]. Cap all the
tubelines and couplings.

FRONT AXLE (CONT’D) Figure 40-30-11
Removal (Cont’d) 1
Figure 40-30-9
1
S4565
Disconnect the centre position sensor (Item 1) and the

S4564 hydraulic tubeline (Item 2) [Figure 40-30-11] from the
steering cylinder.
Disconnect the drain hydraulic tubeline (Item 1) [Figure Figure 40-30-12

40-30-9] from the bottom of the hydrostatic motor and

cap it.
Figure 40-30-10
S4566
Disconnect the drive shaft (Item 1) [Figure 40-30-12]

S4563 from the front axle by removing the four screws.

10] from the hydrostatic motor and cap it. Also cap the
coupling.

Removal (Cont’d)
1
Figure 40-30-13
S4512
Disconnect the frame levelling cylinder by removing the

S4658 screw and nut (Item 1) [Figure 40-30-15] and remove the
pivot pin.
Remove the cover (Item 1) by loosening the two screws Figure 40-30-16
(Item 2) [Figure 40-30-13].

Figure 40-30-14
S4568
S4567 NOTE: Before disconnecting the cylinder, make sure

the cylinder is kept up by means of a bar
[Figure 40-30-16].
Disconnect the six hydraulic tubelines [Figure 40-30-14]
from the front of the machine. Cap the tubelines and the Make sure the stabiliser frame is well supported. Use a
couplings. fork-lift truck to support the frame.
NOTE: Mark all tubelines for correct installation.
IMPORTANT
If the capacity of the fork-lift truck is too low to carry
the front of the machine, first remove the front weight
from the machine (T40170 only).

Removal (Cont’d)
Figure 40-30-17
S4642
Connect the front axle to a 3-point chain as shown in

S4511 [Figure 40-30-19].
Figure 40-30-20
Remove the upper pivot pin (Item 1) [Figure 40-30-17]
on the left side. Repeat for the right side.

WARNING
If the stabiliser frame is not well supported it will fall
down when removing the two pivot pins.
Figure 40-30-18
1 S4641
Remove the 12 front axle mounting bolts and nuts (Item

1) [Figure 40-30-20].
Assembly: Tighten the bolts to 350 N•m.
S4640
Carefully remove the stabiliser frame from the machine

by lowering it and pulling it back [Figure 40-30-18].
NOTE: Be careful when putting down the front of the

machine. Make sure no tubelines or hoses are
distorted.

FRONT AXLE (CONT’D)
Removal (Cont’d)
Figure 40-30-21
S4643
Remove the front axle from the stabiliser frame by means

of the 3-point chain [Figure 40-30-21].

AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

1 2
but this procedure can be completed with the axle
installed in the machine.
3
Turn the steering wheel until the steering cylinder rod is
positioned in the centre. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
S2056
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement
is the same.
1
Tighten the nut (Item 3) [Figure 40-40-3] to 360 N•m
(266 ft-lb) torque.

1
EM9354
Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.
Figure 40-40-2
S2057
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.


PARKING BRAKE Figure 40-50-3
Releasing The Brake For Towing
Block all four wheels to prevent the machine from moving

1
once the parking brake is released.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-1
Towing
Position
S6802
Locate the tow valve (Item 1) [Figure 40-50-3], turn

anticlockwise 90° to the towing position.
The machine is now ready to be towed.

S1394
Figure 40-50-2
S1395
Alternately turn the brake release bolts [Figure 40-50-1]

"IN" (clockwise) 180° turn each until you feel resistance.
Continue to turn each release bolt in equally 180° for a
total of approximately five complete turns.

PARKING BRAKE (CONT'D) Figure 40-50-6
Re-Activating The Brake

Operating
Block all four wheels to prevent the machine from Position 1
moving.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-4
P-52284
Locate the tow valve (Item 1) [Figure 40-50-6] under the

hood, turn clockwise 90° to the operating position.
The parking brake is now re-activated.

S1394
WARNING
Figure 40-50-5
The vehicle will not be able to break until the screws
are returned to their original position.
S1395
Alternately turn the brake release bolts [Figure 40-50-4]

"OUT" (anticlockwise) 90° turn until the torque drops off
sharply. Continue to turn each release bolt out equally
180° turn until the brake release bolt presses against the
bolt housing. After the brake release bolt is touching the
bolt housing turn each brake release bolt "IN" (clockwise)
a 90° turn.

STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
The axle is removed from the machine for photo clarity, 1

but this procedure can be completed with the axle
installed in the machine.
Figure 40-60-1
S2061
Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 150 N•m (110 ft-lb) torque.
Figure 40-60-4
2
S2059

1
Install a straight bar (Item 1) onto the wheel hub and
secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (Item 2) [Figure 40-60-1]
on the pinion shaft.
Figure 40-60-2
S2062
Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.
32 - 35
Degrees
S2060
Use an angle gauge, to obtain a reading of 32 - 35

degrees [Figure 40-60-2].


DRIVE SHAFT Figure 40-70-3
Figure 40-70-1
S2047
1
S1850 Remove the drive shaft out the rear of the machine
[Figure 40-70-3].
Remove the four drive shaft mounting bolts (Item 1) Figure 40-70-4
[Figure 40-70-1] from each end of the drive shaft.

Figure 40-70-2
4
FRONT REAR
1 3 2
1
S4518
S4517 The drive shaft assembly consists of the following parts:

front shaft (Item 1), rear shaft (Item 2), intermediate
support (contains a bearing and a damper) (Item 3),
Remove the intermediate drive shaft support by removing threaded bracket (Item 4) [Figure 40-70-4].
the two bolts (Item 1) [Figure 40-70-2] on the bottom
side of the machine frame.


SERVICE BRAKE Figure 40-80-1
Description
There are two bleed screws located on each side of the

front axle differential housing.
Air trapped in the brake lines can cause a spongy feel

1
and / or delayed activation of the service brake.
2
Use the following procedure to remove air from the brake
circuit.
Bleeding The Brake Circuit
Lift and block the machine. (See Procedure on Page 10- S4560
10-1.)
Figure 40-80-2
NOTE: Position the jack stands to allow starting the
machine and driving the wheels.
On machines with frame leveling the bleed screws are

accessible from both sides of the front axle. 2

1
S4591
Remove the caps and loosen the four bleed screws

(Items 1 and 2) [Figure 40-80-1] and [Figure 40-80-2].
NOTE: Hydraulic fluid will be forced from the bleed

screws during the following procedure:
With the aid of an assistant, start the engine, lower the

restraint bar and apply the service brake until a
continuous stream of clean hydraulic fluid, with no air,
flows from the inside bleed screws (Item 1) [Figure 40-
80-1] and [Figure 40-80-2]. Stop the engine and tighten
the two inside bleed screws.
Start the machine, engage the hydro stat and turn the
wheels until a continuous stream of clean hydraulic fluid,
with no air, flows from the outside bleed screws (Item 2)
[Figure 40-80-1] and [Figure 40-80-2]. Stop the engine
and tighten the two outside bleed screws.
Lower the machine and test for proper brake operation.


REAR AXLE Figure 40-90-2
Position the machine on the work surface.
WARNING
immediately.
W-2145-0290 Lift the rear of the machine and place jack stands under
the frame as shown in [Figure 40-90-2].
Figure 40-91-1
Place a block in front and behind the front wheel.
1 Figure 40-90-3

1
S4587
Rotate the battery disconnect switch (Item 1) [Figure 40-

91-1] to the right, to disconnect the power supply from S4608
the battery.
Remove the eight lug nuts and washers (Item 1) [Figure

40-90-3] from each rear wheel.
Remove both rear wheels.
Installation: Tighten the nuts to 360 N•m (266 ft-lb)

torque.

REAR AXLE (CONT’D)
Figure 40-90-4
IMPORTANT
1 damage the system.
I-2003-0888
Remove the two hoses from the rear steering cylinder.
Figure 40-90-6
S1951

remove the rear fenders.

1
Figure 40-90-5
S4585
Disconnect the two electrical connectors (Item 1) [Figure

1
40-90-6].
Figure 40-90-7
S1850
Remove the four bolts (Item 1) [Figure 40-90-5] and nuts

from the driveshaft.
Installation: Tighten the bolts to 118 N•m (87 ft-lb)

torque.
NOTE: Mark all hoses for correct installation. 1
S4622
Install two jack stands and a floorjack (Item 1) [Figure

40-90-7] under the axle.

REAR AXLE (CONT’D) Figure 40-90-9
Figure 40-90-8
S4623
Remove the jack stands from the axle.

S4584
Have an assistant balance the axle on the floor jack and
lower the floor jack slowly. Roll the axle out from under
Remove the four bolts (Item 1) [Figure 40-90-8] from the the frame [Figure 40-90-9].
rear axle mount bracket.


MAINFRAME
OPERATOR CAB (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW) . . . . . . . 50-10-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
OPERATOR CAB (S/N A8GA13000 & ABOVE,

S/N A8GB13000 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

END BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
AIR INTAKE COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

QUICK-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
REAR WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
PIVOT LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1


JOYSTICK PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW) . . . . . . . . . 50-130-1
JOYSTICK PANEL (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE) . . . . . . . . . 50-131-1
DASH COVER / STEERING COLUMN COVER (S/N A8GA12999 & BELOW, A8GB12999 &
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
DASH COVER / STEERING COLUMN COVER (S/N A8GA13000 & ABOVE, S/N A8GB13000
& ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1
INTERMEDIATE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

Removal of the First Intermediate Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Installation of the First Intermediate Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-2
Removal of the Second Intermediate Boom (T40170) . . . . . . . . . . . . . . . . . . . . . . 50-150-3
Installation of the Second Intermediate Boom (T40170) . . . . . . . . . . . . . . . . . . . . . 50-150-4
BOOM TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

STABILISER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-2
FRONT WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1


OPERATOR CAB (S/N A8GA12999 & BELOW, S/N Figure 50-10-3
A8GB12999 & BELOW)
1
Removal and Installation
Figure 50-10-1
1
S4592
Remove the three screws (Item 1) from the access cover

(Item 2) [Figure 50-10-3] located on the back of the
S4516 canopy.
Remove the access cover.


[Figure 50-10-1]. NOTE: Mark all hoses and electrical connectors for
Stop the engine.
Figure 50-10-4
Relieve hydraulic pressure.
Figure 50-10-2
P-44577
P-29253 Disconnect the two electrical connectors (Item 1) [Figure

50-10-4].

the battery.

OPERATOR CAB (S/N A8GA12999 & BELOW,
S/N A8GB12999 & BELOW) (CONT’D)
Removal and Installation (Cont’d)

IMPORTANT
Figure 50-10-5
damage the system.
I-2003-0888
Figure 50-10-7
1
P-44578 2
Disconnect the four electrical connectors (Item 1) [Figure

50-10-5].

Figure 50-10-6
P-44932
2
Loosen the screw (Item 1) and disconnect the electrical
connector (Item 2) [Figure 50-10-7].
Figure 50-10-8
P-44925
Loosen the screw (Item 1) and disconnect the electrical 2

WARNING P-44933

Remove the nut (Item 1) and ground wires (Item 2)
[Figure 50-10-8].
immediately.
W-2145-0290

OPERATOR CAB (S/N A8GA12999 & BELOW, Figure 50-10-10
Figure 50-10-9
P-25592
1
Remove the heater hoses (Item 1) [Figure 50-10-10]

from the heater assembly.
S4597
Remove the two wires (Item 1) [Figure 50-10-9] from the Figure 50-10-11

fuel sending unit.
Remove the travel / signal levers. (See Removal And

Installation on Page 60-60-1.)
1
Remove the instrument panel. (See Removal And
Remove the switch panel. (See Removal And Installation

on Page 60-80-1.)
Remove the dash cover / steering column cover. (See

Drain the radiator. (See Removal And Installation on

S4598
Page 70-50-1.)
Remove the fuse box cover (Item 1) [Figure 50-10-11].

Figure 50-10-12
1
1
P-53573
Temporarily remove the protective covering (Item 1)

[Figure 50-10-14] from the A/C hoses and expansion
S4599 valve.
Figure 50-10-15
Remove the side cover (Item 1) [Figure 50-10-12].

Figure 50-10-13
1
1
P-53574
P-53572 Remove the bolt (Item 1) and plate (Item 2) [Figure 50-
10-15]. Remove the A/C hoses.
Remove the cover (Item 1) [Figure 50-10-13]. NOTE: Plug the A/C hoses to prevent contamination.
If machine is equipped with air conditioning, remove the

refrigerant from the A/C system. (See Reclamation
Procedure on Page 80-40-1.)

Figure 50-10-16
P-53576
1 Remove the two A/C hoses, heater hoses and harness

from the rear corner of the cab [Figure 50-10-18].
P-53575
Figure 50-10-19
Loosen the mounting bracket bolt (Item 1)

[Figure 50-10-16].
Figure 50-10-17
1
1
1
S4595
Remove the three hoses (Item 1) [Figure 50-10-19].
S4590 Remove any necessary nylon ties.

located under the fuse box.

Figure 50-10-20
P-53604
Remove the engine speed control cable (Item 1) [Figure

50-10-22] from the bracket.
P-44919
Remove any necessary nylon ties, carefully remove the
speed control cable from the engine compartment and
Remove the seven hoses on the right side of the cab into the cab.

[Figure 50-10-20].
NOTE: Adjust the engine speed control cable during
Open the engine cover. installation. (See Removal And Installation on
Page 70-20-1.)
Figure 50-10-21
Close the engine cover.
Figure 50-10-23
P-53603

S4672
50-10-21].
Install a hoist to lift and support the cab [Figure 50-10-

23].

Figure 50-10-24 1
S4671
Remove the two bolts (Item 1) and rubber cushions (Item

2) [Figure 50-10-26].
P-44937A
Lift and remove the cab.
Remove the cab mount bolt (Item 1) [Figure 50-10-24]

from the front of the cab.
Figure 50-10-25
P-44920
Remove the grounding strap (Item 1) and rear mounting

bolt (Item 2) [Figure 50-10-25].


OPERATOR CAB (S/N A8GA13000 & ABOVE, Figure 50-11-3
S/N A8GB13000 & ABOVE)
1
Figure 50-11-1
1
S4592

S4516 canopy.


[Figure 50-11-1]. NOTE: Mark all hoses and electrical connectors for
Stop the engine.
Figure 50-11-4
Relieve hydraulic pressure.
Figure 50-11-2
P-44577
P-29253 Disconnect the two electrical connectors (Item 1) [Figure

50-11-4].

the battery.

OPERATOR CAB (S/N A8GA13000 & ABOVE,
S/N A8GB13000 & ABOVE) (CONT’D)

IMPORTANT
Figure 50-11-5
damage the system.
I-2003-0888
Figure 50-11-7
1
P-44578
2
Disconnect the four electrical connectors (Item 1) [Figure

50-11-5].

Figure 50-11-6
P-44932
2
Figure 50-11-8
P-44925
Loosen the screw (Item 1) and disconnect the electrical 2

WARNING P-44933

sufficient force to enter a person’s body by Remove the nut (Item 1) and ground wires (Item 2)
penetrating the skin. This can cause serious injury [Figure 50-11-8].
immediately.
W-2145-0290

OPERATOR CAB (S/N A8GA13000 & ABOVE, Remove the joystick panel. (See Removal And
S/N A8GB13000 & ABOVE) (CONT’D) Installation on Page 50-131-1.)
Removal and Installation (Cont’d) Figure 50-11-11
Figure 50-11-9 1
S36381
S4597
Remove the two wires (Item 1) [Figure 50-11-9] from the If machine is equipped with air conditioning, remove the

fuel sending unit. refrigerant from the A/C system. (See Reclamation
Procedure on Page 80-40-1.)
Remove the travel / signal levers. (See Removal And
Installation on Page 60-61-1.) Figure 50-11-12

2
Removal And Installation on Page 50-141-1.) 1

Coolant on Page 10-70-1.)
Figure 50-11-10
1
S36333
Mark and remove both A/C hoses (Item 1) [Figure 50-11-

12].
NOTE: Plug the A/C hoses (Item 1) [Figure 50-11-12] to

prevent contamination.
Remove the heater hose (Item 2) [Figure 50-11-12] NOT

connected to the heater valve (Item 3) [Figure 50-11-13].
P-97028

Figure 50-11-13
2
3
P-53575
1 Loosen the mounting bracket bolt (Item 1) [Figure 50-11-

15].
S36334
Figure 50-11-16
Remove the heater hose (Item 1) [Figure 50-11-13].

Remove bolt, nut and clip (Item 2) [Figure 50-11-13].
Figure 50-11-14
P-53576
Remove the two A/C hoses, heater hoses and harness

from the rear corner of the cab [Figure 50-11-16].
S36344
Disconnect the connectors (Item 1) [Figure 50-11-14]

located under the dash cover.

Figure 50-11-17
P-53603
1 Remove the engine speed control cable (Item 1) [Figure

50-11-19].
P-44924
Figure 50-11-20
Remove the three hoses (Item 1) [Figure 50-11-17].

Remove any necessary nylon ties.
Figure 50-11-18
P-53604

P-44919 Remove any necessary nylon ties, carefully remove the

speed control cable from the engine compartment and
into the cab.
Remove the seven hoses on the right side of the cab
[Figure 50-11-18]. NOTE: Adjust the engine speed control cable during
installation. (See Removal And Installation on
Open the engine cover. Page 70-20-1.)

Figure 50-11-21 1
1 P-44937A
Remove the cab mount bolt (Item 1) [Figure 50-11-23]

from the front of the cab.
P-44936A
Figure 50-11-24
Remove the two screws (Item 1) from the access panel

(Item 2) [Figure 50-11-21]. Remove the access panel.
Figure 50-11-22
2
P-44920
Remove the earthing strap (Item 1) and rear mounting

bolt (Item 2) [Figure 50-11-24].
P-44935B
Install a hoist to lift and support the cab [Figure 50-11-

22].

Figure 50-11-25
P-44938B
2 2
Lift and remove the cab [Figure 50-11-26].
P-49050
Remove the two bolts (Item 1) and rubber cushions (Item

2) [Figure 50-11-25].


OPERATOR SEAT Figure 50-20-3
Figure 50-20-1
1
P-44527
1 Remove the two seat mount bolts (Item 1) [Figure 50-20-

P-44525 3] from both sides.
Remove the seat.

Figure 50-20-2

1
P-44526
Raise the seat mount cover (Item 1) [Figure 50-20-1] by

sliding the bottom edge of the seat mount cover to the
right to remove the cover retainers (Item 1) from the seat
frame (Item 2) [Figure 50-20-2].
NOTE: There are several retainers molded into the

bottom edge of the cover.


BOOM ASSEMBLY Figure 50-30-3
Remove the bucket positioning cylinder.

(See “Removal And Installation” on Page 20-30-1.)
2
Figure 50-30-1
S4645
Use a strap and hoist (Item 1) [Figure 50-30-3] to

support the lift cylinder and bucket positioning cylinder.
Remove the pivot pin snap ring (Item 2)

S7431 [Figure 50-30-3] from the rod end.

Figure 50-30-4
Lower the boom onto adequate stands or blocks as
shown [Figure 50-30-1].
Figure 50-30-2
1
1
S4644
Remove the upper pivot pin using a pin removal tool

S4500 (Item 1) [Figure 50-30-4].
NOTE: If a nut must be welded onto the pin for

Remove the rear cover (Item 1) [Figure 50-30-2] from removal the following three steps must be
the machine. performed:
1. Rotate the battery disconnect switch to the right to

disconnect the power supply from the battery.
2. The side window and frame opening must be

protected from sparks.
3. The cylinder rod must be wrapped with a damp

welding blanket to prevent damage.

Figure 50-30-5
1 1
S4515
Disconnect the six hydraulic hoses (Item 1)

S4573 [Figure 50-30-1] from the tubelines.
Figure 50-30-1
After the upper pivot pin has been removed, the rod end
of the cylinders should be lowered onto a wood block,

positioned as shown [Figure 50-30-5].
Figure 50-30-6
S4673
Lower the boom onto adequate stands or blocks by

means of the hoist [Figure 50-30-1].
S4555
Disconnect the harness connectors (Item 1) [Figure 50-

30-6]. (If Equipped)
IMPORTANT
damage the system.
I-2003-0888

BOOM ASSEMBLY (CONT'D) Figure 50-30-4
Removal And Installation (Cont'd) 1
Figure 50-30-2 2
S7433
Remove the bolt (Item 1) and washer (Item 2)

S4677 [Figure 50-30-4] from the boom pin.
Figure 50-30-5
Install a lifting chain (Item 1) [Figure 50-30-2] on the
front of the boom.

Figure 50-30-3
S7434
Remove the boom pin [Figure 50-30-5].

S7432
Lift and remove the boom assembly.
Install a lifting chain (Item 1) [Figure 50-30-3] on the rear

of the boom.
Raise the hoist until the weight of the boom is supported

by the hoist.


END BOOM Figure 50-40-3
Removal
3
Remove the boom tray. (See Removal And Installation on
Page 50-160-1.) Remove the extension cylinder. (See
Cylinder Group Removal And Installation on Page 20-40- 2
1.)
Figure 50-40-1
1
1 S3611
Disconnect the grease nipple (Item 1), the spindle (Item

2), and the pulley (Item 3) [Figure 50-40-3] at the front of
the intermediate boom.
Figure 50-40-4
S3584

Disconnect the retraction chain (Item 1) [Figure 50-40-1]
at the rear of the end boom.
Figure 50-40-2
2
1 1
1
S3586
Disconnect the extension chain (Item 1) [Figure 50-40-4]

at the front of the fixed boom.
S4616
Disconnect the two bolts (Item 1) and the plate (Item 2)

[Figure 50-40-2] at the front of the intermediate boom.

END BOOM (CONT’D) Figure 50-40-7
Removal (Cont’d)
Figure 50-40-5
S3614
Disconnect the extension chain (Item 1) [Figure 50-40-7]

at the rear of the end boom.
S3612
Remove the rear wear pads of the end boom. (See

Begin sliding the end boom from the intermediate boom. Installation on Page 50-51-1.)
Before the end boom is completely removed, position a
hoist and a lifting strap on the front of the end boom (Item
1) [Figure 50-40-5].

Remove the front wear pads of the intermediate boom.
(See Removal on Page 50-50-1.)
Figure 50-40-6
S3587
Carefully remove the end boom completely [Figure 50-

40-6].

Installation
2 1
Figure 50-40-8
1
S3612
Install the end boom (Item 1) into the intermediate boom

(Item 2) [Figure 50-40-10] approximately 10 In.
S3613
Install the front wear pads on the intermediate boom.

Apply grease to the inside top and bottom corners of the (See Installation on Page 50-50-2.) Remove the hoist and
intermediate boom (Item 1) [Figure 50-40-8]. lifting strap and slide the end boom fully into the
intermediate boom.
Install the rear wear pads on the end boom.

(See Installation on Page 50-40-3.) Figure 50-40-11
Figure 50-40-9
S3584
S3614
Connect the retraction chain at the rear of the end boom.
(Item 1) [Figure 50-40-11].
Connect the extension chain (Item 1) [Figure 50-40-9] at
the rear of the end boom.

Figure 50-40-12
1 S3586
Connect the extension chain at the front of the fixed

boom (Item 1) [Figure 50-40-14].
S3611
Install the extension cylinder. (See Cylinder Group

Connect the grease nipple (Item 1), the spindle (Item 2) Removal And Installation on Page 20-40-1.) Install the
and the pulley (Item 3) [Figure 50-40-12] at the front of boom tray. (See Removal And Installation on Page 50-
the intermediate boom. 160-1.) Adjust the extension and retraction chains. (See
Checking And Adjustment Procedure on Page 10-170-1.)

Figure 50-40-13
2
1
1
S4616
Connect the two screws (Item 1) and the plate (Item 2)

[Figure 50-40-13] at the front of the intermediate boom.

WEAR PADS (FRONT) Figure 50-50-3
Removal
Figure 50-50-1
S3595
Remove the upper and side wear pads (Item 1)

[Figure 50-50-3].
S4618
With both upper wear pads removed, use a hoist and

Extend the inner boom and mark the location of the inner lifting strap at the end of the boom, apply upwards
supports and wear pads (Item 1) [Figure 50-50-1]. pressure, lifting the inner boom off the bottom wear pads.
Remove the lower wear pads.
Figure 50-50-2

1
S3596
Remove the bolts of the upper, lower and side wear pads
(Item 1) [Figure 50-50-2].

WEAR PADS (FRONT) (CONT’D) Figure 50-50-6
Installation
1
Figure 50-50-4
S3596
Tighten the bolts (Item 1) [Figure 50-50-6] of the upper

wear pads to 58 N•m (43 ft-lb).
S3594
Figure 50-50-1
Make sure that the surface of the boom is cleaned before
installing the pads [Figure 50-50-4].
Figure 50-50-5

1
S3597
1
Install the four wear pads at the left and right side of the
boom (Item 1) [Figure 50-50-1].
S3595
Install the two upper wear pads (Item 1) [Figure 50-50-

5].

WEAR PADS (FRONT) (CONT’D) Figure 50-50-1
Figure 50-50-1
S3600
Tighten the bolts (Item 1) [Figure 50-50-1] of the lower

wear pads to 58 N•m (43 ft-lb).
S3598
Figure 50-50-1
Tighten the bolts of the wear pads (Item 1) [Figure 50-
50-1] to 58 N•m (43 ft-lb).
With both upper wear pads installed, use a hoist and

lifting strap at the end of the boom, apply upwards
pressure, lifting the inner boom off the bottom wear pads.
Figure 50-50-1
Apply grease to the pads using a grease pump [Figure

50-50-1].
1
S3599
Install the two lower wear pads (Item 1) [Figure 50-50-1].


WEAR PADS (REAR) Installation
Removal Figure 50-51-3
Figure 50-51-1
S3604
S3602
Make sure that the surface of the boom is cleaned before
installing the pads [Figure 50-51-3].
Remove the end / intermediate boom and mark the
location of the wear pads (Item 1) [Figure 50-51-1]. Figure 50-51-4
Figure 50-51-2

1
1
S3605
S3603
Install the six pads and tighten the bolts (Item 1) [Figure
50-51-4] to 39 N•m (29 ft-lb).
With the end / intermediate boom supported, remove the
bolts and the pads (Item 1) [Figure 50-51-2].

WEAR PADS (REAR) (CONT’D)
Figure 50-51-5
S3606
Apply grease to the pads.
Figure 50-51-6

1
S3607
After installing the boom, apply grease to the pads using

a grease pump (Item 1) [Figure 50-51-6].

ENGINE COVER Removal And Installation
Gas Cylinder Removal And Installation Remove the gas cylinder.

1
S6854
Figure 50-60-3

1 1
S6852
Lift the engine cover [Figure 50-60-1]. Add a support to

prevent the cover from closing when the gas cylinder is
removed.
S6853
Remove the retainer clips (Item 1) [Figure 50-60-1] at
both of the ball joints ends. Remove the ball joints from
the ends. Remove the four hinge mounting bolts (Item 1) [Figure
50-60-2] and [Figure 50-60-3].
Remove the gas cylinder.
Remove the engine cover.
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288


AIR INTAKE COWLING Figure 50-70-2
Figure 50-70-1 1
S4596
While supporting the air intake cowling remove the two

S4594 bolts (Item 1) [Figure 50-70-2].
Remove the air intake cowling.

Remove the bolts (Items 1 and 2) [Figure 50-70-1].


FUEL TANK Figure 50-80-3
Figure 50-80-1
P-29256
Drain the fuel from the fuel tank by removing the plug
S4516 (Item 1) [Figure 50-80-3].
Figure 50-80-4
[Figure 50-80-1].
1

Remove the battery. (See “Removal And Installation” on
Page 60-20-1.)
Figure 50-80-2
2
P-50821
Remove the three screws (Item 1) and remove the

access panel (Item 2) [Figure 50-80-4].
P-29280B
Install a hoist to lift and support the cab [Figure 50-80-2].

FUEL TANK (CONT’D) Figure 50-80-7
Figure 50-80-5
1
P-42457
1 1
P-29250 the fuel tank.

Remove the two bolts (Item 1) [Figure 50-80-5] from the
cab spring. Figure 50-80-8

Figure 50-80-6
P-29257
P-29251
Support the fuel tank using a forklift or jack [Figure 50-
80-8].
Remove the two wires (Item 1) [Figure 50-80-6] from the
fuel sending unit.
NOTE: Mark the wires for correct installation.

FUEL TANK (CONT'D) Figure 50-80-11
Figure 50-80-9
P-29253
1
Figure 50-80-12
P-29281
Remove the access panel (Item 1) [Figure 50-80-9].

Figure 50-80-10
P-29254
Remove the mounting bolts (Item 1) [Figure 50-80-11]

and [Figure 50-80-12] from the rear of the fuel tank.
P-29255
Remove the two mounting bolts (Item 1) [Figure 50-80-

10] from the front of the fuel tank.

FUEL TANK (CONT'D)
Figure 50-80-13
P-29259
Carefully lower and remove the fuel tank [Figure 50-80-

13].

QUICK-TACH Figure 50-90-3
Figure 50-90-1
1
1 S4509
Remove the pivot pin retainer bolt (Item 1) [Figure 50-90-

3].
S4616
Figure 50-90-4
Disconnect the hydraulic couplers (Item 1) [Figure 50-
90-1].
Figure 50-90-2

1
S4674
Remove the pivot pin (Item 1) [Figure 50-90-4] to release

the quick-tach from the tilt cylinder.
S3640
Rotate the quick-tach forward fully, using a lifting hoist.

Support the quick-tach as shown [Figure 50-90-2].

QUICK-TACH (CONT’D) Figure 50-90-6
Figure 50-90-5
1
1 S3642
Remove the pivot pin (Item 1) [Figure 50-90-6].

S3539
Remove the quick-tach.
Remove the pivot pin retainer bolt (Item 1) [Figure 50-90- Installation: Apply grease using a grease pump.
5].

REAR WEIGHTS Figure 50-100-3
Figure 50-100-1
S7435
Position a hoist as shown to lift and support the rear

S4500 weight [Figure 50-100-3].
Figure 50-100-4

Figure 50-100-2
2
2
1
2 S7436
S4559 Remove the weight [Figure 50-100-4].
Disconnect the tail light connector (Item 1) [Figure 50-

100-2] from the main harness.
Remove the three weight mounting bolts (Item 2) [Figure

50-100-3].


FENDER Figure 50-110-2
Lift the front of the machine and place jack stands under
the frame. 1
Place a block in front and behind one of the rear wheels.
Figure 50-110-1
2
1
S1951
Remove the four nuts (Item 1) from the fender mount

brackets (Item 2) [Figure 50-110-2].
Remove the fender.
Installation: Tighten the nuts to 125 - 140 N•m (90 - 100

S1954 ft-lb) torque.
Remove the eight lug nuts and washers (Item 1) [Figure

50-110-1] from the tire. Remove the tire.


PIVOT LINK Figure 50-120-3
Rotate the quick-tach back fully.
Figure 50-120-1
P-32150
Rotate the quick tach forward until it is on the ground

[Figure 50-120-3].
P-32006 Figure 50-120-4

120-1] from the pivot.
1
Figure 50-120-2 1
P-29719
Remove the two mounting bolts (Item 1) and cover (Item

2) [Figure 50-120-4].
P-32007
Remove the pivot pin (Item 1) [Figure 50-120-2] and

lower the link.

PIVOT LINK (CONT'D) Figure 50-120-7
Figure 50-120-5
P-32008
Place a floor jack under the pivot link [Figure 50-120-7].

P-32001
Figure 50-120-8

120-5].

Figure 50-120-6
1
P-32004

120-8].
P-32002
Remove the pivot pin (Item 1) [Figure 50-120-6] from the

tilt cylinder.

PIVOT LINK (CONT'D)
Figure 50-120-9
P-32005
Remove the pivot pin (Item 1) [Figure 50-120-9].

Figure 50-120-10
P-32009
Lower the floor jack and remove the pivot link [Figure 50-
120-10].


JOYSTICK PANEL (S/N A8GA12999 & BELOW, Figure 50-130-3
A8GB12999 & BELOW)
Remove the instrument panel. (See Removal And 1

Remove the switch panel. (See Removal And Installation

on Page 60-80-1.)
Remove the dash cover / steering column cover.

1
Figure 50-130-1 1
P-52338
Remove the four bolts (Item 1) [Figure 50-130-3].
Figure 50-130-4
1

P-52336
Remove the fuse box cover (Item 1) and side cover (Item
2) [Figure 50-130-1]. 1
Figure 50-130-2
P-52339
Remove the joystick panel (Item 1) [Figure 50-130-4].
P-52337
Disconnect the frame leveling connector (Item 1) [Figure

50-130-2].


JOYSTICK PANEL (S/N A8GA13000 & ABOVE, Figure 50-131-3
A8GB13000 & ABOVE)

1 2
Figure 50-131-1
1 S36359
Remove three screws (Item 1) [Figure 50-131-3].
P-97028 Remove the joystick panel (Item 2) [Figure 50-131-3]

and place on its side.
Remove the fuse box cover (Item 1) [Figure 50-131-1]. Figure 50-131-4

Figure 50-131-2
1 1
2
1 1
1
S36360
S36358
Remove the screw (Item 1) [Figure 50-131-4].
Remove the four bolts (Item 1) [Figure 50-131-2]. Remove the temperature control knob (Item 2) [Figure
50-131-4].

JOYSTICK PANEL (S/N A8GA13000 & ABOVE, Figure 50-131-6
A8GB13000 & ABOVE) (CONT’D)
1
Figure 50-131-5
1
S36362
1 Mark and remove the connectors from the joystick panel

(Item 1) [Figure 50-131-6].
S36361
Remove the joystick panel.
Remove the nut (Item 1) [Figure 50-131-5].

Remove the temperature control (Item 2) [Figure 50-131-
5] from the joystick panel.

DASH COVER / STEERING COLUMN COVER (S/N Figure 50-140-3
A8GA12999 & BELOW, A8GB12999 & BELOW)
Remove the instrument panel. (See “Removal And

Installation” on Page 60-70-1.) 1
Remove the switch panel. (See “Removal And

Installation” on Page 60-80-1.)
Figure 50-140-1
P-52330
Remove the screw (Item 1) [Figure 50-140-3] from the

right side of the dash.
1 1 Figure 50-140-4

1
P-52328
1
Remove the two screws (Item 1) [Figure 50-140-1] from
the centre of the dash cover.
Figure 50-140-2
1 1
P-52331
1
Remove the four screws (Item 1) [Figure 50-140-4] from

1
the right side of the dash cover.
P-42835
Remove the two dash cover mounting screws (Item 1)

[Figure 50-140-2].

(CONT'D)
Figure 50-140-5
P-42845
1
1
the right side of the column cover.
P-52332 Figure 50-140-8
Remove the five screws (Item 1) [Figure 50-140-5] from

the left side of the dash cover.
Figure 50-140-6
P-42846

left side of the column cover.
P-52335
Lift and remove the dash cover [Figure 50-140-6].

DASH COVER / STEERING COLUMN COVER (S/N
(CONT'D)
Figure 50-140-9
P-42848
Remove the steering column cover [Figure 50-140-9].


DASH COVER / STEERING COLUMN COVER (S/N Remove the signal / travel levers. (See “Removal And
A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE) Installation” on Page 60-61-1.)
Removal And Installation Figure 50-141-3
Figure 50-141-1
1
2
S36364
S36377
Remove the nut (Item 1) and knob (Item 2) [Figure 50-
141-3]
Remove the cover (Item 1) [Figure 50-141-1].

Figure 50-141-2 Figure 50-141-4
2 1
2
1
S36365
S36378
Remove the nut (Item 1) [Figure 50-141-2]. Remove the nut (Item 1) and washer (Item 2) [Figure 50-
141-4].
Remove the steering wheel (Item 2) [Figure 50-141-2].
Installation: Tighten the nut to 40 N•m (29.5 ft-lb) torque.
Remove the instrument panel. (See “Removal And

Remove the switch panel.

(See “SWITCH PANEL (S/N A8GA13000 - 14999,
A8GB13000 - 14999)” on Page 60-81-1.)
(See “SWITCH PANEL (S/N A8GA15000 & ABOVE, S/N
A8GB15000 & ABOVE)” on Page 60-82-1.)

A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)
(CONT’D)

1
2
Figure 50-141-5
S36367
1
Pull out the blower hose [Figure 50-141-7].
Loosen the retainer screw (Item 1) [Figure 50-141-7]

S36366
Remove the cap (Item 2) [Figure 50-141-7].

Remove the louver cap (Item 1) [Figure 50-141-5].

Figure 50-141-8
Figure 50-141-6
1
S36371
S36372
Disconnect the connector (Item 1) [Figure 50-141-8].

Remove the two screws (Item 1) [Figure 50-141-6].

(CONT’D)
Removal And Installation (Cont’d) 2

1
Figure 50-141-9
S36369
Pull out the blower hose [Figure 50-141-11].
Loosen the retainer screw (Item 1) [Figure 50-141-11].

S36368
Remove the cap (Item 2) [Figure 50-141-11].

Remove the louver cap (Item 1) [Figure 50-141-9].

Figure 50-141-12
Figure 50-141-10
S36370
S36373
Remove the two dash cover mounting plugs (Item 1)

[Figure 50-141-12].

(CONT’D)
Figure 50-141-13
2 1
1
1 2
S36376
1 Remove the five screws (Item 1) [Figure 50-141-15] from

the column cover.
S36375 Remove the column cover (Item 2) [Figure 50-141-15].
Remove the seven screws (Item 1) from the dash cover

(Item 2) [Figure 50-141-13].
Lift up the dash cover (Item 2) [Figure 50-141-13].
Figure 50-141-14
S35374

from the dash cover.
Remove the dash cover.

INTERMEDIATE BOOM Figure 50-150-3
Removal of the First Intermediate Boom 1
Remove the boom tray. (See Removal And Installation on 2

Page 50-160-1.)
Remove the extension cylinder. (See Cylinder Group

Remove the end boom. (See Removal on Page 50-40-1.)
Figure 50-150-1
S4611
Disconnect the two screws (Item 1) and the plate (Item 2)

[Figure 50-150-3] at the rear of the intermediate boom.
Figure 50-150-4

1
2 2
S4617
Disconnect the retraction chain at the front of the second

intermediate boom (Item 1) / fixed boom (Item 2) [Figure
50-150-1].
Figure 50-150-2
S3619
Disconnect the spindle (Item 1) and the pulley (Item 2)

Remove the rear wear pads of the first intermediate

boom. (See Removal on Page 50-51-1.)
1
S3617
Begin sliding the first intermediate boom from the second

intermediate boom / fixed boom. Before the intermediate
boom is completely removed, position a hoist and a lifting
strap (Item 1) [Figure 50-150-2] on the front of the boom.
Remove the front wear pads of the second intermediate

boom / fixed boom. (See Removal on Page 50-50-1.)
Carefully remove the intermediate boom completely.

INTERMEDIATE BOOM (CONT’D) Figure 50-150-7
Installation of the First Intermediate Boom
Figure 50-150-5 1
S3619
Connect the spindle (Item 1) and the pulley (Item 2)

S3613
Figure 50-150-8
Apply grease to the inside top and bottom corners of the
second intermediate boom / fixed boom [Figure 50-150-
5].

Install the rear wear pads on the first intermediate boom.
(See Installation on Page 50-51-1.)
Figure 50-150-6 2
1
1
S3617
Install the first intermediate boom (Item 1) into the

second intermediate boom / fixed boom (Item 2) [Figure
50-150-8] approximately 10 in.
Install the front wear pads on the second intermediate

boom / fixed boom. (See Installation on Page 50-50-2.)
S4611
Remove the hoist and lifting strap and slide the first
Connect the two screws (Item 1) and the plate (Item 2) intermediate boom fully into the second intermediate
[Figure 50-150-6] at the rear of the intermediate boom. boom / fixed boom.

INTERMEDIATE BOOM (CONT’D) Removal of the Second Intermediate Boom (T40170)
Installation of the First Intermediate Boom (Cont’d) Remove the first intermediate boom See “Removal of the
First Intermediate Boom” on page 50-150-1
Figure 50-150-9
Figure 50-150-10
S3584
1
S4617
Connect the retraction chain at the front of the second

intermediate boom / fixed boom (Item 1) [Figure 50-150- Disconnect the retraction chain at the front of the fixed
9]. boom (Item 1) [Figure 50-150-10].

Install the end boom. (See Installation on Page 50-40-3.) Figure 50-150-11
Install the extension cylinder. (See Cylinder Group

1
Install the boom tray. (See Removal And Installation on
Page 50-160-1.)
Adjust the extension and retraction chains. (See

S3617
Begin sliding the intermediate boom from the fixed boom.

Before the intermediate boom is completely removed,
position a hoist and a lifting strap (Item 1) [Figure 50-
150-11] on the front of the boom.
Remove the front wear pads of the fixed boom. (See

Removal on Page 50-50-1.)
Carefully remove the intermediate boom completely.

INTERMEDIATE BOOM (CONT’D) Installation of the Second Intermediate Boom
(T40170)
Removal of the Second Intermediate Boom (T40170)
(Cont’d) Figure 50-150-14
Figure 50-150-12
1
S3613
S4611
Apply grease to the inside top and bottom corners of the
fixed boom [Figure 50-150-14].
Disconnect the two screws (Item 1) and the plate (Item 2)
[Figure 50-150-12] at the rear of the intermediate boom. Install the rear wear pads on the intermediate boom.
(See Installation on Page 50-51-1.)

Figure 50-150-13
Figure 50-150-15
1
1
2
2
S3619
S4611
Disconnect the spindle (Item 1) and the pulley (Item 2)

[Figure 50-150-13] at the rear of the intermediate boom. Connect the two screws (Item 1) and the plate (Item 2)
Remove the rear wear pads of the intermediate boom.
(See Removal on Page 50-51-1.)

INTERMEDIATE BOOM (CONT’D) Figure 50-150-18
Installation of the Second Intermediate Boom

(T40170) (Cont’d)
Figure 50-150-16
1 1
S3584
Connect the retraction chain at the front of the fixed boom

(Item 1) [Figure 50-150-18].
S3619
Install the first intermediate boom (See “Installation of the
First Intermediate Boom” on page 50-150-2).
Connect the spindle (Item 1) and the pulley (Item 2)
[Figure 50-150-16] at the rear of the intermediate boom. Adjust the extension and retraction chains. (See

Figure 50-150-17
S3617
Install the intermediate boom (Item 1) into the fixed boom

(Item 2) [Figure 50-150-17] approximately 10 In.
Install the front wear pads on the fixed boom. (See

Remove the hoist and lifting strap and slide the first
intermediate boom fully into the fixed boom.


BOOM TRAY Figure 50-160-3
Figure 50-160-1
1
2
1
S4500
Remove the rear cover (Item 1) [Figure 50-160-3] from

the machine.
S3575
Figure 50-160-4
Fully extend the boom and remove the two attachment
screws (Item 1) located on top of the last element, except
for the screw (Item 2) [Figure 50-160-1] located at the
head of the boom.

Figure 50-160-2
1
2
S4555
1
Disconnect the light harness connector (Item 1) (If

equipped) and the secondary auxiliary harness
connector (Item 2) [Figure 50-160-4] (If Equipped) at the
rear of the boom.
S4652
Retract the boom gently and remove the remaining screw

(Item 1) [Figure 50-160-2].

BOOM TRAY (CONT’D) Figure 50-160-7
Figure 50-160-5
S4655
Disconnect the four hydraulic hoses (Item 1) [Figure 50-

160-7] at the front of the boom.
S4654
Figure 50-160-8
Disconnect the two connectors (Item 1) [Figure 50-160-
5] at the front of the boom (If Equipped).

1 1
IMPORTANT
S4557
damage the system.
I-2003-0888 Remove the four attachment screws (Item 1) [Figure 50-
160-8] at the rear of the boom.
Figure 50-160-6
S4555
Disconnect the four hydraulic hoses (Item 1) [Figure 50-

160-6] from the tubelines at the rear of the boom.

BOOM TRAY (CONT’D) Figure 50-160-11

1
Figure 50-160-9
S4656
1
Extract the boom tray (Item 1) [Figure 50-160-11]

through the rear of the boom.
S4576
Figure 50-160-12
Remove the two attachment screws (Item 1) and remove
the block (Item 2) [Figure 50-160-9].
Figure 50-160-10

1
S4657
1
Extend the boom tray by pulling at the end of the
tubelines (Item 1) [Figure 50-160-12].
S4575
Remove the two attachment screws (Item 1) and skid

(Item 2) [Figure 50-160-10].

BOOM TRAY (CONT’D)
Figure 50-160-13
S3610
Disconnect the tubelines (Item 1) [Figure 50-160-13].

STABILISER FRAME Figure 50-170-3
Removal
Figure 50-170-1
1
S2818

S3216 valve block. Put a blank plug on the hose and pull the
hose back into the machine frame.
Lift the stabilisers and extend and support the boom on Figure 50-170-4
adequate stands [Figure 50-170-1].

Figure 50-170-2
1
1
S7486
S3217 Support the stabiliser frame with a sling or chain (Item 1)

[Figure 50-170-4].
Remove the two hoses for oil flow from and to the Note: Position the sling / chain as close as possible
machine (Item 1) [Figure 50-170-2]. Put blank plugs on to the centre of gravity of the stabiliser frame
the hoses and pull them back into the machine frame. (see [Figure 50-170-4]).
Note: Firmly tighten the blank plugs. When starting

the machine there will be permanent hydraulic
pressure on one of the hoses (port ‘P’ on
valve block).

STABILISER FRAME (CONT’D) Installation
Removal (Cont’d) Figure 50-170-7
Figure 50-170-5
S7486
S3214
Move the palet with the stabiliser frame under the boom.
Install a sling or chain on the stabiliser frame as shown
Place a hand pallet truck with empty pallet under the [Figure 50-170-7].
stabiliser frame and remove the two lower bolts (Item 1).
Then carefully remove the upper two bolts (Item 2) NOTE: Position the sling / chain as close as possible

[Figure 50-170-5]. to the centre of gravity of the stabiliser frame
(see [Figure 50-170-7]).
Figure 50-170-6
Start the machine and slowly raise the boom until the
stabiliser frame is in the right position [Figure 50-170-7].
Slowly lower the boom on adequate stands [Figure 50-

170-7].
Figure 50-170-8
S7486
1
Start the machine and slowly lift the boom a bit
[Figure 50-170-6].
Remove the stand which supports the boom.

S3214
Slowly lower the boom until the stabiliser frame rests
safely on the pallet [Figure 50-170-6].
Put the stabiliser frame in place and install the two upper
bolts (Item 2). The install the two lower bolts (Item 1)
[Figure 50-170-8].

STABILISER FRAME (CONT’D) Figure 50-170-11
1
Figure 50-170-9
S3217
Install the two hoses for oil flow from and to the machine
S7486 (Item 1) [Figure 50-170-11].
Figure 50-170-12
Remove the sling or chain (Item 1) [Figure 50-170-9]
from the stabiliser frame.

Figure 50-170-10
S3216
Raise the boom and remove the stands [Figure 50-170-

S2818 12].
Install the hose (Item 1) [Figure 50-170-10] to the valve

block.


FRONT WEIGHT Figure 50-180-3
Figure 50-180-1
1 1
1 1
S4621
Screw a hoisting bolt in the hole of the front weight as

S4619
shown in [Figure 50-180-3].
Remove the two hydraulic tubeline support blocks (Item Release the front weight from the machine by removing
1) [Figure 50-180-1] by removing the screws. the bolts and nuts (Item 1) [Figure 50-180-3].

Figure 50-180-2 Remove the front weight from the machine by lifting it up
and pulling it back.
S4547

front weight.


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION (S/N A8GA12999 & BELOW, S/N A8GB12999 &
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
Fuses, Diode And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
ELECTRICAL SYSTEM INFORMATION (S/N A8GA13000 & ABOVE, S/N A8GB13000 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-2
Fuses, Diodes And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
TRAVEL / SIGNAL LEVER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW) 60-60-1
TRAVEL / SIGNAL LEVER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE) 60-61-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

SWITCH PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW) . . . . . . . . . . . 60-80-1
Parts description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
SWITCH PANEL (S/N A8GA13000 - 14999, A8GB13000 - 14999) . . . . . . . . . . . . . . . 60-81-1

SWITCH PANEL (S/N A8GA15000 & ABOVE, S/N A8GB15000 & ABOVE) . . . . . . . . . 60-82-1

BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
WIPER MOTOR (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

WIPER MOTOR (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-101-1

WIPER MOTOR (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-102-1

PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

SERVICE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Connecting The Laptop Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Entering The Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3
Warnings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-5
Calibrate Inch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Calibrate Creep Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-7
Program / Update Susmic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
FRAME LEVEL SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8GA11001-14999,

S/N A8GB11001-14999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Fitting The Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/N A8GB15000 & ABOVE) . . . 60-160-1
System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-3
System Failure Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
System Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-9
LLMS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-10
LLMS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-12
LLMC Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-14
LLMC Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-16
BCC MAIN CONTROLLER (S/N A8GA12001 & ABOVE, S/N A8GB12001 & ABOVE) 60-170-1

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ELECTRICAL SCHEMATIC
T40140 (S/N A8GA1100 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
Printed FEBRUARY 2012
Page 2 of 19
Printed in Brussels 6921109
510 of 895
T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
Printed FEBRUARY 2012

Page 3 of 19
6921109
Printed in Brussels
511 of 895
T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
Printable Version Click Here T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
Printable Version Click Here T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
523 of 895
T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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T40140 (S/N A8GA11001 A8GA11999)
Printable Version Click Here T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
525 of 895
T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
526 of 895
T40140 (S/N A8GA11001 A8GA11999)
T40140 (S/N A8GC1100 A8GC11999)
T40170 (S/N A8GB1100 A8GB11999)
T40170 (S/N A8GD1100 A8GD11999)
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ELECTRICAL SYSTEM INFORMATION (S/N
A8GA12999 & BELOW, S/N A8GB12999 & BELOW)
Troubleshooting Chart WARNING

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 authorised Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE

Battery will not take 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

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The earth connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.


ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diode And Relay Location / Identification
(CONT’D) The electrical system is protected by fuses, diodes and
relays.
Description
Figure 60-10-1
The telescopic handler has a 12 volt, negative ground
alternator charging system. The electrical system is
protected by fuses located in the cab in the right console.
The fuses will protect the electrical system when there is
an electrical overload. The reason for the overload must
be found before starting the engine again. 1
S40025
Remove the console cover (Item 1) [Figure 60-10-1].

Figure 60-10-2
1 1
P-52172
Remove the cover(s) from the rows of fuses / relays /

diodes (Item 1) [Figure 60-10-2] to check or replace
fuses, diodes or relays.
Two relays and three fuses are located in the rear of the
engine compartment.

ELECTRICAL SYSTEM INFORMATION (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW) (CONT’D)
Fuses, Diode And Relay Location / Identification (Cont’d)
Figure 60-10-3

E18
F3
F2
F1
E2
E1
S6934

A8GA12999 & BELOW, S/N A8GB12999 & BELOW) REF GAUGE FUNCTION PROTECTED
(CONT’D) 32 7.5 A Fan direction reversing (option)
and side offset correction
Fuses, Diode And Relay Location / Identification
(Cont’d)
01 20 A Air conditioning fan (option)
Fuses And Diodes [Figure 60-10-3] 02 7.5 A Air conditioning compressor
(option)
REF GAUGE FUNCTION PROTECTED F01 50 A Switched power fuse (+)
1 15 A Front work lights F02 40 A Unswitched power fuse (+)
2 15 A Rear work lights F03 50 A Preheat (glow plugs)
3 10 A Lighting and full-beam control Relays [Figure 60-10-3]
4 15 A Headlamps
5 7.5 A Road alarm and ceiling light REF FUNCTION PERFORMED
6 15 A Full-beam 1 Front work lights
7 10 A Cigarette lighter 2 Rear work lights
8 7.5 A Left side-lights 3 Road horn
9 7.5 A Right side-lights 4 Not used
10 7.5 A Hazard warning lights 5 Hydraulic function on boom

11 DIODE 1 A Parking brake 6 Headlamps
12 DIODE 1 A Advance safety if parking brake 7 Full-beam
tight
8 Advance safety if parking brake tight
13 10 A Second hydraulic function on
9 Starting safety if transmission is in gear
boom (option)
10 Not used
14 15 A Joystick control box
11 Slow travel speed
15 7.5 A Stability indicator and fuel pump
12 Second hydraulic function on boom
16 3A Hydraulic function on boom
13 Backup lights/backup alarm
17 7.5 A Rotating beacon (option)
14 Not used
18 10 A Brake lights, rear hydraulic
options, stop lights 15 Prevent raising of the stabilisers
19 7.5 A Slow travel speed 16 Stabilisers
20 15 A Front wiper 17 Raise left stabiliser
21 7.5 A Transmission control box supply 18 Raise right stabiliser
22 7.5 A Engine cutoff 19 Radio control for acceleration of the engine
23 7.5 A Joystick supply 20 Not used
24 7.5 A Direction indicators 21 Not used
25 10 A Steering mode control
26 20 A Heating fan E01 Starting motor relay
27 7.5 A Direction of travel E02 Preheat relay
28 7.5 A Instrument panel supply
29 10 A Reversing light and roof E15 12V power relay after contact
windscreen wiper (option) E16 Air conditioning compressor (option)
30 7.5 A Rear windscreen wiper: Rear E17 Air conditioning fan (option)
windscreen and roof washer
E18 Centre for the directional signals (located
31 10 A Boom angle measurement beneath the fuse box)

(CONT’D)
Fuses, Diodes And Relays (Cont’d)
Figure 60-10-4
S3531
3 5

4
1
S3533

compartment. The relay/fuse receptacles are located
under the air conditioning compressor [Figure 60-10-4].
FUSES
Ref. Description Amp

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
Ref. Description
4 Starting Motor Relay
5 Preheat Relay

ELECTRICAL SYSTEM INFORMATION (S/N AVOID INJURY OR DEATH
A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE) Instructions are necessary before operating or
servicing machine. Read and understand the
Troubleshooting Chart Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
The following troubleshooting chart is provided for warnings and instructions in the manuals when
assistance in locating and correcting problems which are making repairs, adjustments or servicing. Check for
most common. Many of the recommended procedures correct function after adjustments, repairs or
must be done by authorised Bobcat Service Personnel service. Untrained operators and failure to follow
only. instructions can cause injury or death.
W-2003-0807
WARNING
PROBLEM CAUSE
Battery will not take 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


1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The earth connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diodes And Relays
(CONT’D) Figure 60-11-2
Description
Figure 60-11-1 1 1
P-97029
The electrical system is protected by fuses, diodes and

P-97028 relays.
Remove the console cover (Item 1) [Figure 60-11-2].

The telescopic handler has a 12 volt, negative earth

alternator charging system. The electrical system is
Remove the cover(s) from the rows of fuses / relays /
protected by fuses located in the cab in the right console
diodes (Item 1) [Figure 60-11-2] to check or replace
(Item 1) [Figure 60-11-1].
fuses, diodes or relays.
The fuses will protect the electrical system when there is
Two relays and two fuses are located in the rear of the
an electrical overload. The reason of the overload must
engine compartment.
be found before starting the engine again.

ELECTRICAL SYSTEM INFORMATION (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE) (CONT’D)
Fuses, Diodes And Relay Location / Identification (Cont’d)
Figure 60-11-3
28
12 *
32 21 14 7
27
11
26 16
20 13 6 10
31 25
9
24 12 5 15
19 8
23
4 7
18 11
22 6
21 17 5
3
30 10 14
20 4
19 16 9 2 3
13
29 18 2
15 8 1
17

1
P-97030
The location and description are shown below and [Figure 60-11-3]
FUSES AND DIODES RELAYS

Ref Description. Amp Ref. Description Amp Ref Description
1 Rear Work Lights 15 21 Travel Controller 15 1 Rear Work Lights
2 Front Work Lights 15 22 Fuel Pump / Brake Fail Pressure 7.5 2 Front Work Lights
Switch (If Equipped)
3 Headlights 10 23 Joystick 7.5 3 Horn
4 Low Beam Headlights 15 24 Direction Signal 7.5 4 Blue Work Lights (If Equipped)
5 Horn, Cab Light 7.5 25 Steering Mode Valve 10 5 Front Auxiliary Hydraulic
6 High Beam Headlights 15 26 Heater and HVAC 30 6 Low Beam Headlights
7 12V Accessory Plug 10 27 Travel Direction 7.5 7 High Beam Headlights
8 Left Park Lights 7.5 28 Instrument Panel 7.5 8 Transmission / Parking Brake
9 Right Park Lights 7.5 29 Top Wiper, Rear Travel Light 10 9 Neutral Start
10 Hazard Lights 7.5 30 Rear Wiper, Rear and Top Washer 7.5 10 Not Used
11 Parking Brake D* 31 Boom Angle Sensor 10 11 Low Travel Speed
12 Transmission / Parking Brake D* 32 Reverse Cooling Fan / Frame Levelling 7.5 12 2nd Auxiliary Hyd
13 2nd Auxiliary Hyd 10 13 Backup Lights / Back-up Alarm
14 Control Box 7.5 14 Fuel Pump
15 Longitudinal Stability 7.5 15 Stabiliser Locking System
Indicator / AMA / Fuel Pump (Optional)
16 Front Auxiliary Hyd 3 16 Stabiliser Lockout
17 Rotating Beacon 7.5 17 Raise Left Stabiliser
18 Stop Lights / Rear Aux hyd 10 18 Raise Right Stabiliser
19 Low Travel Speed 7.5 19 Radio control for throttle
20 Front Wiper 15 20 Stabiliser Locking System
(Optional)
21 Reverse Cooling Fan
*D - Diodes (Items 11 and 12) inserted with the tab toward the front of the machine [Figure 60-11-3].

(CONT’D)
Fuses, Diodes And Relays (Cont’d)
Figure 60-11-4
S3531
3 5

4
1
S3533

compartment. The relay / fuse receptacles are located
next to the air conditioning compressor [Figure 60-11-4].
FUSES
Ref. Description Amp

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
Ref. Description
4 Starting Motor Relay
5 Preheat Relay

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. 1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention P-42338
and wash eye with clean, cool water for at least 15
minutes.
Remove the battery hold down clamp (Item 1) [Figure
If electrolyte is taken internally drink large quantities 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Figure 60-20-3
W-2065-0807

Figure 60-20-1
2 1
P-42341
Always disconnect the negative cable (Item 1) [Figure

P-50821 60-20-3] first to prevent sparks.
Remove the positive battery cable (Item 2) [Figure 60-

Remove the battery access door (Item 1) [Figure 60-20- 20-3].
1].
Remove the battery.

BATTERY (CONT'D)
Servicing
Figure 60-20-4
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
P-29246
Figure 60-20-6
Figure 60-20-5

S4895
S4894
The battery cables must be clean and the connections

Always clean the terminals and cable ends when tight. Remove acid or corrosion from the battery and
installing a new battery [Figure 60-20-4] and [Figure 60- cables with a sodium bicarbonate (baking soda) and
20-5]. water solution [Figure 60-20-6].
When installing the battery in the machine, do not touch Check the electrolyte level in the battery. Add distilled
any metal parts with the battery terminal posts. water as needed.
Connect and tighten the battery cables. Connect the Put Battery Saver (P/N 6664458) or grease on the
negative (-) cable last to prevent sparks. battery terminals and cable ends to prevent corrosion.

BATTERY (CONT'D)
Using A Booster Battery (Jump Starting)
If it is necessary to use a booster battery to start the

IMPORTANT
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and Damage to the alternator can occur if:
disconnect the battery cables. (Booster Cables) • Engine is operated with battery cables
disconnected.
The key switch must be OFF. The booster battery must • Battery cables are connected when using a fast
be 12 volt. charger or when welding on the Telescopic
Handler. (Remove both cables from the battery.)
Figure 60-20-7 • Extra battery cables (booster cables) are
connected wrong.
I-2345-0311
Figure 60-20-8
1 2

P-50821
Remove the battery access door (Item 1) [Figure 60-20-

7]. P-42339
NOTE: The battery compartment is located in front of

the left rear tyre, on the back side of the cab. Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the positive terminal (Item 1) [Figure
60-20-8] on the telescopic handler battery.
WARNING Connect the end of the second cable to the negative (-)
terminal of the booster battery. Connect the other end of
BATTERY GAS CAN EXPLODE AND CAUSE the same cable to the negative terminal (Item 2) [Figure
SERIOUS INJURY OR DEATH 60-20-8] on the telescopic handler battery.
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery Keep cables away from moving parts. Start the engine.
make final connection (negative) at machine frame.
After the engine has started, remove the earth (-) cable
Do not jump start or charge a frozen or damaged (Item 2) [Figure 60-20-8] first.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before Remove the cable from the positive terminal (Item 1)
connecting or disconnecting cables to battery. Never [Figure 60-20-8].
lean over battery while boosting, testing or charging.
W-2066-0910


ALTERNATOR Figure 60-30-3
Figure 60-30-1
1 S6841
Loosen and remove the alternator adjusting bolt (Item 1)

S6840 [Figure 60-30-3].
Figure 60-30-4

Remove the four bolts (Item 1) and belt shield (Item 2)
[Figure 60-30-1].
1
Figure 60-30-2
S6842
Loosen and remove both mounting bolts (Item 1) [Figure

60-30-4].
1
S6851 Remove the alternator.
Remove the three connectors (Item 1) [Figure 60-30-2]

from the back of the alternator.

ALTERNATOR (CONT’D) Figure 60-30-7
Adjusting The Alternator Belt
Stop the engine.
Open the engine cover. 1
Figure 60-30-5
S6844
Move the alternator until the belt has 8,0 mm (0.3125 in)
1 movement at the middle of the belt span (Item 1) [Figure
60-30-7] with 20 N•m (15 ft-lb) of force.
Tighten the adjustment and mounting bolts.

S6840

Install the belt shield.
Remove the four bolts (Item 1) and the belt shield (Item Close the engine cover.
2) [Figure 60-30-5].
Figure 60-30-6
2
S6843
Loosen the two alternator mounting bolts (Item 1)

[Figure 60-30-6].
Loosen the adjustment bolt (Item 2) [Figure 60-30-6].

STARTER Removal And Installation
Testing Figure 60-40-3
Figure 60-40-1
Bat
S 1
M
Cranking
Motor
P18440
A-1992
The key switch must be in the OFF position. the battery.

The battery must be at full charge. Figure 60-40-4
The cable connections on the battery must be clean and
tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
2 1
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Bat
S
M P-53364
Remove the access cover mounting bolt (Item 1) and

remove the access cover (Item 2) [Figure 60-40-4].
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT’D)
Figure 60-40-5
S6849
Remove the three wires (Item 1) [Figure 60-40-5] from

the starter.

Figure 60-40-6
1
S6850
Remove the three nuts and bolts (Item 1) [Figure 60-40-

6] and remove the starter.
Installation: Tighten to 54 - 61 N•m (40 - 45 ft-lb) torque.
NOTE: The starter is not serviceable. If starter is

damaged the entire assembly must be
replaced.

STARTER (CONT’D)
1. Housing
2. Seal
3. Dowel
4. Screw
5. Screw Not available at time of printing.
6. Starter motor
7. Stud
8. Nut
S4896


LIGHTS Figure 60-50-3
Rear Light Removal And Installation
Figure 60-50-1
1
1
P-29537
1
Remove the two lens retainer screws (Item 1)
1 [Figure 60-50-3].
S7421
Figure 60-50-4
Remove the two rear cover mounting bolts (Item 1)
[Figure 60-50-1]. Remove the cover.

Figure 60-50-2
1 1 1
P-27804
Remove the two light mounting bolts (Item 1) [Figure 60-

P-50973 50-4].
Remove the light assembly.

Disconnect the light harness connector (Item 1) [Figure
60-50-2] from the main harness.

LIGHTS (CONT'D) Figure 60-50-6
Front Light Removal And Installation
Figure 60-50-5
1
P-27806
1
Remove the two bolts (Item 1) [Figure 60-50-6] and
remove the light.
P-27805

Disconnect the harness (Item 1) [Figure 60-50-5] from
the light.

LIGHTS (CONT'D) Figure 60-50-9
Front Light Removal And Installation (Cont’d)

3
Figure 60-50-7 1
1
2
S36331
Disconnect the connectors (Item 1) and remove the light

(Item 2) [Figure 60-50-9].
1 Loosen the indicator light (Item 3) [Figure 60-50-9].
S36329
Figure 60-50-10

Remove six screws (Item 1) [Figure 60-50-7] from the
light.
Figure 60-50-8
2
1
1
S36332
Disconnect the connector (Item 1) and remove the

S36330 indicator light (Item 2) [Figure 60-50-10].
Loosen the front light (Item 1) [Figure 60-50-8].


TRAVEL / SIGNAL LEVER (S/N A8GA12999 & Figure 60-60-3
BELOW, S/N A8GB12999 & BELOW)

1
Installation on Page 60-70-1)
Figure 60-60-1
1 P-52344
Disconnect the two signal control wire connectors (Item

1) [Figure 60-60-3].
Figure 60-60-4
P-52340

the battery. 1
Figure 60-60-2
1
1
P-52345

the travel / signal levers.
P-52343
Disconnect the travel control wire harness connector

(Item 1) [Figure 60-60-2].

BELOW, S/N A8GB12999 & BELOW) (CONT’D)
Figure 60-60-5
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-60-7] in the steering
P-52347 column.
Remove the signal lever (Item 1) [Figure 60-60-5].

Figure 60-60-6
P-52348
Remove the travel lever (Item 1) [Figure 60-60-6].

ABOVE, S/N A8GB13000 & ABOVE)
Figure 60-61-1
1
S36380

P-52340
NOTE: Steering wheel is removed for photo clarity.
Rotate the battery disconnect switch (Item 1) [Figure 60- Figure 60-61-4

the battery.

Installation on Page 60-70-1)
Figure 60-61-2 1
P-52347
Remove the signal lever (Item 1) [Figure 60-61-4].
S36379
Disconnect the signal and travel control wire harness

connectors (Item 1) [Figure 60-61-2].

TRAVEL / SIGNAL LEVER (S/N A8GA13000 &
ABOVE, S/N A8GB13000 & ABOVE) (CONT’D)
Figure 60-61-5
P-52348
Remove the travel lever (Item 1) [Figure 60-61-5].

Figure 60-61-6
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-61-6] in the steering
column.

INSTRUMENT PANEL Figure 60-70-3

1
Figure 60-70-1
1
1
P-52323
Remove the five instrument panel mounting bolts (Item 1)

[Figure 60-70-3].
P-25486 Figure 60-70-4

Remove the temperature control knob (Item 1) [Figure
60-70-1] (If Equipped).
Figure 60-70-2
1
P-25580
Tilt the instrument panel forward and disconnect all

connectors [Figure 60-70-4]. Remove the instrument
panel.
P-25487
NOTE: Mark the connectors for correct installation.
Remove the nut (Item 1) [Figure 60-70-2] letting the

temperature controller fall inward.

INSTRUMENT PANEL (CONT’D) Figure 60-70-6

2
Figure 60-70-5 1
S36323
1 1
Disconnect the two connectors (Item 1) [Figure 60-70-6].
Remove the instrument panel (Item 2) [Figure 60-70-6].

S36324

Pry a sharp flat tool under the rim on both sides (Item 1)
of the instrument panel (Item 2) [Figure 60-70-5].
Push in the metal plates on both sides (Item 1) and pull

out the instrument panel (Item 2) [Figure 60-70-5].

SWITCH PANEL (S/N A8GA12999 & BELOW, Figure 60-80-2
A8GB12999 & BELOW)
Figure 60-80-1
P-52325
1
Disconnect the harness connectors from the back of the
switch panel [Figure 60-80-2].
S4603
NOTE: Mark all connectors for ease of installation.
Remove the five screws (Item 1) [Figure 60-80-1]. Remove the switch panel.

SWITCH PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW) (CONT’D)
Parts description
39
34 14
13
35 12
15
32 18
33
5
19
2 17 21
16 19
4
1
30 24
20
6
19
7
31
22
28 27

25 26
8
23
3
9
29
10
10
11
WITHOUT FRAME LEVELING
36 37 38 40 41 S3087

SWITCH PANEL (S/N A8GA12999 & BELOW,
A8GB12999 & BELOW) (CONT’D)
Parts Description (Cont’d)
1. L.H. control panel plate

2. R.H. control panel plate
3. Screw
4. Instrument panel
5. Bezel
6. Switch, beacon light
7. Warning Switch
8. Heating Control Valve
9. Fan Speed Switch
10. Bezel for outer left and right positions
11. Bezel for middle positions
12. Trailer turn indicator
13. Steering mode indicator
14. Steering mode switch
15. Lever Switch
16. Switch, head lamp
17. Working light switch
18. Fog light switch
19. Blank Plug

20. Switch, rear wiper / washer
21. Switch, roof wiper (Option)
22. Switch, transmission mode
23. Locking switch
24. Switch, aux. hydr.
28. Start Switch
29. Set of keys (Start)
30. Knob
31. Set of keys
32. Screw
33. Stability indicator and wire harness
34. Washer
35. Nut
36. Support for frame levelling knob
37. Screw
38. Switch (proportional)
39. Spacer
40. Screw
41. Plate


SWITCH PANEL (S/N A8GA13000 - 14999, Figure 60-81-3
A8GB13000 - 14999)

2
Figure 60-81-1
1 S36354
1
Disconnect both LSI connectors from the back of the

switch panel [Figure 60-81-3].
2
S36355
Remove the switch panel (Item 2) [Figure 60-81-3].
Remove the six screws (Item 1) [Figure 60-81-1]. Disconnect both LLMI connectors (Item 1) [Figure 60-81-

3].
Remove the Start key and nut cover (Item 2) [Figure 60-
81-1] from the switch panel. Remove the switch panel (Item 2) [Figure 60-81-3].
Figure 60-81-2
3
2
S39224
Take out the switch row (Item 1) from the switch panel in
order to have a grip on the Start key switch and remove
the nut from the Start key switch (Item 2) [Figure 60-81-
2].
Press the Start key switch (Item 2) [Figure 60-81-2] into

the switch panel.
Disconnect the connectors from the switch panel

switches.


SWITCH PANEL (S/N A8GA15000 & ABOVE, S/N Figure 60-82-2
A8GB15000 & ABOVE)
Figure 60-82-1
1
3
2
1
S39224
1
1 order to have a grip on the Start key switch and remove
2].
2 Press the Start key switch (Item 2) [Figure 60-82-2] into

the switch panel.
S38712
Disconnect the connectors from the switch panel
switches.
Remove the six screws (Item 1) [Figure 60-82-1].
82-1] from the switch panel. Figure 60-82-3
S39443
Disconnect both LLMI connectors (Item 1) [Figure 60-82-

3].


BRAKE LIGHT SWITCH Adjustment

S/N A8GA13000 & Above, S/N A8GB13000 & Above: 2
Remove the dash cover / steering column cover. 1

Figure 60-90-1
P-27150

Loosen the nut (Item 1) [Figure 60-90-3].

1 With the brake pedal at rest, turn the adjustment bolt
(Item 2) [Figure 60-90-3] until it touches the brake light
switch plug.
P-52341 Tighten the nut (Item 1) [Figure 60-90-3].
Disconnect the switch connector (Item 1) [Figure 60-90-

1] from the wiring harness.
Figure 60-90-2
P-27149
Loosen the nut (Item 1) [Figure 60-90-2]. Remove the

switch.


WIPER MOTOR (FRONT) Figure 60-100-3
S/N A8GA12999 & Below, S/N A8GB12999 & Below: 1


Figure 60-100-1
P-25646
Remove the two mounting bracket bolts (Item 1) [Figure

1 1
60-100-3].
Figure 60-100-4

P-25644
Remove the four lower mounting bracket bolts (Item 1)

[Figure 60-100-1].
Figure 60-100-2
P-25920
1 Reposition the steering column assembly (as shown)

[Figure 60-100-4].
P-25645
Disconnect the front wiper connector (Item 1) [Figure 60-

100-2] from the main harness.
Reposition the main wire harness to the right side of the

cab.

WIPER MOTOR (FRONT) (CONT'D) Figure 60-100-7
Figure 60-100-5
P-25641
Remove the wiper arms from the wiper motor shafts

P-25639 [Figure 60-100-7].
Figure 60-100-8
Remove the spray tube (Item 1) [Figure 60-100-5].

Figure 60-100-6 1
1 1
P-25642
P-25640 Remove both outer nuts (Item 1) [Figure 60-100-8].
Flip the wiper covers and remove the two nuts (Item 1)
[Figure 60-100-6].

WIPER MOTOR (FRONT) (CONT'D) Figure 60-100-10
Figure 60-100-9
P-25647
Remove the wiper motor from inside the cab [Figure 60-
P-25643 100-10].
Remove both inner nuts and washers (Item 1) [Figure

60-100-9].


WIPER MOTOR (TOP) Figure 60-101-3
Figure 60-101-1
P-25655
1
Disconnect the wiper motor connector (Item 1) [Figure
P-52342 60-101-3] from the harness.
Figure 60-101-4
Remove the three screws (Item 1) [Figure 60-101-1]
from the upper panel.

Figure 60-101-2
P-25649
Remove the squirter tube (Item 1) [Figure 60-101-4].

P-25654
Slide the upper panel forward on the support rails

[Figure 60-101-2].
Lower the panel.

WIPER MOTOR (TOP) (CONT'D) Figure 60-101-7

1
Figure 60-101-5
2 P-25651
Remove the plastic nut (Item 1) and extension post (Item

P-25648 2) [Figure 60-101-7].
Figure 60-101-8
Flip open the wiper covers and remove the nut (Item 1)
and clip (Item 2) [Figure 60-101-5].

1
Figure 60-101-6
P-25652
While supporting the wiper motor inside the cab, have an

P-25650 assistant remove the two nuts (Item 1) [Figure 60-101-
8].
Remove the wiper arms from the wiper shafts [Figure Remove the wiper motor.
60-101-6].

WIPER MOTOR (REAR) Figure 60-102-3
Figure 60-102-1
P-25658
1
1 Flip open the wiper cover and remove the nut (Item 1)
P-52342 [Figure 60-102-3].
Figure 60-102-4
Remove the three screws (Item 1) [Figure 60-102-1]
from the upper panel and slide the upper panel forward.

Figure 60-102-2
P-25659
1 Remove the wiper arm [Figure 60-102-4].

P-25656
Disconnect the rear wiper motor connector (Item 1)

[Figure 60-102-2] from the harness.

WIPER MOTOR (REAR) (CONT'D) Figure 60-102-6
Figure 60-102-5
1
P-25660
Remove the plastic cover (Item 1) and two nuts (Item 2)

P-25662 [Figure 60-102-6].
Remove the wiper motor.

Have an assistant support the wiper motor [Figure 60-
102-5].

PEDAL ASSEMBLY Figure 60-110-3


Figure 60-110-1
P-25249
Remove the accelerator cable (Item 1) from the pedal

Figure 60-110-4

1
P-52341

from the brake light switch.
1
Figure 60-110-2
P-25638
1 Remove the three hoses (Item 1) [Figure 60-110-4] from

the brake valve.
IMPORTANT
P-42865
Disconnect the connector (Item 1) [Figure 60-110-2] tubelines and ports to keep dirt out. Dirt can quickly
from the inching switch. damage the system.
I-2003-0888

PEDAL ASSEMBLY (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 60-110-6
Figure 60-110-5
1 2
P-42869
1
P-25637
Remove the bolt (Item 1) and spring (Item 2) [Figure 60-
110-6].
Remove the mounting bolts (Item 1) [Figure 60-110-5].
Figure 60-110-7

Remove the pedal assembly.
P-42870
Remove the roll pin (Item 1) and pedal (Item 2) [Figure

60-110-7].

PEDAL ASSEMBLY (CONT’D) Figure 60-110-10

1
Figure 60-110-8
1
1
1
P-42874
Remove the three bolts (Item 1) [Figure 60-110-10] from

P-42871 both bearing flanges.
Figure 60-110-11
Installation: Align the hole (Item 1) in the pedal with the
hole (Item 2) [Figure 60-110-8] in the shaft.

Figure 60-110-9
P-42875
Remove the shaft and bearing assembly [Figure 60-110-

P-42872 11].
Loosen the two set screws (Item 1) [Figure 60-110-9] on

the two bearings.

Figure 60-110-12
1 2 1
2
P-42877
2 Remove the four bolts (Item 1), spacers (Item 2)

P-42876 [Figure 60-110-14] and nuts from the brake valve.
Figure 60-110-15
Remove the flanges (Item 1) and bearings (Item 2)
[Figure 60-110-12].

Figure 60-110-13
P-42879
Remove the brake valve (Item 1) [Figure 60-110-15].

P-42878
Remove the three fittings (Item 1) [Figure 60-110-13]

from the brake valve.

Figure 60-110-16
1
2 P-42881
Remove the pedal (Item 1) [Figure 60-110-17].

P-42880
Remove the retainer pin (Item 1) and washer (Item 2)

[Figure 60-110-16].


INCHING SWITCH Adjustment


Figure 60-120-1

P-42865
Remove the tie strap (Item 1) and disconnect the switch S40034
connector (Item 2) [Figure 60-120-1] from the harness.
Figure 60-120-2 Remove the dash cover / steering column cover.

With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) so that it is 8 mm (0.31 in) away
from the switch body (Item 2) [Figure 60-120-3].
Check that the potentiometer rod (Item 3) [Figure 60-

120-3] is in contact with the centre of the adjusting bolt.
When adjustment is complete, tighten the nut (Item 4)

[Figure 60-120-3] without turning the adjusting bolt.
1
1
P-27147
Remove the two mounting bolts and nuts (Item 1) [Figure

60-120-2].
Installation: Be sure the switch is on the front side of the

mounting bracket.
Remove the switch.


SERVICE SOFTWARE Figure 60-130-3
Connecting The Laptop Computer S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW
Figure 60-130-1

1
P-47340
Figure 60-130-4
S40025
Figure 60-130-2

1
S97029
Locate the ACD connector (Item 1) [Figure 60-130-3]

P-97028 and [Figure 60-130-4].
Remove the fuse box cover (Item 1) [Figure 60-130-1]

and [Figure 60-130-2].

SERVICE SOFTWARE (CONT’D) Entering The Service Software
Connecting The Laptop Computer (Cont’d) Figure 60-130-7
Figure 60-130-5
2
1
P-45352
P-47342
Click the telescopic handler icon (Item 1) [Figure 60-130-
7] to enter the program.
Plug the connector (Item 1) from the laptop computer into
the ACD connector (Item 2) [Figure 60-130-5]. Figure 60-130-8

Figure 60-130-6
P-45350
S40027
The option screen will appear when entering the
telescopic handler service analyzer [Figure 60-130-8].
Open the laptop and begin [Figure 60-130-6]. The com port can be changed, if com port 1 is already
being used.

SERVICE SOFTWARE (CONT’D) Monitor Screen
Entering The Service Software (Cont’d) Figure 60-130-11
Figure 60-130-9
1
P-45348
P-45348
Select the Monitor icon (Item 1) [Figure 60-130-11].
This is the Main Screen of the telescopic handler Figure 60-130-12

analyzer program [Figure 60-130-9].

Figure 60-130-10
P-45329
P-45349 The Monitor screen displays the engine RPM, travel

control position, battery voltage, propel curve, sensor
voltage, brake release switch, inch / brake pedal, creep
The options icon will take you to the options screen potentiometer (is so equipped), transmission mode, drive
[Figure 60-130-10]. The com port can be changed, if switch and creep switch [Figure 60-130-12].
com port 1 is already being used.
If one of the icons does not change when the function is
operated, the circuit is not operating properly or the
susmic controller has a malfunction.

SERVICE SOFTWARE (CONT’D) Figure 60-130-15
Monitor Screen (Cont’d)
Figure 60-130-13
1
P-45332
1 The Work Switch is turned on, the icon (Item 1) will turn
P-45330 on and the Transmission mode will change to work (Item
2) [Figure 60-130-15].
The Inch / Brake pedal graph (Item 1) [Figure 60-130-13] Figure 60-130-16
should move as the pedal is pressed down.

Figure 60-130-14
1
P-45333
P-45331 With the Creep Switch turned on, the icon (Item 1)
[Figure 60-130-16] will turn on. The creep potentiometer
icon will change as the creep adjustment is turned.
The travel control position lever (Item 1) [Figure 60-130-
14] should move as the lever in the telescopic handler is
moved.

Warnings Screen
Figure 60-130-17
P-45334
The warning screen will show codes and problem with

P-45348 the controller [Figure 60-130-18].
Error # Description
Select on the warning icon (Item 1) [Figure 60-130-17].
01 Sensor supply voltage-sensor voltage out

of range
17 Software did not load properly-Restart
program and reload software
18 Inch pedal calibration failed-recalibrate the
inch pedal
19 Inch / brake potentiometer-no pedal setup
done, value too low, value too high
20 Engine speed pickup-engine speed
missed when starting engine
21 Propel current-short cut, open circuit
22 F-N-R switch-short cut between forward
and reverse
23 Engine speed pickup-engine speed
interrupted
24 Hydro motor propel current-short cut, open
circuit
25 Creep drive calibration failed-recalibrate
the creep drive potentiometer
26 Creep drive potentiometer-value too low,
value too high
27 Motor speed pickup-motor speed
interrupted

Calibrate Inch Pedal
Figure 60-130-19
P-45345
Press the brake pedal down approximately half the stroke

P-45348 and click on the set max position icon (Item 1) [Figure
60-130-21].
Select the calibrate inch pedal icon (Item 1) [Figure 60- Figure 60-130-22
130-19].

Figure 60-130-20
1 1
P-45351
P-45346 Release the brake pedal and click on the set min position
icon (Item 1) [Figure 60-130-22].
Click on the Start Calibration (Item 1) [Figure 60-130-

20].

SERVICE SOFTWARE (CONT’D) Calibrate Creep Potentiometer
Calibrate Inch Pedal (Cont’d) Figure 60-130-24
Figure 60-130-23
1
1
P-45348
P-45346
Select the calibrate creep icon (Item 1) [Figure 60-130-
24].
Click the exit (Item 1) [Figure 60-130-23] to get out of the
calibrate inch pedal. Figure 60-130-25

1
2
P-45335
Select the creep box (Item 1) and then click the continue
icon (Item 2) [Figure 60-130-25].

Calibrate Creep Potentiometer (Cont’d)
Figure 60-130-26
1
1
P-45337
Turn the creep potentiometer anticlockwise and click on

P-45341 the set min position icon (Item 1) [Figure 60-130-28].
Figure 60-130-29
Click the start calibration icon (Item 1) [Figure 60-130-
26].

Figure 60-130-27
P-45339
1
Click the exit icon (Item 1) [Figure 60-130-29] to exit the
P-45338 creep calibration screen.
Turn the creep knob clockwise and click the set max
position icon (Item 1) [Figure 60-130-27].

Program / Update Susmic Controller
Figure 60-130-30
P-45347
Click the exit icon (Item 1) [Figure 60-130-32] after the

P-45348 controller has been programmed.
Select the Program / Update icon (Item 1) [Figure 60-

130-30].

Figure 60-130-31
P-45342
Click the program controller icon (Item 1) [Figure 60-130-

31].


FRAME LEVEL SPEED SWITCH Removal
Description Lower the boom completely and turn off the engine.
Figure 60-140-1 Figure 60-140-2
1
1
S3669 S7421
The T40140 and T40170 models are equipped with a Remove the two bolts (Item 1) and remove the rear cover
frame level speed switch (Item 1) [Figure 60-140-1] (Item 2) [Figure 60-140-2].

located on the left rear side of the boom. This switch
reduces the speed of the frame leveling after the boom is Figure 60-140-3
raised over 25 degrees.
3
2
1
S3669
Disconnect the harness connector (Item 1), remove the

two bolts (Item 2) and the switch / bracket assembly (Item
3) [Figure 60-140-3].

FRAME LEVEL SPEED SWITCH (CONT’D) Figure 60-140-5
Installation
Figure 60-140-4
S37403
3 Start the engine.

S3669
While holding the frame leveling switch (Item 1)
[Figure 60-140-5] raise the boom. When the boom
Install the switch / bracket assembly (Item 1) using the reaches 25 degrees the speed of the frame leveling
two bolts (Item 2) [Figure 60-140-4]. should decrease.

Plug the connector (Item 3) [Figure 60-140-4] into the
harness.

LONGITUDINAL STABILITY INDICATOR Calibration Procedure
CALIBRATION (S/N A8GA11001-14999,
S/N A8GB11001-14999)
Fitting The Sensor
Figure 60-150-1 IMPORTANT

The following adjustments must be done on a flat
surface, without braking and must conform to the
telescopic handler safety prescriptions.
I-2346-EN-0511
Lower the boom completely and turn off the engine.

1
Figure 60-150-2
2
2
S3084
Remove the paint around the two M10-threaded holes on

the rear axle and verify flatness of the surface. The
surface must be perfectly flat.
Degrease the surface. 22 1

1
Apply Loctite® to the threads of both screws. S3085
Install the sensor (P/N 6910655) (Item 1) [Figure 60-

150-1] by alternately fastening both screws until a torque 1. Turn off the ignition. Push buzzer button (Item 1)
value of 60 N•m (44 ft-lb) is reached. [Figure 60-150-2] and hold it.
2. While holding the buzzer button (Item 1) [Figure 60-

150-2] pressed, start the machine. Hold the button for
another 5 seconds and release it when the green
LED’s light up.
3. With the machine unloaded and the boom retracted,

raise the boom until the maximum angle.
4. Wait until the machine stabilizes.
5. Push the buzzer button (Item 1) [Figure 60-150-2] for

5 seconds and wait until the “ STOP” light turns red.
6. Lower the boom.
7. Take a load that can make the machine tip (do not
exceed the maximum authorised load) over and lift it
30 centimeters abover the ground.
8. Extend the boom till the rear wheels do no longer

touch the ground. Use, if needed, the shunt key
(located above the contact key).

LONGITUDINAL STABILITY INDICATOR
CALIBRATION (S/N A8GA11001-14999,
S/N A8GB11001-14999) (CONT’D)
Calibration Procedure (Cont’d)
WARNING
The machine must be secured to the ground to
prevent tipping.
W-2920-0511
9. Push the buzzer button (Item 1) [Figure 60-150-2] for

5 seconds and wait until all lights of the indicator turn
on.
10. If the shunt key has been activated, turn it off now.
11. Retract the boom and then extend again to check if

the LEDs (Item 2) [Figure 60-150-2] light up in the

right order and the buzzer works and if the system
works correctly.
The order is: green, orange, buzzer, red and “STOP”.
Aggravating movements (such as extending the
boom) will be stopped when the “STOP” light turns on.
12. Remove the load.

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/ Follow the procedure below to calibrate the LLMC
N A8GB15000 & ABOVE) system:
System Calibration NOTE: Calibration must be performed within a time

span of 5 minutes. If longer, the LLMC will
Figure 60-160-1 return to its original settings.
NOTE: During the procedure below, the buzzer will

be activated whenever the TEST button is
1 pushed.
Figure 60-160-3
2
S39205
2
Before calibration, drive the machine for a while in order
to warm the axles, then check tightening torque of the

two bolts (Item 1) of the LLMS (Longitudinal Load
Moment Sensor) (Item 2) [Figure 60-160-1]. Torque
S38711
value should be 65 N•m (48 ft-lb).
Figure 60-160-4
Park the machine on flat level ground and align the front
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
Figure 60-160-2
S0007
1. Push and hold the TEST button (Item 1) [Figure 60-

160-3] while starting the machine (START) [Figure
S39203 60-160-4] then quickly press the TEST button (Item 1)
[Figure 60-160-3] for 3 times within the first 4
seconds after power on.
Using the LLMC override switch, decrease the rear axle
load pressure by picking up a load and extending the
NOTE: To indicate that the system enters calibration
boom until the machine topples over (rear wheels off the
mode, the LED bar (Items 2 and 3) [Figure 60-
ground) [Figure 60-160-2].
160-3] will be blinking and the buzzer sounds
intermittent for 3 seconds.
NOTE: Do not move or reposition the machine after
decreasing the rear axle load pressure.
2. The green LED’s (Item 2) [Figure 60-160-3] light up
Retract the boom for 3 m (10 ft) and place the load on the to indicate the system is ready to record the first
ground. Then retract the boom and turn off the engine. calibration point.

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/ Figure 60-160-6
N A8GB15000 & ABOVE) (CONT’D)
System Calibration (Cont’d)
Figure 60-160-5
S39203
6. Pick up the load and extend the boom until the

machine topples over (rear wheels off the ground)
S39202 [Figure 60-160-6].
7. Press and release the TEST button (Item 1)

3. Without attachment and with the attachment carrier [Figure 60-160-3] to record the second calibration

fully tilted up, fully retract and raise the boom [Figure point.
60-160-5].
8. To indicate the calibration has been validated, the
4. Press and release the TEST button (Item 1) LED bar (Items 2 and 3) [Figure 60-160-3] lights up
[Figure 60-160-3] to record the first calibration point. for 3 seconds and the buzzer sounds two times.
5. The orange and red LED’s (Item 3) [Figure 60-160-3] NOTE: If the buzzer sounds and LED’s light up in a
light up to indicate the system is ready to record the particular configuration, a calibration failure
second calibration point. has occurred. (See System Failure Reports on
Page 60-160-4.)
Calibration is finished. The LLMC system automatically
WARNING returns to normal mode.
Always perform the LLMI / LLMC calibration test after

TIPPING CAN CAUSE SERIOUS INJURY OR DEATH system calibration. (See Calibration Test on Page 60-
160-3.)
Keep the boom low, only raise the load 500 mm (20
in) when calibrating the LLMI / LLMC system.
W-2929-1111

Calibration Test
The Longitudinal Load Moment Control (LLMC) system 1

calibration can be tested by performing the following
procedure:
3
Park the machine on flat level ground and align the front
and rear wheels straight ahead.
2
NOTE: A load will be needed to topple the machine.
Figure 60-160-7
S38711
1. Raise the boom, fully retracted and without

attachment.
2. Tilt the attachment carrier fully up.
3. Push and hold the TEST button (Item 1) [Figure 60-

160-8].
4. After five seconds, all LED’s will shortly light up and

the buzzer sounds discontinuously.
S39203 5. The calibration test starts now. Two results are

possible:
Using the LLMC override switch, decrease the rear axle - the four green LED’s (Item 2) [Figure 60-160-8] light
load pressure by picking up a load and extending the up, calibration is OK.
boom until the machine topples over (rear wheels off the - the orange and red LED’s (Item 3) [Figure 60-160-
ground) [Figure 60-160-7]. 8] light up, calibration is out of range. Please redo
calibration of the LLMC system. (See System
NOTE: Do not move or reposition the machine after Calibration on Page 60-160-1.)
decreasing the rear axle load pressure.
6. Release the TEST button (Item 1) [Figure 60-160-8].
Retract the boom for 3 m (10 ft) and place the load on the
ground. NOTE: After pressing the TEST button (Item 1)
[Figure 60-160-8] longer than 60 seconds, the
procedure will automatically end and the
system will return to normal mode.
NOTE: The system always returns to normal mode

when the TEST button (Item 1) [Figure 60-160-
8] is released during the procedure.

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/N A8GB15000 & ABOVE) (CONT’D)
System Failure Reports
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Power Supply LLMI Voltage Low Normal Battery voltage
low.
LLMI Voltage Out Normal

Of Range
LLMC Voltage Low No aggravating Battery voltage

movements low.
possible.
Shunt is allowed.
LLMC Voltage Out No aggravating

Of Range movements
possible.
Shunt is allowed.
BCC Voltage Low No aggravating Battery voltage

movements low.
possible.
Shunt is allowed.
BCC Voltage Out No aggravating

Of Range movements
possible.
Shunt is allowed.

System Failure Reports (Cont’d)
MACHINE
BEHAVIOR
Internal CRC Error - LLMI, LLMC or Identify the faulty
Program Flash BCC not controller and re-
programmed program.
correctly.
Test Button - The Test button is Release the Test

pressed for more button. After 10
than 10 seconds seconds, system
when the LLMI / startup can be
LLMC system is repeated.
started. If not successful,
- The Test button is replace the LLMI.
pressed for more
than 60 seconds in
the calibration test

procedure.
LLMS Sensor Scale Too No aggravating Calibration points Do system calibration
Tight movements too close. again within a time span
possible. of less than 5 minutes.
Shunt is allowed.
Calibration Values No aggravating Calibration not Do system calibration

Reversed movements successful. again within a time span
possible. (Recordings of first of less than 5 minutes.
Shunt is allowed. and second
calibration point
have been
swapped.)
Calibration Values No aggravating Do system calibration
Out of Range movements again within a time span
possible. of less than 5 minutes.
Shunt is allowed.
Calibration Time- No aggravating The calibration Do system calibration

out movements took more than 5 again within a time span
possible. minutes. of less than 5 minutes.
Shunt is allowed.

MACHINE
BEHAVIOR
LLMS LLMI Linked The speed of the - The LLMI linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMI.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMI has the rear axle and do
stopped sending system calibration
CAN frame. again.
LLMC Linked The speed of the - The LLMC linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMC.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMC has the rear axle and do
stopped sending system calibration
CAN frame. again
LLMI / LLMC No movement - The LLMS inputs - Check the harness
Sensor allowed. have been between the LLMS and

Signature swapped between the LLMI / LLMC.
the LLMI and the - Do system calibration
LLMC. again within a time span
- The LLMI and / or of less than 5 minutes.
the LLMC was
reprogrammed.
LLMS Value Shift After 30 seconds: No aggravating Do system calibration
(toward movements again within a time span
stability) possible. of less than 5 minutes.
Shunt is allowed.
LLMS Value Shift No aggravating Do system calibration

(toward movements again within a time span
instability) possible. of less than 5 minutes.
Shunt is allowed
Sensor Normal The difference - Do system calibration

Redundancy 1 between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
first level. needed.

MACHINE
BEHAVIOR
LLMS Sensor No movement The difference - Do system calibration
Redundancy 2 allowed. between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
second level. needed.
Sensor Frame No aggravating Faulty LLMS. Replace the LLMS and

Default movements do system calibration
possible. again within a time span
Shunt is allowed of less than 5 minutes.
Switches Retract Switch Boom considered - The retract switch - Check the harness
not retracted while is disconnected between the “boom

this failure is on. - There is a short- retracted” switch and
circuit in the switch the LLMC.
or in the harness. - Check the function of
the switch.
5° Switch Boom angle - The 5° switch is - Check the harness

considered over disconnected. between the 5° switch
5° while this - There is a short- and the LLMC.
failure is on. circuit in the 5° - Check the function of
switch or in the the switch.
harness.
Radio Control / No aggravating Short-circuit in the Check the radio control

Man Platform movements radio control / man / man platform mode
Mode possible. platform mode activation key switch
Shunt is allowed activation key and its electrical
switch (=shunt key harness to the LLMC.
switch) or in the
harness between
the key and the
LLMC.

MACHINE
BEHAVIOR
BCC State Rereading No movement
Of allowed.
Relay K13bis Shunt is allowed.
(Safety
Valve)
State Rereading No aggravating

Of movements
Relay K13 (Stop possible.
Aggravating Shunt is allowed.
Movements)
Joystick Output No movement There is a short- Check the harness

Out Of Range allowed. circuit between the between the joystick

joystick and the and the BCC.
BCC that makes
the movement
command out of
the range ¼ - ¾ of
the battery
voltage.
Joystick Set Point No movement
And Valve allowed.
Command
Discordance

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, Figure 60-160-11
System Components Identification

1
Figure 60-160-9
S39205
The LLMS (Longitudinal Load Moment Sensor) (Item 1)

[Figure 60-160-11] measures the actual load on the rear
S38711 axle.
The LLMS is equipped with dual electronics, which

The LLMI (Longitudinal Load Moment Indicator) (Item 1) independently measure the same load. The first
[Figure 60-160-9] which is located on the dashboard,

measurement is used by the LLMI, while the second
indicates the stability level of the machine, using a LED measurement is used by the LLMC. The most critical
bargraph and a buzzer. measurement of both will have priority.
Figure 60-160-10 Figure 60-160-12
1
1
S39226 EM7526
The LLMC (Longitudinal Load Moment Controller) (Item The boom angle sensor (5°) (Item 1) [Figure 60-160-12]
1) [Figure 60-160-10] which is located under the measures the boom angle. If the boom angle is lower
dashboard, reduces and stops the boom movements in than five degrees and the machine is in unstable
relation to the machine stability. This controller combines condition, boom movement speed is reduced.
with other controllers in the machine.
The boom retracted sensor (Item 2) [Figure 60-160-12]
detects if the boom is fully retracted. When the boom is
retracted all boom movements will be fully operational at
any angle. The buzzer is deactivated with retracted
boom.

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/
LLMS Removal
System Components Identification (Cont’d)
Figure 60-160-15
Figure 60-160-13
S39231
S38712
For better access to the LLMS, turn the rear wheels fully
The LLMC system override switch key (“shunt key”) (Item to the left [Figure 60-160-19].
1) [Figure 60-160-13] can be used to override the LLMC

system. The key switch has three positions: Figure 60-160-16
1. Middle Position (Stable Position): machine under

LLMC control. 1
2. Turned Clockwise (Stable Position): machine usable
with radio control / man platform.
3. Turned Anticlockwise (Unstable Position): overriding
of the LLMC system. As soon as the key is released
the LLMC system will be active again.
Figure 60-160-14
P-29253
1
the battery.
S39438
The BCC Main Controller (Item 1) [Figure 60-160-14] is

located in the rear right corner of the operator cab. The
BCC manages the hydraulics functions of the machine in
relation to joystick position, sensor inputs and safety
device signals.

LLMS Removal (Cont’d) 1
Figure 60-160-17 2
S39215
1
Remove the two bolts (Item 1) and remove the LLMS

(Item 2) [Figure 60-160-19].
P-50821

cab.
Remove the access cover (Item 2) [Figure 60-160-17].
Figure 60-160-18
1
2
S39216
Disconnect the electrical connector (Item 1) [Figure 60-

160-18] (labeled as “XLLMS”).
Cut any tie straps that hold the LLMS cable (Item 2)
[Figure 60-160-18] and fully extract the cable out of the
machine.

LLMS Installation
Raise the boom and install the approved boom stop. (See 2
3
the Operation & Maintenance Manual for more
information.)
Figure 60-160-20
1
S39218
Route the LLMS cable (Item 1) [Figure 60-160-22]

through the opening inside the frame to the area under
the boom.
Install two tie straps (Items 2 & 3) [Figure 60-160-22] to

secure the cable to the nearby hose(s).

S39217
Figure 60-160-23
Clean the axle sensor area (Item 1) [Figure 60-160-20]

to remove rust and / or dirt.
Figure 60-160-21
2
2
1
1
S39219
Under the boom, route the LLMS cable (Item 1) further to

the cab side and then up through the opening (Item 2)
S39215 [Figure 60-160-23] in the frame.
Install a tie strap (Item 3) [Figure 60-160-23] to secure

Position the LLMS (Item 1) and install the two bolts (Item the cable to the nearby hoses.
2) [Figure 60-160-21].
NOTE: Apply Loctite® 243 to the bolts.
Tighten the two bolts (Item 2) [Figure 60-160-21] in three

progressive steps:
- 25 N•m (18.4 ft-lb)
- 45 N•m (33.2 ft-lb)
- 65 N•m (47.9 ft-lb).

2
LLMS Installation (Cont’d)
Figure 60-160-24
3 1
2
2
P-50821
1 4
Install the access cover (Item 1) [Figure 60-160-26].
S39220 Install the three screws (Item 2) of the access cover (Item
1) [Figure 60-160-26].
Route further until the cable (Item 1) [Figure 60-160-24] Figure 60-160-27

is fully extended.
The connector (Item 2) is now located next to the opening 1

(Item 3) [Figure 60-160-24] in the frame, which leads to
the back of the cab.
Install a tie strap (Item 4) [Figure 60-160-24] to secure

the cable to the nearby hoses.
Figure 60-160-25
P-29253
2

160-27] to the left, to connect the power supply from the
1 battery.
Remove the approved boom stop and lower the boom.
S39221
Plug the LLMS connector (Item 1) into the “XLLMS”

connector (Item 2) [Figure 60-160-25] at the back of the
cab.

LLMC Controller Removal
Figure 60-160-28
1
1
P-52345

P-29253
Figure 60-160-31

the battery.
Figure 60-160-29
3
1
1
1
S39223
Remove the travel / signal levers from the steering

2 column, such that the dash cover can be partly lifted
1 [Figure 60-160-31].
S39222
Remove the eleven screws (Item 1) [Figure 60-160-29]

from the column cover.
Remove the column cover (Item 2) [Figure 60-160-29].

dash cover.

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, Press the Start key switch (Item 2) [Figure 60-160-33]
S/N A8GB15000 & ABOVE) (CONT’D) into the switch panel.
LLMC Controller Removal (Cont’d) Partly remove the switch panel (Item 3) [Figure 60-160-
33], in order to access to the LLMC controller.
Figure 60-160-32
Figure 60-160-34
2 1
2 1
S39225

Remove and discard both plugs (Item 1) [Figure 60-160-
34] from the dash cover.
S38712
Lift the dash cover approximately 15 cm (6 in).

160-32] from the switch panel. Figure 60-160-35
Remove the screws (Item 2) [Figure 60-160-32] from the

switch panel.
Figure 60-160-33
3 S39230
2
Remove the tie strap (Item 1) [Figure 60-160-35].
S39224
order to have a grip on the Start key switch and remove
33].

LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, LLMC Controller Installation
Figure 60-160-38
LLMC Controller Removal (Cont’d)
Figure 60-160-36
2
1
1
3
S39229
1
S39227
S39226 Remove the two right hand brackets (Item 1) [Figure 60-
160-38] from the new LLMC controller. (The old controller
brackets, which are mounted on the machine, will be
Remove the bolt (Item 1) and nut (Item 2) [Figure 60- used instead.)

160-36] from the nearest left hand controller bracket.
Figure 60-160-39
the right hand side of the controller.
2
NOTE: The two right hand side brackets are left on
the cab frame. The screws that attach the
brackets to the controller are removed
instead.
NOTE: The controller is originally mounted with only

three brackets.
Figure 60-160-37
1 1
S39228
Plug both connectors (Item 1) labeled as “XLLMC1” and

“XLLMC2” onto the connectors of the new LLMC
controller (Item 2) [Figure 60-160-39].
NOTE: The connectors can not be erroneously

swapped.
2
S39228
Remove the controller (Item 1) from the dashboard and

disconnect both connectors (Item 2) [Figure 60-160-37]
labeled as “XLLMC1” and “XLLMC2”.

LLMC Controller Installation (Cont’d)
Figure 60-160-40
3
2
1
S39225
1
2 Install two new plugs (Item 1) [Figure 60-160-42].

S39227
S39226 Figure 60-160-43
Install the two screws (Item 1) [Figure 60-160-40] at the

right hand side of the controller.
Install the bolt (Item 2) and nut (Item 3) [Figure 60-160- 3

40].
Figure 60-160-41
1
2
S39224
1
Put the switch panel (Item 1) [Figure 60-160-43] back in

place.
Install the Start key switch (Item 2) into the switch panel
and install the nut that holds the Start key switch (Item
2) [Figure 60-160-43].
S39230
Install the switch row (Item 3) [Figure 60-160-43].
Install a new tie strap (Item 1) [Figure 60-160-41].
Lower the dash cover to its original position.

3
LLMC Controller Installation (Cont’d)
Figure 60-160-44
2
2
1 2
1
2 1
S39222
1
Put the column cover (Item 1) [Figure 60-160-46] back in
1 place.
Install the eleven screws (Item 2) [Figure 60-160-46] of

the column cover.
2

Install the screw (Item 3) [Figure 60-160-46] of the dash
cover.
S38712
Figure 60-160-47
Install the screws (Item 1) [Figure 60-160-44] of the
switch panel. 1
Install the nut cover (Item 2) [Figure 60-160-44] of the
Start key switch.
Figure 60-160-45
P-29253

160-47] to the left, to connect the power supply from the
1 battery.
P-52345
Put the travel / signal levers back in place and install the
two screws (Item 1) [Figure 60-160-45].

BCC MAIN CONTROLLER (S/N A8GA12001 & ABOVE, Figure 60-170-3
S/N A8GB12001 & ABOVE)
1
Figure 60-170-1 2
4
4
4
1
3
5
S39439
Unlock the connector (Item 1) by sliding the lock (Item 2)

away from the connector. Carefully remove the connector
P18440 (Item 1) [Figure 60-170-3] from the BCC controller.
Repeat the above step for the second connector (Item 3)

[Figure 60-170-3].

the battery.
Figure 60-170-4
Figure 60-170-2
1
1
1
2
1
S39440
S39438
Remove the four screws (Item 1) from the controller and

The BCC main controller (Item 1) [Figure 60-170-2] is remove the controller from the mounting plate (Item 2)
located in the rear right corner of the operator cab. [Figure 60-170-4].


JOYSTICK Figure 60-180-2
Figure 60-180-1
1 S4546
Disconnect the electrical connector by loosening the

S4545 screws (Item 1) [Figure 60-180-2] and pulling it back.
Remove the four joystick mounting screws (Item 1)

[Figure 60-180-1] and pull the joystick upwards.

NOTE: The joystick is not serviceable and must be
replaced as a complete unit.


ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
OIL COOLER / RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1


ENGINE COMPONENTS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Glow Plugs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE / HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4

RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Turbo Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Turbo Charger Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Turbo Charger Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-6
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-8
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-9
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-14
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-17
Changing Valve Springs (With Cylinder Head Installed) . . . . . . . . . . . . . . . . . . . . 70-110-18

Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-19
Timing Case And Drive Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-21
Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-22
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-24
Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-25
Pistons And Connecting Rods Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-26
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-26
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-29
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Connecting Rod Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-34
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-35
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-36
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-36
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-37
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-37

Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-38
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-39
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Engine Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-41
Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-42
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-42
Oil Screen And Pick-up Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-43
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-43
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-44
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-45
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 70-110-45
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-46
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-46
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Piston Cooling Jet alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-48

Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-49
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-50


ENGINE INFORMATION
Specifications
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
General
Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 105 (4.134)
Stroke 127 (5.000)
Compression Ratio 18.2:1
Displacement 269 in³. (4,4 liters)
Firing Order 1-3-4-2

Cylinder Head
Head Thickness 117,95 - 118,05 (4.643 - 4.647)

Head Thickness After Machining (Minimum) 117,20 (4.614)
Valve Seat Angle Inlet / Exhaust 45° / 30°
Leak Test Pressure 0,2 MPa (2 bar)(29 psi)
Valve Guides
Inside Diameter 9,000 - 9,022 (0.3543 - 0.3552 )

Outside Diameter 13,034 - 13,047 (0.5131 - 0.5137)
Valve Guide Clearance In The Cylinder Head (Interference) 0,007 - 0,047 (0.0003 - 0.00019)
Overall Length:
Intake 128,838 - 129,288 (5.0724 - 5.0901)
Exhaust 128,184 - 128,634 (5.0466 - 5.0643)
Protrusion From Bottom 0.486 - 0.498 (12,35 - 12,65)

ENGINE INFORMATION (CONT'D)
Specifications (Cont’d)
parentheses.
Exhaust Valves
Valve Stem Diameter 8,938 - 8,960 (0.3519 - 0.3 528)

Valve Guide Clearance 0,040 - 0,062 (0.0016 - 0.0024)
Maximum 0,15 (0.006)
Valve Head Diameter 41,51 - 41,75 (1.634 - 1.644)
Valve Face Angle 30°
Overall Length 128,184-128,634 (5.0466 - 5.0643)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0,45 (0.018)
Exhaust Depth (Production) 1,55 - 1,8 (0.0610 - 0.0713)
Exhaust Depth (Service) 2,06 (0.081)

Intake Valves
Valve Stem Diameter 8,95 - 8,98 (0.3525 - 0.3535)

Valve Guide Clearance 0,025 - 0,069 (0.0010 - 0.0027)
Maximum 0,13 (0.005)
Valve Head Diameter 46,28 - 46,53 (1.8220 - 1.8319)
Valve Face Angle 45°
Overall Length 128,838 - 129,288 (5.0724 - 5.0901)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 45°
Valve Clearance 0,20 (0.008)
Intake Depth (Production) 1,60 - 1,85 (0.0630 - 0.0728)
Intake Depth (Service) 2,09 (0.082)
Valve Springs
Installed Height 36,17 (1.4240)

Installed Height Pressure 312 N (70 lb)
Number Of Active Coils 3.8

parentheses.
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter 24,962 - 24,987 (0.9828 - 0.9837)

Clearance Between Rocker Arm Bushing and Shaft 0,26 - 0,89 (0.0010 - 0.0035)
Maximum 0,17 (0.007)
Pistons And Piston Rings
Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 39,703 - 39,709 (1.5631 - 1.5633)
Piston Projection Above the Block Deck 0,21 - 0,35 (0.008 - 0.0137)
Top Ring Groove Width Tapered
Second Ring Groove Width 2,56 - 2,58 (0.1008 - 0.1016)

Third Ring Groove Width 3,02 - 3,04 (0.1189 - 0.1197)
Top Ring Barrel Face, Molybdenum insert, Keystone
Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 2,48 - 2,49 (0.097 - 0.098)
Third Ring Width 2,97-2,99 (0.1169 - 0.1177)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0,065 - 0,110 (0.0026 - 0.0043)
Third Ring Side Clearance 0,03 - 0,07 (0.0011- 0.0027)
Top Ring End Gap 0,30 - 0,45 (0.0118 - 0.0117)
Second Ring End Gap 0,65 - 0,85 (0.0275 - 0.0374)
Third Ring End Gap 0,30 - 0,55 (0.0118 - 0.0216)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 39,694 - 39,700 (1.5628 - 1.5630)
Piston Height Above Cylinder Block 0,21 - 0,35 (0.008 - 0.014)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 43,66 - 43,84 (1.7190 - 1.7259)
Bushing Inside Diameter (Reamed) 39,723 - 39,738 (1.5638 - 1.5645)
Piston Pin Bushing Clearance 0,023 - 0,044 (0.0009 - 0.0017)

parentheses.
Connecting Rods And Bearings
Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 67,21 - 67,22 (2.6460 - 2.6465)
Length Between Centres 219,05 - 219,10 (8.624 - 8.626)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 31,62 - 31,88 (1.245 - 1.255)
Bearing Thickness At The Centre 1,835 - 1,842 (0.0723 - 0.0725)
Bearing Clearance 0,034 - 0,081 (0.0013 - 0.0032)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Crankshaft

Main Journals 76,159 - 76,180 (2.9984 - 2.9992 )
Maximum Wear And Out Of Round Of The Journals And 0,04 (0.0016)
Crank Pins
Crank Pin Diameters 63,47 - 63,49 (2.499 - 2.500)
Width Of Crank Pins 40,35 - 40,42 (1.589 - 1.591)
Maxiumum Crankshaft End Play 0,51 (0.0201)
Thrust Washer Thickness: Std. 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)
Main Bearing Oil Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Undersize Journals And Crank Pins 0,25 (0.010), 0,50 (0.020), 0,75 (0.030)

parentheses.
Crankshaft (Cont'd)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0,10 (0.004)
Journal #1 Mounting
Journal #2 0,08 (0.0031)
Journal #3 0,15 (0.0059)
Journal #4 0,08 (0.0031)
Journal #5 Mounting
Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
ITEM 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

1 75,905 - 75,926 75,651 - 75,672 75,397 - 75,418
(2.9884 - 2.9892) (2.9784 - 2.96792) (2.9684 - 2.9692)
2 63,216 - 63,236 62,962 - 62,982 62,708 - 62,728
(2.4888 - 2.4896) (2.4788 - 2.4796) (2.4688 - 2.4696)
3 39,47 (1.5539) maximum - -
4 37,44 (1.4740) maximum - -
5 44,68 (1.7591) maximum - -
6 40,55 (1.5965) maximum - -
7 Do not machine this diameter - -
8 3,68 - 3,96 (0.1449 - 0.1559) - -
9 4,36 - 4,60 (0.1717 - 0.1811) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0,25 (0.010) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.

parentheses.
Main Bearings
Type Steel Back, 20% Tin Aluminium

All Others 31,62 - 31,88 (1.244 - 1.255)
Bearing Thickness (centre) 2,083 - 2,089 (0.0820 - 0.0823 )
Bearing Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Thrust Washers
Type Steel back, bearing material

Position Each Side Of Centre Main Bearing
Standard 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)

Camshaft And Thrust Washer
Journal #1 Diameter 50,711 - 50,737 (1.9965 - 1.9975)

Cam Lift (Intake) 7,031 - 7,131 (0.2768 - 0.2807)
Cam Lift (Exhaust) 7,363 - 7,463 (0.2899 - 0.2938)
Maximum Wear And Out Of Round 0,05 (0.0021)
Camshaft End Play (Production) 0,10 - 0,55 (0.004 - 0.022)
Service Limits 0,60 (0.023)
Thrust Washer Type 360°
Thrust Washer Thickness 5,49 - 5,54 (0.216 - 0.218)
Thrust Washer Recess Depth 5,54 - 5,64 (0.218 - 0.222)
Cylinder Block
Cylinder Bore Diameter 105,000 - 105,025 (4.1338 - 4.1348)

Main Bearing Bore Diameter 80,416 - 80,442 (3.166 - 3.167)

parentheses.
Cylinder Liners
Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 104,25 - 104,28 (4.105 - 4.106)
Production Liner Clearance 0,03 - 0,08 (0.001 - 0.003)
Production Liner Inside Diameter 100,00 - 100,03 (3.937 - 3.938)
Service Liner Clearance ±0,03 (±0.001)
Inside Diameter Of Service Liner With Flame Ring 100,0 - 100,63 (3.937 - 3.961)
(Installed)
Maximum 0,25 (0.010)
Flange Thickness 3,81 - 3,86 (0.150 - 0.152)
Liner Projection From Deck Surface 0,10 (0.004) Above or 0,10 (0.004) Below
Hose Angle 30 / 35°

Piston Cooling Jets 9 N•m (79.7 in-lb)
Fuel Injection Pump
Type DELPHI DP 310 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 29,4 MPa (294 bar) (4263 psi)
Fuel Lift Pump
Type Electrically operated

Method of Drive Electric Motor 12V / 24V
Standard Pressure 41- 69 kPa (0,41 - 0,69 bar) (6 - 10 psi)
Minimum Pressure (@ idle speed) 25 kPa (0,25 bar) (3.6 psi)

parentheses.
Timing Case And Timing Gears
Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 34,93 - 34,95 (1.375 - 1.376)
Camshaft Hub Outside Diameter 34,90 - 34,92 (1.3741 - 1.3747)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 29,99 - 30,02 (1.417 - 1.419)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 47,625 - 47,650 (1.875 - 1.8760)
Crankshaft Gear Hub Diameter 47,625 - 47,645 (1.875 - 1.8758)
Crankshaft Gear Clearance -0,020 - +0,020 (-0.0008 - +0.0008)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 57,14 - 57,18 (2.2495 - 2.2512)

(With Needle Bearings) 72,35 - 72,36 (2.8484 - 2.8488)
Width Of Idler Gear And Bushing Assembly (Fitted) 30,14 - 30,16 (1.186 - 1.187)
Flanged Bushing Inside Assembly (Fitted) 50,78 - 50,80 (1.999 - 2.000 )
Idler Gear Hub Outside Diameter 50,70 - 50,74 (1.9961 - 1.9976)
Idler Gear Hub Bushing Clearance 0,04 - 0,10 (0.0016 - 0.0039)
Gear End Play (Production Limits) 0,10 - 0,20 (0.004 - 0.008)
Service Limit 0,38 (0.015)
Backlash For All Gears 0,08 (0.003) Minimum

parentheses.
Oil Pump, Gear And Relief Valve
Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0,152 - 0,330 (0.0059 - 0.0129)
End Play
Inner Rotor 0,038 - 0,089 (0.0014 - 0.0035 )
Outer Rotor 0,025 - 0,076 (0.0010 - 0.0029)
Oil Pump Idler Gear Bushing I.D. 16,012 - 16,038 (0.6303 - 0.6314)
Idler Shaft O.D. 15,966 - 15,984 (0.6285 - 0.5292)
Idler Gear Shaft Bushing Clearance 0,028 - 0,072 (0.0011 - 0.0028)
Oil Pump Idler Gear End Play 0,050 - 0,275 (0.0019 - 0.0108)
Relief Valve Plunger Bore Diameter 19,250 - 19,300 (0.7578 - 0.7598)

Relief Valve Plunger Outside Diameter 19,186 - 19,211 (0.7553 - 0.7563)
Clearance 0,039 - 0,114 (0.0015 - 0.0044)
Length Of The Spring (Installed) 80,94 (3.1866)
Load On The Spring (Installed) 25 - 65 kPa (0,25 - 0,36 bar) (3.6 - 5.2 psi)
Pressure To Open Pressure Relief Valve 414 - 469 kPa (4,14 - 4,69 bar) (60 - 68 psi)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter 55 - 83 kPa (0,55 - 0,83 bar)(8 - 12 psi)
Turbocharger
Type Garrett GT25
Flywheel
Run-Out Less than 0,30 (0.012 )

Misalignment 0,03 (0.001) @ 25 (1.0)

parentheses.
Water Pump And Thermostat
Type Centrifugal, Gear Drive

Shaft Outside Diameter 21,425 - 21,438 (0.8435 - 0.8440)
Drive Gear Bore Diameter 21,375 - 21,400 (0.8415 - 0.8425)
Drive Gear Shaft Clearance 0,025 - 0,063 (0.0009 - 0.0024)
Impeller Bore Diameter 11,943 - 11,971 (0.4701 - 0.4712 )
Impeller Shaft Outside Diameter 11,997 - 12,008 (0.4723 - 0.4727)
Impeller Clearance On Shaft 0,026 - 0,065 (0.0010 - 0.0025)
Bearing Bore Diameter 39,989 - 40,014 (1.5743 - 1.5753)
Bearing Diameter 39,989 - 40,000 (1.5743 - 1.5747)
Bearing Clearance In Pump Body +0,025 / -0,011 (+0.0009 / -0.0005)
Thermostat Type Wax Pellet, Bypass Blanking

NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BY-PASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
82°C (180°F) 77° / 85°C (170° / 185°F) 92° / 98°C (198° / 208°F) 0.35 (9,0)

Engine Torque Component
COMPONENT N•M FT-LB

Bridge Piece To Block 16 12
Camshaft Gear Bolt 95 70
Connecting Rod Nuts
Step 1 18 13
Final 70 52
Crank Pulley Bolts 115 85
Cylinder Head Bolt
Step One 50 37
Step Two 100 74
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 271 200
Exhaust Manifold Bolts 40 33
Flywheel Cover To Housing 63 46
Flywheel Housing To Cylinder Block 75 55
Flywheel To Crankshaft Bolts 115 85

Fuel Injector Nut 35 26
Fuel Injection Pump Gear Nut 24 18
Fuel Injection Pump Flange Nuts 24 18
Fuel Lift Pump Bolts 22 16
High Pressure Fuel Lines Fittings 30 22
Idler Gear Hub Bolts 44 33
Main Bearing Bolts
Step 1 88 65
Step 2 170 125
Step 3 250 185
Oil Pan Bolts 10 8.9
Oil Pan Plug 34 25
Oil Pump Cover 22 16
Oil Pump To Front Main Cap 9,5 8.4
Oil Transfer Plate Bolts 44 32
Piston Cooling Jets 9 7
Rear Oil Seal Housing Bolts 22 16
Rocker Cover Nuts (With Shim Washer) 9 7
Rocker Shaft Bracket Nuts 27 20
Timing Case To Block 22 16
Timing Case Cover To Timing Case Bolts 22 16
Turbocharger To Manifold Nuts 44 33
Water Pump To Timing Case Bolts and Nuts 22 16

Troubleshooting
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorised Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue / white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

Troubleshooting (Cont'd)

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides / stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken / worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.

15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.


ENGINE SPEED CONTROL Figure 70-20-3
Figure 70-20-1
2 P-53128

P-25249
70-20-3] from the linkage.
Remove the floor mat and insulation from the cab floor.
Figure 70-20-4

Remove the speed control cable (Item 1) from the pedal
Remove the battery box cover.
Figure 70-20-2
P-53127
1
Remove the engine speed control cable from the
mounting bracket (Item 1) [Figure 70-20-4].
P-25250 Remove any necessary cable ties, carefully remove the

speed control cable.
Carefully pull the speed control cable (Item 1) [Figure

70-20-2] through the cab and into the battery box.


MUFFLER Figure 70-30-2
Figure 70-30-1
S40029
1
Remove the clamp (Item 1) [Figure 70-30-2].

P-53129
Remove the muffler.

Remove the exhaust mounting bolts (Item 1) [Figure 70-
30-1].


AIR CLEANER
Housing Removal And Installation
Figure 70-40-1
P-53131

Loosen the clamps (Item 1) [Figure 70-40-1] and remove
the hoses from the air cleaner.
Figure 70-40-2
P-53132
Remove both mounting bolts (Item 1) [Figure 70-40-2].
Remove the air cleaner housing assembly.


OIL COOLER / RADIATOR S/N A8GA12999 & Below, S/N A8GB12999 & Below:
Remove the engine cover. (See Removal And Installation

on Page 50-60-1.) 1
1
Coolant on Page 10-70-1.)
Remove the fan motor. (See Removal And Installation on

Page 20-140-1.)
Figure 70-50-1
S6891
2
Remove the two nuts (Item 1) [Figure 70-50-3] from the

condenser.
Figure 70-50-4

1
1
S6859
Remove the two lower radiator hoses (Item 1) [Figure

70-50-1].
Remove the lower hydraulic hose (Item 2) [Figure 70-50-

1].
S6860
Figure 70-50-2
Position the condenser (Item 1) [Figure 70-50-4] (as

shown).
S6890
Remove the upper hydraulic hose (Item 1) [Figure 70-50-

2].

OIL COOLER / RADIATOR (CONT’D)
S/N A8HM13000 & Above, S/N A8HN13000 & Above:
Figure 70-50-5
S36349

Loosen the nut (Item 2) [Figure 70-50-5].
Figure 70-50-6
S36350
Position the condenser (Item 1) [Figure 70-50-6] (as

shown).

OIL COOLER / RADIATOR (CONT’D) Figure 70-50-9
Figure 70-50-7
S7438
Install a hoist and chain to the oil cooler / radiator [Figure

70-50-7].

Figure 70-50-8
S7437
Lift and remove the oil cooler / radiator assembly [Figure

70-50-9].
P-22025
Remove both oil cooler / radiator mounting bolts (Item 1)

[Figure 70-50-8] from the bottom of the engine pan.

Figure 70-50-10
1
1
S6865
Remove the wear pads (Item 1) [Figure 70-50-12].

S6863
Figure 70-50-13
Remove both rubber mounts (Item 1) [Figure 70-50-10]

by turning anticlockwise.

Figure 70-50-11
1 1
2 1
2
1 S6866
Remove the bolts (Item 1) and remove the upper bracket

1
(Item 2) [Figure 70-50-13].
S6864
Remove the seven bolts (Item 1) and remove the bracket

(Item 2) [Figure 70-50-11].

Figure 70-50-14
2
2
S6869
Remove the plate (Item 1) by removing the four screws

S6867 (Item 2) [Figure 70-50-16].
Separate the oil cooler from the intercooler.

Support the oil cooler / radiator assembly as shown
[Figure 70-50-14].

Figure 70-50-15
2 1 1
1
S6868
Remove the three bracket mounting bolts (Item 1) (both

sides) and remove the condenser mounting bracket (Item
2) and shroud (Item 3) [Figure 70-50-15].


ENGINE AND ENGINE MOUNTS Figure 70-60-2
Remove the engine / hydrostat assembly. (See “Removal

And Installation” on Page 70-90-1.)
NOTE: Put the engine / hydrostat assembly on

blocks, to allow access to remove the motor
mount bolts.
Remove the hydrostatic pump. (See “Removal And

Remove the flywheel and housing. (See “Removal And

Installation” on Page 70-100-1.) S6871
If equipped with air conditioning, remove the hoses from

the compressor. (See “Removal And Installation” on Remove the hose (Item 1) [Figure 70-60-2] and
Page 80-50-1.) reposition.

1
S6870 S6872
Remove the hose (Item 1) [Figure 70-60-1] from the Remove the lower radiator hose (Item 1) [Figure 70-60-
thermostat housing. 3] from the water pump.

ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-60-6
Figure 70-60-4
P-55515
1
Remove the intake tube from the turbo by loosening the
P-53808 clamp (Item 1) [Figure 70-60-6].
Figure 70-60-7
Remove the intake hose (Item 1) [Figure 70-60-4] from
the turbo.

Figure 70-60-5
S6909
1 Loosen the clamp (Item 1) and remove the intake tube

S6916 (Item 2) [Figure 70-60-7].
Loosen the hose clamp (Item 1) [Figure 70-60-5] and

remove the hose from the engine.

Figure 70-60-8
1
1
S6893
Remove the two bolts and nuts (Item 1) [Figure 70-60-

P-53809 10] and remove the two fuse assemblies.
Figure 70-60-11
Remove the three bolts (Item 1) and exhaust tube (Item
2) [Figure 70-60-8].

Figure 70-60-9
1
2
P-53812
Reposition the electrical harness [Figure 70-60-11] (as

P-53810 shown).
Remove the bolt and nut (Item 1) at the rear of the engine
compartment and remove the access panel (Item 2)
[Figure 70-60-9].

Figure 70-60-12
1
1
S6873
Remove both front engine mount bolts (Item 1) [Figure

S6919 70-60-14].
Installation: Tighten the engine mount bolts to 250-271

Install a lifting bracket (Item 1) [Figure 70-60-12] in the N•m (185-200 ft-lb) torque.
position shown.

Figure 70-60-15
Figure 70-60-13
S6918
S6917
Lift and remove the engine [Figure 70-60-15].

Install a hoist and chain to the lifting brackets [Figure 70-
60-13] (as shown).

ENGINE COMPONENTS AND TESTING Figure 70-70-2
Fuel Injection Pump Removal
NOTE: Read and fully understand the following

procedure before removing the fuel injection
pump. Failure to remove the pump correctly
will result in incorrect pump timing and the 2
pump will have to be sent to an authorised
Delpi dealer to be retimed. The internal
adjustment for pump timing is tamper proof.
High and low idle adjustments of the fuel
injection pump are factory set and
adjustments cannot be made to the fuel pump. 1
Set the engine to TDC number one cylinder compression P-55774

stroke. (See “Procedure” on page 70-80-1.)
Figure 70-70-1 Loosen the lock bolt (Item 1) and move the washer (Item
2) [Figure 70-70-2] (to the position shown). Retighten
the locking screw to 17 N•m (12 ft-lb) torque.
Remove the nut and washer (Item 1) [Figure 70-70-1].

1 Figure 70-70-3
P-55531
NOTE: If the fuel pump nut (Item 1) [Figure 70-70-1] is

loosened before the fuel pump timing is set
and the pump locked, the fuel pump timing will
be lost and the fuel pump will have to be sent P-55529
into the dealer to be reset.
Apply pressure anticlockwise by hand to the fuel pump Using a gear puller, remove the fuel pump gear [Figure
gear to remove backlash from the gears. 70-70-3].

ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-6
Fuel Injection Pump Removal (Cont'd)
Figure 70-70-4
P-55524
Remove the fuel line (Item 1) [Figure 70-70-6] from the

P-55522 front of the pump.
Figure 70-70-7
Remove the harness (Item 1) [Figure 70-70-4].

NOTE: Mark the connectors for correct installation.
Figure 70-70-5
1
P-55525
Remove the fuel line (Item 1) [Figure 70-70-7] from the

rear of the pump.
P-55523
Remove the connector (Item 1) [Figure 70-70-5] from the

top of the pump.

Fuel Injection Pump Removal (Cont'd)
Figure 70-70-8
1
1
P-55533
Disconnect the return spring (Item 1) [Figure 70-70-10]

P-55526 from the pump linkage.
Figure 70-70-11
Remove the four fuel tubelines (Item 1) [Figure 70-70-8].

IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289
Figure 70-70-9
P-55528
Remove the mount bolt (Item 1) [Figure 70-70-11] from

the bracket.
P-55527
Remove the tubeline (Item 1) [Figure 70-70-9] from the

top of the pump.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Installation
Fuel Injection Pump Removal (Cont'd) The engine must be set to TDC number one cylinder,
compression stroke before the pump is fitted. (See
Figure 70-70-12 “Procedure” on page 70-80-1.)
NOTE: The new fuel pump will be supplied with the

1 pump shaft in the locked position. Do not
1 unlock the shaft of the fuel pump until the fuel
pump gear is fitted.
Install a new O-ring onto the pump flange.
Figure 70-70-13
1
1
1
P-55532
Remove the three mount bolts (Item 1) [Figure 70-70-12]

and remove the pump.

1
P-55532
Install the fuel pump and tighten the three bolts (Item 1)
Figure 70-70-14
P-55528
Install the mount bolt (Item 1) [Figure 70-70-14]. Do not

tighten at this time.

Fuel Injection Pump Installation (Cont'd)
Figure 70-70-15
2
1
2
P-55775
Loosen the locking bolt (Item 1) and move the washer

P-55531 (Item 2) [Figure 70-70-17] to the position shown and
tighten the bolt to 12 N•m (9 ft-lb) torque.
Fit the gear (Item 1) onto the tapered shaft. Make sure Retighten the nut (Item 1) [Figure 70-70-16] to 88 N•m
the fuel pump gear is correctly in mesh with the idle gear (65 ft-lb) torque.

and install the washer and nut (Item 2) [Figure 70-70-
15]. Do not tighten at this time. Figure 70-70-18
NOTE: The backlash must be removed before the fuel

injection pump is released. Failure to do so
will make the fuel pump timing incorrect.
1
Figure 70-70-16
P-55776
Remove the two timing pins (Item 1) [Figure 70-70-18].
Lightly lubricate each gear with clean engine oil.

P-55530
Install the timing case cover. (See “Timing Cover
Installation” on page 70-110-20.)
Apply pressure anticlockwise by hand to the fuel pump
gear to remove the backlash from all the gears. Tighten Install the glow plugs. (See “Glow Plugs Removal And
the nut (Item 1) [Figure 70-70-16] to 24 N•m (18 ft-lb) Installation” on page 70-70-13.)
torque.
Install the rocker cover. (See “Rocker Cover Removal
And Installation” on page 70-110-5.)

Figure 70-70-19
1
1 1
P-55525
Install the tubelines (Item 1) [Figure 70-70-21] to the

P-55528 pump and tighten to 30 N•m (22 ft-lb) torque.
Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-70-19] to 44
N•m (32 ft-lb) torque. Figure 70-70-22

Figure 70-70-20
1
1
P-55524
P-55533
Install the fuel line (Item 1) [Figure 70-70-22] on the front
of the pump.
Connect the return spring (Item 1) [Figure 70-70-20] to
the pump linkage.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injectors Removal And Installation
Figure 70-70-23
WARNING
1 death. Fluid leaks under pressure may not be visible.
2 Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
Figure 70-70-1
P-55523
1
Install the two fuel lines (Item 1) [Figure 70-70-22] and
[Figure 70-70-23].

Install the electrical connector (Item 2) [Figure 70-70-
1 2
23].
Figure 70-70-24
1
S6894
Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-70-1].
1
Installation: Tighten the bolts to 9 N•m (79.7 in-lb)
torque.
P-55522
Install the harness (Item 1) [Figure 70-70-24].
Remove air from the system.

Fuel Injector Removal And Installation (Cont'd)

1
Figure 70-70-1
1
P-55777
Disconnect the four injector tubelines (Item 1) [Figure

S6895 70-70-3] from the injector pump.
Installation: Tighten the tubelines to 27 N•m (20 ft-lb)

Remove the breather hose (Item 1) [Figure 70-70-1]. torque.

Figure 70-70-2
3 3
S6896
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-70-2].
Remove the three bolts (Item 3) and remove the fuel filter
assembly (Item 4) [Figure 70-70-2].

Fuel Injector Removal And Installation (Cont'd)
1
IMPORTANT 1
2
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-4 3
P-55614
Remove the fuel return hoses (Item 1) and remove the

bolt (Item 2) and clamp (Item 3) [Figure 70-70-5].
1
1 Installation: Tighten bolt to 35 N•m (26 ft-lb) torque.
1
Figure 70-70-6

S6897
Disconnect the injector tubelines (Item 1) [Figure 70-70-

4] from the injectors.
Installation: Tighten the tubelines to 30 N•m (22 ft-lb)

torque.
Remove the tubelines.

P-55615
Remove the injector from the cylinder head [Figure 70-

70-6].

ENGINE COMPONENTS AND TESTING (CONT'D) Checking The Fuel Lift Pump
Fuel Injectors Removal And Installation (Cont'd) Figure 70-70-9
Figure 70-70-7
1
P-55525
P-55617
Remove the fuel lift pipe (Item 1) [Figure 70-70-9] from
the injector pump, fit a suitable pipe with a pressure test
Installation: The roll pin must be in the position shown point and connect a pressure gauge.
[Figure 70-70-7].

Operate the engine at idler for 2 minutes to allow any
Figure 70-70-8 trapped air to be removed.
Standard pressure should be 41 - 69 kPa (0,41 - 0,69

bar) (6 - 10 psi).
P-55616
Installation: Always replace the copper washer (Item 1)

[Figure 70-70-8] at the nozzle. If the washer remains in
the cylinder head, it must be removed.

ENGINE COMPONENTS AND TESTING (CONT'D) Compression Checking
Fuel Lift Pump Removal And Installation The tools listed will be needed to do the following
procedure:
Figure 70-70-10
MEL10630 - Engine Compression Kit
MEL1352 - Compression Adapter
The engine must be at operating temperature.

2
Remove the glow plugs. (See “Glow Plugs Removal And
1 Figure 70-70-12
S6898
Remove the two fuel lines (Item 1) and electrical harness

(Item 2) [Figure 70-70-10] from the fuel lift pump / filter

assembly.
1
Figure 70-70-11
P-55631
Install the correct compression adapter (Item 1) [Figure

1 70-70-12] into the cylinder head.
Figure 70-70-13
S6899
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-70-11] and remove the fuel lift pump/filter
assembly.
P-55632
Connect the compression gauge to the adapter [Figure

70-70-13].
Make sure the engine speed control is fully backward

(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200 - 300 RPM.

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Checking
Compression Checking (Cont’d) Disconnect the glow plug cables and leads.
If the measurement is below the allowable limit, check the Figure 70-70-15
cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 0,2 - 0,3 MPa (2 - 3

bar) (43.5 - 72.5 psi).
Compression tests should only be used to compare

between the cylinders of an engine. (If one or more
cylinders vary by more than 350 kPa (3,5 bar) (51 psi)
then those cylinders can be faulty.
Figure 70-70-14
P-55629
Use an ohmmeter to check the glow plugs [Figure 70-70-

15].

Figure 70-70-16
P-55633
Push the button on the compression gauge to release

pressure [Figure 70-70-14].
Connect the fuel stop solenoid.
P-55630
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-70-16].
The reading must be between 1 and 2 ohm [Figure 70-

70-16]. If the resistance is infinite, the coil of the glow
plug is broken.
Repeat the procedure for each glow plug.

Glow Plugs Removal And Installation
Disconnect the negative (-) cable from the battery. 1

2 1
1
Figure 70-70-17
3
1 2
S6900
Remove the nut (Item 1) [Figure 70-70-19] from the top

of each glow plug.
1
S6894 Installation: Tighten to 2 N•m (1.5 ft-lb) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 70-19] from the glow plug.
injector cover (Item 2) [Figure 70-70-1].
Remove the glow plug connecting strap (Item 3) [Figure
Installation: Tighten the bolts to 9 N•m (79.7 in-lb) 70-70-19].
torque.
Figure 70-70-20
Figure 70-70-18
3
1
1
2
S6901
S6895
Loosen and remove the glow plugs (Item 1) [Figure 70-

Remove the hose clamp (Item 1), the bolt (Item 2) and 70-20].
remove the breather (Item 3) [Figure 70-70-18].
Installation: Tighten the glow plug to 15 N•m (13 ft-lb)
torque.


ENGINE TIMING Figure 70-71-2
Procedure
The tool listed will be needed to do the following

procedure:
MEL-1638 Camshaft Timing Pin 1
MEL-1639 Crankshaft Timing Pin
Remove the rocker cover. (See Rocker Cover Removal

And Installation on page 70-110-5.)
Remove the glow plugs. (See Glow Plugs Removal And

Installation on page 70-70-13.) P-55601
Remove the timing case cover. (See Timing Cover Carefully rotate the crankshaft in the normal direction of
Removal on page 70-110-20.) rotation. Align the hole in the crankshaft with the hole in
the cylinder block and timing case and install the
NOTE: The marks on the timing gears are not to be crankshaft timing pin (MEL-1639) (Item 1) [Figure 70-71-
used as timing marks. The marks indicate the 2]. Push the pin fully into the hole.
front of the gear only.
Figure 70-71-3

Figure 70-71-1
1 2
P-55602
P-55600
Insert the camshaft timing pin (MEL-1638) (Item 1)
[Figure 70-71-3] through the hole in the camshaft gear
To set the number one piston to TDC on the correct and into the body of the timing case. With the two pins
stroke, rotate the crankshaft in the normal direction of fitted the engine is set at TDC number one on the
rotation until the intake valve (Item 1) of the number four compression stroke.
cylinder has just opened and the exhaust valve (Item 2) NOTE: The camshaft timing pin is a push fit into the
[Figure 70-71-1] of the same cylinder has not closed timing case. The camshaft gear can rotate a
completely. small amount when the pin is fitted. This
allows the assembly of the gears and removal
of the backlash from the gears, with the timing
pins fitted.
Remove the timing pin from each gear.
Install the timing case cover. (See Timing Cover
Installation on page 70-110-20.)
Install the glow plugs. (See Glow Plugs Removal And
Install the rocker cover. (See Rocker Cover Removal And


ENGINE / HYDROSTAT ASSEMBLY Figure 70-80-2
Remove the engine cover. (See Removal And Installation

on Page 50-60-1.)
Remove the air intake cowling. (See Removal And

1
P-44577
Drain the radiator. (See Removal And Installation on
Page 70-50-1.)
Remove the battery. (See Removal And Installation on 70-80-2].
Page 60-20-1.)
Figure 70-80-3
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)

Remove the drive shaft. (See Removal And Installation
on Page 40-70-1.)
If equipped with air conditioning, remove the refrigerant

from the A/C system. (See Reclamation Procedure on
Page 80-40-1.)
1
Figure 70-80-1
P-44578

70-80-3].
2
S4592

canopy.
NOTE: Mark all hoses and electrical connectors, for


ENGINE / HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-6
Figure 70-80-4
2
2
1
P-44932

P-44925 connector (Item 2) [Figure 70-80-6].
Figure 70-80-7

Figure 70-80-5
1
1 P-44933
Remove the nut (Item 1) and ground wires (Item 2)

P-44930 [Figure 70-80-7].
Disconnect the electrical connector (Item 1) [Figure 70-

80-5].

Figure 70-80-8
1
P-53572
Remove the cover (Item 1) [Figure 70-80-10].
Figure 70-80-11
P-53570A

Figure 70-80-9 1
P-53573
1
Temporarily remove the protective covering (Item 1)

[Figure 70-80-11] from the A/C hoses and expansion
valve.
S4599

ENGINE / HYDROSTAT ASSEMBLY (CONT'D) S/N A8GA13000 & Above, S/N A8GB13000 & Above:
Removal And Installation (Cont'd) Figure 70-80-14
Figure 70-80-12
1
P-97028
P-53574
Remove the bolt (Item 1) and plate (Item 2) [Figure 70- Remove the dash cover / steering column cover. (See
80-12]. Remove the A/C hoses. Removal And Installation on Page 50-141-1.)

NOTE: Plug the A/C hoses to prevent contamination. Remove the joystick panel. (See Removal And
Figure 70-80-13
Figure 70-80-15
P-53585
S36381

located under the fuse box. Remove the side cover (Item 1) [Figure 70-80-15].

Figure 70-80-16
1
S36344

S36333 located under the fuse box.

16].

Remove the heater hose (Item 2) [Figure 70-80-16] NOT

connected to the heater valve (Item 3) [Figure 70-80-17].
Figure 70-80-17
2
3
S36334
Remove the heater hose (Item 1) [Figure 70-80-17].
Remove bolt, nut and clip (Item 2) [Figure 70-80-17].


1
For all models:
Figure 70-80-19
1 1
P-56463
Remove the three hoses (Item 1) [Figure 70-80-21] from

1 the backside of the pump.
P-53575 Figure 70-80-22

Loosen the mounting bracket bolt (Item 1) [Figure 70-80-
19].
Figure 70-80-20
2
1
P-56477
2
Remove the four bolts (Item 1) and remove the hose
(Item 2) [Figure 70-80-22] from the hydrostatic pump.
1
P-53576
Remove the two A/C hoses (Item 1) and harness (Item 2)

[Figure 70-80-20] completely from the rear corner of the
WARNING
cab.
immediately.
W-2145-0290

Figure 70-80-23
P-56468
Loosen the hose clamp (Item 1) [Figure 70-80-25] and

P-56478 remove the hose.
Figure 70-80-26
backside of the pump.

Figure 70-80-24
1
P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 70-80-26].
IMPORTANT
IMPORTANT When repairing hydrostatic and hydraulic systems,
When repairing hydrostatic and hydraulic systems, tubelines and ports to keep dirt out. Dirt can quickly
clean the work area before disassembly and keep all damage the system.
parts clean. Always use caps and plugs on hoses, I-2003-0888
damage the system.
I-2003-0888

Figure 70-80-27
1 P-56486
Remove the tubeline (Item 1) [Figure 70-80-29].

P-58089
Figure 70-80-30

hydrostatic pump.

Figure 70-80-28 1
1
P-56488
Remove the two wires (Item 1) [Figure 70-80-30] from

the solenoids.
P-56485

Figure 70-80-31
P-56491

P-58092
Figure 70-80-34

tubeline.

Figure 70-80-32
P-56493
1
P-56490
Remove the four bolt flange hose (Item 1) [Figure 70-80-

32] from the front of the pump.

Figure 70-80-35
1 1
S6839
1

P-58088 the tow valve.
Figure 70-80-38
the hydraulic reservoir.

Figure 70-80-36
1
P-53603

S6902 70-80-38].
Remove the two heater hoses (Item 1) [Figure 70-80-36]

from the engine.

Figure 70-80-39
P-29534
Remove the heater hoses, fuel lines and speed control

P-53604 cable from the engine compartment and route through
the access hole [Figure 70-80-41].
Remove the engine speed control cable (Item 1) [Figure Figure 70-80-42

Figure 70-80-40
1
1
2
2 1
P-44924
S6903 Remove the three hoses (Item 1) [Figure 70-80-42].
Remove any necessary nylon ties.

Cut the tie strap (Item 1) and remove the two fuel lines
(Item 2) [Figure 70-80-40].

Figure 70-80-43
S6905
Install a chain hoist to lift and secure the engine

S6904 assembly [Figure 70-80-45].
Figure 70-80-46
Remove nut (Item 1) [Figure 70-80-43] from the starter.

Figure 70-80-44
P-53619
P-53624 Remove the engine assembly mounting bolt (Item 1)

[Figure 70-80-46] from the lower front.
Route the ground strap mounting bolt (Item 1) [Figure

70-80-44].

Figure 70-80-47
S6907
Remove the three engine assembly mounting bolts (Item

S6906 1) [Figure 70-80-47], [Figure 70-80-48], and [Figure 70-
80-49].
Figure 70-80-48 Figure 70-80-50

1
S6908 P-53629
Lift the engine assembly up approximately 25 mm (1 in)

and remove the engine assembly from the machine
[Figure 70-80-50].


FLYWHEEL AND HOUSING Figure 70-90-3
Remove the engine / hydrostat assembly. (See Removal

1
NOTE: Set the engine / hydrostat assembly on
blocks, to allow access to remove the motor
mount bolts.
Remove the hydrostatic pump. (See Removal And

Remove the starter. (See Removal And Installation on

Page 60-40-1.) P-53796
Figure 70-90-1
Remove both rear engine mounting bolts (Item 1) [Figure
70-90-2] and [Figure 70-90-3].
Installation: Tighten engine mounting bolts to 250 - 271


Figure 70-90-4
P-53793
Install lifting brackets and hoist on the housing to lift and

support [Figure 70-90-1].
Figure 70-90-2
P-53797
Lifting from the housing assembly, raise the engine

slightly and place support blocks under the oil pan
1 [Figure 70-90-4].
Lower the engine assembly on the support blocks.
P-53794

FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-7
Figure 70-90-5 1
1
1
P-53800
Remove the six coupler mounting bolts (Item 1) [Figure

P-53798 70-90-7]. Remove the coupler.
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft-

Loosen and remove the ten flywheel housing mount bolts lb) torque.
(Item 1) [Figure 70-90-5].

Figure 70-90-8
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft-
lb) torque.
Figure 70-90-6
P-53801
Remove two of the flywheel mount bolts and install two

P-53799 guide studs (Item 1) [Figure 70-90-8] in the flywheel to
prevent the fly wheel from falling.
Remove the flywheel housing from the engine [Figure

70-90-6].

FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-11
Figure 70-90-9
B-05559
2 Install a dial indicator to check the flywheel run out

P-53803 [Figure 70-90-11].
Flywheel run out must be less than 0,30 mm (0.012 in).

Install a chain hoist (Item 1) [Figure 70-90-9].
Figure 70-90-12

Remove the remainder of the bolts (Item 2) [Figure 70-
90-9]. Remove the flywheel by sliding outward over the
guide studs.
203 mm (8”)
Installation: Tighten the flywheel bolts to 115 N•m
(85 ft-lb) torque.
Figure 70-90-10
3 3
2 2
1
B-05560
2 Check the alignment of the flywheel face [Figure 70-90-

2 12].
The misalignment must not be more than 0,03 mm (0.001

in) total indicator reading for every 25 mm (1.0 in) of the
P-53804 flywheel radius from the crankshaft axis to the dial gauge
plunger.
If removing the backing plate (Item 1) is required, loosen Example: The misalignment must not be greater than
and remove the eight mounting bolts (Item 2 and 3) 0,203 mm (0.008 in) at 203 mm (8 in) from the centreline
[Figure 70-90-10]. of the crankshaft towards the outside of the flywheel.
Installation: Tighten the bolts (Item 2) to 63 N•m (46 ft- During this check keep the crankshaft pressed toward the
lb) and the bolts (Item 3) to 75 N•m (55 ft-lb) torque. front so crankshaft end play will not affect the reading.
Check the flywheel and ring gear for wear or damage.

Replace as needed.

FLYWHEEL AND HOUSING (CONT'D) Ring Gear Installation
Removal And Installation (Cont'd) The ring gear is a heat expansion fit on the flywheel.
Ring Gear Removal Do not heat the ring gear to a temperature greater than
250°C (480°F) make sure the ring gear chamfer is in the
Before the ring gear is removed note the position of the correct position.
chamfer on the teeth.
Heat the ring gear enough to expand it and hit it with a

hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.

RECONDITIONING THE ENGINE
Turbo Charger Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Two Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Two Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35

Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged / restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps / setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.

RECONDITIONING THE ENGINE (CONT'D) Turbo Charger Removal And Installation
Turbo Charger Description Figure 70-100-2
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
2
Figure 70-100-1
P-55619
Remove the two bolts (Item 1) and remove the exhaust

elbow (Item 2) [Figure 70-100-2].
Figure 70-100-3

1
P-55618
The turbocharger (Item 1) [Figure 70-100-1] is located

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than 1
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
P-55515
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
Loosen the intake tube clamp (Item 1) [Figure 70-100-3].
The turbocharger should only be serviced by an
authorised dealer or repair shop.

RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-6
Turbo Charger Removal And Installation (Cont'd)
Figure 70-100-4
2
1
P-55621
Remove the oil return line (Item 1) [Figure 70-100-6].

S6909
Figure 70-100-7
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-100-4].

Figure 70-100-5
1 1
1 P-55624
Remove the four nuts (Item 1) [Figure 70-100-7] for the

turbocharger to exhaust manifold flange.
P-55623
Installation: Apply anti-seize compound to the mounting
studs. Tighten the nuts to 44 N•m (33 ft-lb) torque.
Disconnect the oil supply tubeline (Item 1) [Figure 70-
100-5]. Remove the turbocharger and gasket from the exhaust
manifold.
Installation: Fill the bearing housing with clean oil
through the oil supply port. Tighten banjo fitting to The turbocharger must only be serviced by an authorised
22 N•m (16 ft-lb) torque. repair shop.
Before starting the engine, disconnect the electrical stop

control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.

RECONDITIONING THE ENGINE (CONT'D) Fuel Injector Cover Removal And Installation
Exhaust Manifold Removal And Installation Figure 70-100-10
Remove the turbocharger. (See Turbo Charger Removal

And Installation on Page 70-110-2.) 1
Figure 70-100-8
1
1 1
1
S6894
Remove the three bolts (Item 1) [Figure 70-100-10] and

remove the cover.
P-55625
Installation: Tighten the bolts to 9 N•m (7 ft-lb) torque.

Remove the eight mount bolts (Item 1)
[Figure 70-100-8].
Remove the exhaust manifold and gasket.
Figure 70-100-9
5 2 8
1
4 3 7
6
P-55625
Installation: Tighten the bolts in the sequence shown


Rocker Cover Removal And Installation
Remove the fuel injector cover. (See Fuel Injector Cover

Figure 70-100-11 1
S6895
Remove the breather hose (Item 1) [Figure 70-100-13].

1
Figure 70-100-14
P-55515

Loosen the intake tube clamp (Item 1) [Figure 70-100-
11].
Figure 70-100-12
1
2
2
1
S6896
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-100-14].
S6909
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-100-12].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Removal
Rocker Cover Removal And Installation (Cont'd) Remove the turbo charger. (See Turbo Charger Removal
Figure 70-100-15
Remove the exhaust manifold. (See Exhaust Manifold
1 1
Remove the alternator. (See Removal And Installation on
Page 60-30-1.)
Remove the fuel lift pump. (See Fuel Lift Pump Removal
Remove the fuel injectors. (See Fuel Injectors Removal

1
1 Remove the glow plugs. (See Glow Plugs Removal And

1 Installation on Page 70-70-13.)
P-55519
Figure 70-100-17
Remove the ten mount bolts (Item 1) [Figure 70-100-15].

Figure 70-100-16
1 10 3 5
8
P-55681
7
6 4 9 2 Disconnect the engine cooling temperature sensor (Item
P-55519 1) [Figure 70-100-17].
NOTE: Mark wires for correct installation.

Installation: Tighten the bolts in the sequence shown

Cylinder Head Removal (Cont'd)

2
Figure 70-100-18 1
1
P-55684
1
Remove the two bolts (Item 1) and remove the coolant
P-55682 by-pass tube (Item 2) [Figure 70-100-20].
Remove the rocker cover. (See Rocker Cover Removal

Disconnect the intake manifold pressure sensor (Item 1) And Installation on Page 70-110-5.)
[Figure 70-100-18].

Remove the rocker shaft assembly. (See Rocker Shaft
Reposition the harness. Disassembly And Assembly on Page 70-110-12.)
Figure 70-100-19 Figure 70-100-21
P-55683 P-8718A
Remove the tubeline (Item 1) [Figure 70-100-19]. Remove the push rods [Figure 70-100-21].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Inspection
Cylinder Head Removal (Cont'd) Figure 70-100-23
Figure 70-100-22
1 1 1 1 1 3
8
9 5 1 4
2
3
10 7
6 2 3
B-5564
B-23183
Put a straight edge on the cylinder head as shown in
[Figure 70-100-23].
Release the cylinder head bolts evenly and gradually in
the sequence shown [Figure 70-100-22]. Using a feeler gauge between the straight edge and

head, check for warping.
Check the head bolts for distortion and damage. Replace
as needed. Maximum allowed (Item 1) is 0,03 mm (0.0012 in), (Item
2) is 0,05 mm (0.0019 in) and (Item 3) [Figure 70-100-
Lift off the cylinder head and clean the bottom face. 23] is 0,05 mm (0.0019 in).
The head can be machined removing only a minimum

amount. Head thickness must not be less than 117,20
mm (4.614 in).
Completely clean the rest of the head.
Check for cracks or other damage.

Cylinder Head Installation

3
2 6 10 7
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
Clean any debris out of the cylinder bores.
Figure 70-100-24 1
5 9 8 4
B-23183
2
1
Tighten the head bolts to 50 N•m (37 ft-lb) in the
FRONT TOP
sequence shown [Figure 70-100-25].
Tighten the head bolts to 100 N•m (74 ft-lb) in the

sequence shown [Figure 70-100-25].

Figure 70-100-26
B-5562
1
NOTE: The locating pins (Item 1) are pressed in the
engine block so the head gasket (Item 2)
[Figure 70-100-24] can be positioned
correctly.
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [Figure 70-100-24] marks in the correct position.
P-8839
Lower the cylinder head in position.
Additional tightening of the head bolts requires the use of

a torque angle gauge (Item 1) [Figure 70-100-26].
Tighten the short bolts to 225° and long bolts to 270° in
the same sequence as shown in [Figure 70-100-25].

Cylinder Head Installation (Cont'd)
Figure 70-100-27 2
225° 270°
2
P-55684
Install the coolant by-pass pipe (Item 1) and two screws

B-5563A (Item 2) [Figure 70-100-29].
Tighten the screws to 22 N•m (16 ft-lb) torque.

If no angle gauge is available make a suitable mark on
the head bolt corner. Make another mark on the cylinder Figure 70-100-30

head the correct number of flats away [Figure 70-100-
27]. Turn the head bolt until the lines match.
Figure 70-100-28
1
P-55683
Install the tubeline (Item 1) [Figure 70-100-30].

P-8718A
Install the push rods [Figure 70-100-28].
Make sure the push rods seat in the tappet sockets.
Install the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-110-12.)
Install the rocker cover. (See Rocker Cover Removal And


RECONDITIONING THE ENGINE (CONT'D) Install the glow plugs. (See Glow Plugs Removal And
Cylinder Head Installation (Cont'd)
Install the fuel injectors. (See Fuel Injectors Removal And
Figure 70-100-31 Installation on Page 70-70-7.)
Install the fuel lift pump. (See Fuel Lift Pump Removal
Install the alternator. (See Removal And Installation on

Page 60-30-1.)
Install the exhaust manifold. (See Exhaust Manifold

Install the turbo charger. (See Turbo Charger Removal

1 And Installation on Page 70-110-2.)
P-55682
Connect the intake manifold pressure sensor (Item 1)

[Figure 70-100-31].

Figure 70-100-32
P-55681
Connect the engine cooling temperature sensor (Item 1)

[Figure 70-100-32].

RECONDITIONING THE ENGINE (CONT'D) Valve Removal
Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned
to the same position.
NOTE: Make an identification mark on each rocker
arm assembly in order to show the location. Figure 70-100-34
Figure 70-100-33
4 5
2 3
3
2 P-8720A
P-8719A
Using a valve spring compressor compress the springs

and remove the retainers (Item 1) [Figure 70-100-34].
Remove the clips (Item 1) [Figure 70-100-33] from both
ends of the shaft. Release the compressor and remove the valve spring
cap (Item 2), spring (Item 3), valve seal / spring seat
Remove the rocker arm (Item 2) and spring (Item 3) washer (Item 4) and valve (Item 5) [Figure 70-100-34].
[Figure 70-100-33].
Clean and inspect all components.
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.
Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.
Shaft O.D. 24,962 - 24,987 mm

(0.9828 - 0.9837 in)
Rocker Arm Bore Dia. 25,013 - 25,051 mm
(0.9848 - 09.863 in)
Clearance Between Rocker Arm 0,026 - 0,089 mm
and Shaft (0.0010 - 0.0035 in)
If the clearance is more than 0,13 mm (0.005 in) replace

the bushing(s).

RECONDITIONING THE ENGINE (CONT'D) Valve Depth Checking
Valve Springs Checking Figure 70-100-36
Figure 70-100-35
35,17 mm
(1.3846 in)
N-00533
B-5552
Check the valve depth as shown in [Figure 70-100-36].
Use the following chart [Figure 70-100-35]. The maximum depth is 2,06 mm (0.0811 in) for both
intake and exhaust valves.

Valve Springs
If the valve is below the limits, install a new valve and
Compressed Height 35,17 mm (1.3846 in)
recheck the valve depth. If it is still below limits a new
Installed Pressure 335 N (75 lb) valve seat insert must be installed.
When the depth is less than 1,53 - 1,81 mm (0.060 -

0.071 in) the seat can be ground to lower the valve depth.

RECONDITIONING THE ENGINE (CONT'D) Interference fit of valve guide to cylinder head:
0,007 - 0,047 mm (0.0003 - 0.0019 in).
Valve Guides Checking
Overall Diameter (Item 3) [Figure 70-100-37]
Figure 70-100-37
Intake and Exhaust 51,00 - 51,50 mm
1 (2.018 - 2.027 in)
Protrusion from bottom recess for valve spring;

(Item 4) [Figure 70-100-37] 12,35 - 12,65 mm
3 (0.486 - 0.498 in)
To check the valve guides for wear using a valve.
2 Set up dial indicator gauge (Item 1) [Figure 70-100-37]

as shown.
B-5551
Lift the valve (Item 2) 15,0 mm (0.60 in) and move the
valve in and away from the gauge (Item 1) [Figure 70-
Figure 70-100-38 100-37]. Record this reading.

If the clearance exceeds 0,13 mm (0.005 in) for intake or
0,15 mm (0.006 in) for exhaust (Item 3) [Figure 70-100-
38] the valve guide needs to be replaced.
1 3
B-5566A
The valve guides can be checked for wear with either of

the operations listed in [Figure 70-100-37] or [Figure 70-
100-38].
Use the following chart to check valve guides.
Inside Diameter
(Item 1) [Figure 70-100-37] 9,00 - 9,022 mm
(0.3543 - 0.3552 in)
Outside Diameter (Item 2) [Figure 70-100-37]

Intake and Exhaust 13,034 - 13,047 mm
(0.5131 - 0.5137 in)

RECONDITIONING THE ENGINE (CONT'D) Valve Guide Installation
Valve Guide Removal Figure 70-100-40
Clean the guide bore in the head.
Figure 70-100-39

B-5548
Clean the guide bore in the head.
Lubricate the outer surface of the new guide (Item 1)

B-5549 [Figure 70-100-40] with the engine oil.
Put the guide in position on the valve guide removal /

Install a valve guide removal / installation tool (Item 1) on installation tool (Item 2) [Figure 70-100-40].
the valve guide (Item 2) [Figure 70-100-39].
Pull the guide into the cylinder head.
Pull the guide (Item 2) [Figure 70-100-39] out of the
cylinder head. When correctly positioned the top of the guide should
extend 12,35 - 12,65 mm (0.486 - 0.498 in) above the
valve spring seat [Figure 70-100-37].

RECONDITIONING THE ENGINE (CONT'D) Cutting A Valve Seat
Valves Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-100-41 Select the correct size cutter.
Valve Seat Angle Inlet / Exhaust 45° / 30°
Figure 70-100-42
4
1
B-5567

Use the following chart [Figure 70-100-41] to check the
valve dimensions.
N-00532
Ref. Valve Specifications

1. Intake 128,838 - 129,288 mm Carefully turn the cutter in a clockwise direction using
(5.0724 - 5.0901 in) even downward pressure. Keep the valve seat as narrow
Exhaust 128,184 - 128,634 mm as possible [Figure 70-100-42].
5.0466 - 5.0643 inch
2. Intake 8,953 - 8,975 mm Remove any cutting debris.
(0.3525-0.3533 in)
Exhaust 8,938 - 8,960 mm Install the valve and lightly tap.
(0.3519 - 0.3528 in)
Check the valve depth to make sure that it is within limits.
3. Intake 46,28 - 46,53 mm
(See Valve Guides Checking on Page 70-110-14.)
(1.8220 - 1.8319 in)
Exhaust (1.634 - 1.644 in) NOTE: If the valve seat is worn or damaged, a new
41,51 - 41,75 mm valve seat insert can be installed.
4. Intake 1,60 - 1,85 mm
(Production) (0.0630 - 0.0728 in)
Intake (Service 2,09 mm (0.0823 in)
Max.)
Exhaust (Pro- 1,55 - 1,81 mm
duction) (0.0610 - 0.0713 in)
Exhaust (Ser- 2,06 mm (0.0811 in)
vice Maximum)
Intake / Exhaust 45° / 30°
Valve Face
Angle

RECONDITIONING THE ENGINE (CONT'D)
Valve Seat Assembly
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 70-100-43
4 5

1
2 3
P-8720A
Lubricate the valve stems (Item 1) [Figure 70-100-43]

with clean engine oil and install them in the respective
guides.
Install new valve seals / spring seat washer (Item 2)

[Figure 70-100-43].
Install the spring (Item 3) [Figure 70-100-43] on the

washer (make sure the larger diameter is against the
cylinder head).
Place the valve cap (Item 4) [Figure 70-100-43] on the

spring.
Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-100-43].

Changing Valve Springs (With Cylinder Head

Installed)
Remove the rocker cover.
Figure 70-100-44
N-00531
Install the valve spring compressor and adapter [Figure

70-100-45].
Compress the valve springs squarely and remove the

B-5565 retainers.

NOTE: Do not rotate the crankshaft while the valve
Rotate the crankshaft clockwise until the intake valve has springs are removed.
opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-100-44] will be at Release the compressor and remove the valve spring(s).
approximately T.D.C.
Place the new valve springs in position.
Remove the rocker shaft assembly.
Compress the valve springs and install the retainers.

Valve Clearance Adjustment
Adjust the valve clearance as follows:
Figure 70-100-46
1 2 3 4 5 6 7 8
2 1
B-5569
Figure 70-100-48
3 Cylinder 1 2 3 4
B-5568 No.
Valve No. 1 2 3 4 5 6 7 8
Valve

Loosen the lock nut (Item 1) [Figure 70-100-46]. 1=Intake I E I E I E I E
E=Exhaust
Turn the adjustment screw (Item 2) [Figure 70-100-46]
until the correct clearance is obtained. Use the following sequence to set the valves [Figure 70-
100-47] and [Figure 70-100-48].
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
70-100-46]. a. With the rocker arm rocking (valves 7 and 8) on No.
4 cylinder set clearance at No. 1 cylinder (valves 1
and 2).
Adjust the valve clearance as follows:
b. With the rocker arm rocking (valves 3 and 4) on No.
0,20 mm (0.008 in) Intake 2 cylinder set clearance at No. 3 cylinder (valves 5
and 6).
0,45 mm (0.018 in) Exhaust
c. With the rocker arm rocking (valves 1 and 2) on No.
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.
and 4).

RECONDITIONING THE ENGINE (CONT'D) Crankshaft Pulley Removal And Installation
Timing Case And Drive Assembly Description Figure 70-100-50
The timing case is made of aluminum and the cover is

made of tin and in most applications, the timing gears are
made of steel. The drive from the crankshaft passes to
the idler gear, to the camshaft gear, to the gear on the 1
fuel injection pump and to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft. 1
Timing Cover Removal 2
Remove the water pump. (See Water Pump Removal on

Page 70-110-40.)
S6912
Figure 70-100-49
Remove the three bolts (Item 1) and thrust block (Item 2)
[Figure 70-100-50].
Installation: Tighten the bolts to 115 N•m (85 ft-lb)

torque.

1
2
1 Remove the pulley.
Front Oil Seal Removal And Installation
1 Remove the crankshaft pulley. (See Crankshaft Pulley

1
Remove the oil seal using a seal removal tool.
1
S6911
Do not damage the edge of the seal housing.
Remove the timing cover bolts (Item 1) and remove the Figure 70-100-51
timing cover (Item 2) [Figure 70-100-49].
Timing Cover Installation
Clean the gasket mating surfaces.
Place the gasket and timing cover on the engine.
Remove the timing pins if fitted.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
1
Install the water pump. (See Water Pump Installation on P-55686
Page 70-110-40.)
Do not tighten bolts at this time. Install the oil seal (Item 1) [Figure 70-100-51] into the
housing using the special tool.
Tighten the cover bolts and water pump bolts to 22 N•m
(16 ft-lb) torque. Install crankshaft pulley. (See Crankshaft Pulley Removal

Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal on 1

Page 70-110-20.)
Remove the crankshaft pulley. (See Crankshaft Pulley

Remove the fuel injection pump. (See Fuel Injection

Pump Removal on Page 70-70-1.)
Figure 70-100-52
P-55689
1
Remove the idler gear (Item 1) [Figure 70-100-54] by
moving the gear assembly forward and lifted over the
front oil seal housing.
NOTE: Do not turn the crankshaft with the idler gear

2
removed.

Figure 70-100-55
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
by-pass tube (Item 2) [Figure 70-100-52].
Figure 70-100-53
3 1
P-55690
Remove the bolt (Item 1) and washer (Item 2) [Figure

70-100-55].
2
1
P-55688
Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-100-53].

RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Installation
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-100-56
Figure 70-100-58
1
1 2
2
2
2
2
P-55691
2 P-55692
Remove the camshaft gear (Item 1) [Figure 70-100-56].

Fit the timing case (Item 1) onto the cylinder block and

NOTE: Use care not to lose the key from the key way. hand tighten the bolts (Item 2) [Figure 70-100-58].
Figure 70-100-57 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-100-58] to 22 N•m (16 ft-lb)
torque.
1
1
Figure 70-100-59
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-100-57] from the front of
P-55691
the oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-100-59] for correct
alignment.

Timing Case And Gear Installation (Cont'd)
Figure 70-100-60
2
1 P-55688
Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-100-62].
Tighten the bolts to 44 N•m (33 ft- lb) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
100-60] and tighten to 95 N•m (70 ft-lb) torque. Figure 70-100-63

Figure 70-100-61
1
2
2
P-55684
P-55689
Install the coolant by-pass tube (Item 1) using the two
bolts (Item 2) [Figure 70-100-63].
Install the idler gear (Item 1) make sure the hole (Item 2)
[Figure 70-100-61] is towards the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Install the crankshaft pulley. (See Crankshaft Pulley

Install the timing cover. (See Timing Cover Installation on

Page 70-110-20.)

Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

1
Remove the timing case. (See Timing Case And Gear

Remove the rocker cover, rocker assembly and push

rods. (See Rocker Cover Removal And Installation on
Page 70-110-5.) P-8741
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-100-64 100-65].
2 Figure 70-100-66

1
1
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts (Item 1) [Figure 70-100-64].
Carefully remove the camshaft (Item 1) [Figure 70-100-
Remove the oil pan (Item 2) [Figure 70-100-64] and 66].
gasket.
Installation: Tighten the oil pan mounting bolts to 22


RECONDITIONING THE ENGINE (CONT'D) Camshaft And Tappets Installation
Camshaft And Tappets Removal (Cont’d) Clean and inspect the camshaft and tappets for
excessive wear and damage.
Figure 70-100-67
Inspect the camshaft bushing for excessive wear and
damage.
NOTE: Only the front camshaft journal bore has a

bushing.
1 Clearance between the camshaft journals, the bushing

1 and camshaft bore is 0,06 - 0,14 mm (0.0025 - 0.0055
in).
Make sure all components are clean and lubricated with

clean engine oil.
Figure 70-100-68
P-8743
Remove the tappets (Item 1) [Figure 70-100-67] from the

block.

1
1
P-08743
Install the tappets (Item 1) [Figure 70-100-68].
Figure 70-100-69
P-8742
Carefully install the camshaft (Item 1) [Figure 70-100-

69].

RECONDITIONING THE ENGINE (CONT'D) Pistons And Connecting Rods Description
Camshaft And Tappets Installation (Cont’d) The pistons have a Quadram combustion chamber. They
have two compression rings and one oil control ring. The
Figure 70-100-70 top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings.
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
1 steel. The connecting rods on the turbocharged engines
2 have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by
serrations and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two

compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine
P-8741 identification number to order new parts.
Pistons And Connecting Rods Removal

Install the camshaft thrust washer (Item 1). Make sure
that the dowel pin (Item 2) [Figure 70-100-70] lines up Figure 70-100-71

with the hole in the thrust washer.
Install the timing case. (See Timing Case And Gear

Check camshaft end play. The end play for a new engine
is 0,10 - 0,55 mm (0.004 - 0.022 in), service limits 0,60
mm (0.023 in).
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump 1

P-08744
Install the push rods and rocker assembly. (See Rocker
Shaft Disassembly And Assembly on Page 70-110-12.)
Remove the cylinder head. (See Cylinder Head Removal
Install the timing cover. (See Timing Cover Installation on on Page 70-110-6.)
Page 70-110-20.)
Remove all the carbon from the top of the cylinder liners.
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.) Remove the oil pan. (See Oil Pan Removal And
Remove the oil pick up screen and tube (Item 1) [Figure

70-100-71].

Pistons And Connecting Rods Removal (Cont’d)
Figure 70-100-72
1 1
1 1 1 1
1
1
P-08746
Inspect the crankshaft journals (Item 1) [Figure 70-100-

P-08743 74] for wear or damage.
NOTE: Keep all parts together so they can be

Mark and remove the connecting rod caps (Item 1) replaced in their original position.
[Figure 70-100-72].

NOTE: Before installing the pistons check cylinder
NOTE: Do not allow the connecting rods to hit the bore for wear or damage. (See Cylinder Liner
cooling jets. Inspection on Page 70-110-48.)
Figure 70-100-73
P-08745
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-100-73]. Push the
piston and rod assemblies out the top of the cylinder.

RECONDITIONING THE ENGINE (CONT'D) Piston Ring End Gap
Pistons And Connecting Rods Disassembly Figure 70-100-77
Figure 70-100-75
1 1
4
4
B-05571
B-05570
Place the piston rings in the upper part of the cylinder to
check the end gap [Figure 70-100-77].
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-100-75] as shown on the connecting rod. Top Ring End Gap 0,30 - 0,45 mm

(0.0118 - 0.0117 in)
Figure 70-100-76
Second Ring End Gap 0,65 - 0,85 mm
(0.0256 - 0.0335 in)
1 Third Ring End Gap 0,30 - 0,55 mm
4 (0.0118 - 0.0216 in)
Piston Ring Installation
Figure 70-100-78
P-13999
Remove the piston rings (Item 1) [Figure 70-100-76] with

a ring expander.
Remove the snap rings (Item 2) [Figure 70-100-76]

which retain the piston pin.
B-05572
Push the piston pin (Item 3) [Figure 70-100-76] out by
hand. If the pin doesn't push out easily, heat the piston to
40°- 50°C (100° - 120°F) for easier removal. Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring
Remove the connecting rod (Item 4) [Figure 70-100-76]. [Figure 70-100-78].

RECONDITIONING THE ENGINE (CONT'D) Piston Ring Groove Clearance
Piston Ring Installation (Cont'd) Figure 70-100-80
Use a ring expander to install the piston rings.
Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.
Figure 70-100-79
2
B-05576
With the piston rings installed, check the groove

1 clearance [Figure 70-100-80].
Top Ring Wedge

B-05575
Second Ring Side Clearance 0,065 - 0,110 mm
(0.0026 - 0.0043 in)
Install the oil control ring over the spring (Item 1) [Figure Third Ring Side Clearance 0,03 - 0,07 mm
70-100-79]. (0.0011 - 0.0027 in)
Make sure the ring gap is 180° from the latch pin.
Install the cast iron ring with the tapered face (Item 2)
[Figure 70-100-79] in the second groove with the word
TOP or symbol facing the top of the piston.
New second rings have a green identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [Figure 70-100-79] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-100-79] has an internal

step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.
Make sure the ring gaps are 120° apart.

RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Assembly
Connecting Rod Inspection Figure 70-100-82
Figure 70-100-81
127 mm 127 mm
(5”) (5”)
± 0,25 mm ± 0,25 mm 2
(0.010”) (0.010”)
P-13999
B-05577
Install the connecting rod (Item 1), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-100-82] in the piston.
Checking the connecting rod for distortion [Figure 70-
100-81]. Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square Apply a light coat of oil to the piston and piston rings.
and parallel within the limits of ± 0,25 mm
(0.010 in) . NOTE: Make sure the piston ring end gaps are 120°
apart.
Measure this 127 mm (5.0 in) on each side of the
connecting rod axis on a test fixture. Figure 70-100-83
With the piston pin bushing installed the limit is reduced

to ± 0,06 mm (0.0025 in).
Check the pin bushing for wear or damage. Replace as

needed.
Connecting Rod Bushing Replacement
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
B-05578
Ream the bushing to get the proper clearance of 0,023 -
0,044 mm (0.0009 - 0.0017 in) between the small end
bushing and piston pin. Install the ring compressor over the piston rings [Figure
70-100-83].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.

Piston And Connecting Rod Installation (Cont'd)
Figure 70-100-84 1
FRONT B-05580
Install the upper and lower bearing shells in position

B-05579 making sure the locating tang (Item 1) [Figure 70-100-
86] is in the correct position.
When the piston has cleared the cooling jet, rotate the NOTE: New connecting rod nuts must be installed
piston assembly so that the arrow or FRONT mark is each time the rod caps are removed.

toward the front of the engine [Figure 70-100-84].
Figure 70-100-87
Figure 70-100-85
1 1
1
1
1 1
P-08743
P-08745
Install the caps (Item 1) [Figure 70-100-87] and nuts.

Clean the bearing surfaces and crank pin. Lubricate the Gradually tighten the nuts to 18 N•m (13 ft-lb) torque.
crank pin (Item 1) [Figure 70-100-85] with clean engine Tighten to a final torque of 70 N•m (52 ft-lb). The
oil. fasteners must be tightened a further 120°.
Rotate the crankshaft. The crankshaft must rotate

smoothly.

RECONDITIONING THE ENGINE (CONT'D) Crankshaft And Bearings Description
Piston And Connecting Rod Installation (Cont'd) The crankshaft is a chrome-moly forging which has five
main journals. End play is controlled by two half thrust
Figure 70-100-88 washers on both sides of the centre main bearing.
The main bearings have steel backs with a aluminium/ tin

bearing material. The main bearing caps are made of
cast iron.
The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.
Crankshaft And Bearings Removal
Figure 70-100-89
1
1
P-08744
Install the oil pick up tube and screen (Item 1) [Figure

70-100-88].

Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.)
Checking Piston Height
Rotate the crankshaft until the piston is approximately at

P-08748
top dead centre (T.D.C.).
Using a dial indication gauge, pre-load the plunger on the Remove the water pump. (See Water Pump Removal on
top surface of the block and zero the gauge. Page 70-110-40.)
Carefully move the dial gauge so that the plunger is on Remove timing case cover. (See Timing Cover Removal
top of the piston above the axis of the piston pin. on Page 70-110-20.)
Rotate the crankshaft to bring the piston to it's highest Remove the fuel injection pump. (See Fuel Injection
point. Record this gauge reading. Pump Removal on Page 70-70-1.)
When installed, the top surface of the piston is slightly Remove the timing gears and timing case. (See Timing
above the surface of the cylinder block. Case And Gear Removal on Page 70-110-21.)
The height above the surface of the block should be 0,21 Remove the flywheel. (See Removal And Installation on
to 0,35 mm (0.008 to 0.014 in). Page 70-100-1.)
Install the cylinder head. (See Cylinder Head Installation Remove the pistons and connecting rods, keeping them
on Page 70-110-9.) in order. (See Pistons And Connecting Rods Removal on
Page 70-110-26.)
Remove the rear oil seal housing (Item 1) [Figure 70-

100-89].

Crankshaft And Bearings Removal (Cont’d)
Figure 70-100-90
1 1
1 1 1 1
1
P-08750
Remove the main bearing caps (Item 1) [Figure 70-100-

P-08749 92].
Figure 70-100-93
Remove the two bolts (Item 1) [Figure 70-100-90]
retaining the bridge piece.

Remove the bridge piece.
Figure 70-100-91
1 1 1 1 1
P-08753
Remove the thrust washers from the sides of the centre

main bearing bore [Figure 70-100-93].
P-08746
Mark the main bearing caps (Item 1) [Figure 70-100-91]

for correct installation.
Remove the main bearing cap bolts.

RECONDITIONING THE ENGINE (CONT'D) Inspection Of Crankshaft And Bearings
Crankshaft And Bearings Removal (Cont'd) Figure 70-100-96
Figure 70-100-94
A-02763
P-08751
Check the crankshaft for wear [Figure 70-100-96]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-100-94]. 0,04 mm (0.0016 in).

Figure 70-100-95 The main journals and the crank pins of standard size
can be machined 0,25 mm (0.010 in) 0,50 mm (0.020 in)
or 0,75 mm (0.030 in).
NOTE: (See Specifications on Page 70-10-1.) for more

crankshaft specifications.
Check the oil clearance of the bearings.
All Main Bearings 0,057 - 0,117 mm

(0.0022 - 0.0046 in)
Thrust Washer Thickness

Standard 2,26 - 2,31 mm
P-08752
(0.089 - 0.091 in)
Oversize 2,45 - 2,50 mm
(0.096 - 0.098 in)
Remove the crankshaft bearings from the engine block
[Figure 70-100-95].
Keep the bearings with their respective caps for

installation.

Crankshaft And Bearings Installation
Figure 70-100-97
P-08753
Clean and install the upper and lower thrust bearings on

P-08754 each side of the centre main bearing [Figure 70-100-99].
Clean the main caps and install the bearings.

Clean the main bearing bores and install the upper
bearing shells in position. Lubricate the bearings with Lubricate the bearings with clean engine oil.

clean engine oil [Figure 70-100-97].
Install the main cap bolts and torque in steps working
NOTE: Only the upper half of the bearings has oil from the centre outward.
lubrication holes and must be installed in the
cylinder block. Step 1 88 N•m (65 ft-lb)
Figure 70-100-98 Step 2 170 N•m (125 ft-lb)

Step 3 245 N•m (180 ft-lb)
Clean the bridge piece and apply a bead of LOCTITE

#518 in the corners and around the thread holes on the
block.
P-08751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-100-98].
Make sure the locating pins for the main caps are in
position.

RECONDITIONING THE ENGINE (CONT'D) Rear Oil Seal Removal
Crankshaft And Bearings Installation (Cont'd) Remove the bolts that retain the seal housing. Remove
the housing.
Figure 70-100-100
Inspect the seal for wear or damage. Replace even if
there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
Rear Oil Seal Housing Positioning
The tool listed will be needed to do the following

procedure;
MEL1532 - Rear Crankshaft Seal Installation Tool
P-08755 Figure 70-100-102
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-100-100].

Tighten the bridge retaining bolts to 16 N•m (12 ft-lb)
torque.
Figure 70-100-101
1
2
B-05581
The seal can be installed from flush with the housing face
2 (Item 1) to 6,86 mm (0.27 in) (Item 2) [Figure 70-100-
102] back from the housing face. Install seal so that the
seal lip does not line up with any worn areas on the
crankshaft.
P-08756
Inject LOCTITE #518 into the groove (Item 1) at each end

of the bridge piece. Continue to inject sealant until it exits
the lower groove (Item 2) [Figure 70-100-101] at the
front and rear of the piece.

RECONDITIONING THE ENGINE (CONT'D) Carefully push the seal and housing (Item 3) [Figure 70-
100-104] over the tool and crankshaft and into position
Rear Oil Seal Housing Positioning (Cont’d) on the dowels. Remove the tool.
Figure 70-100-103 Figure 70-100-105
N-00550 P-08748
Install the seal in the seal housing using the seal Tighten the bolts (Item 1) [Figure 70-100-105] to 22 N•m
installation tool. Seat the seal to the correct depth (16 ft-lb) torque.

[Figure 70-100-103].
Checking Crankshaft End Play
Rear Oil Seal Installation
The axial movement of the crankshaft is controlled by two
Install the new seal in the housing. half thrust washers placed on both sides of the centre
main bearing.
Figure 70-100-104
Figure 70-100-106
3
B-05581
P-08840
Make sure the dowels (Item 1) [Figure 70-100-104] are

in the block correctly. Install a dial indicator on the end of the crankshaft
[Figure 70-100-106].
Install the new gasket (Item 2) on the housing (Item 3)
[Figure 70-100-104]. Pry the crankshaft to the rear of the cylinder block and
set the dial indicator to zero.
Install the seal replacer tool (PD145-3) (Item 4) [Figure
70-100-104] on the crankshaft.
Lubricate the seal, tool, and crankshaft with clean engine

oil.

RECONDITIONING THE ENGINE (CONT'D) Cooling System Description
Checking Crankshaft End Play (Cont'd) Figure 70-100-109
Figure 70-100-107
1
S6913
P-08841
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-100-109], to assist the
Remove the pry bar and record the dial indicator reading flow of the coolant through the system.
[Figure 70-100-107].

The water pump is gear driven from the gear off the fuel
The end play specification is 0,05 - 0,38 mm injection pump.
(0.002 - 0.015 in) maximum.
From the water pump, the coolant passes through a
If end play is excessive there is over size thrust washers passage in the timing case.
available to reduce movement.
The coolant passes through a passage in the left side of
Figure 70-100-108 the cylinder block to the rear of the cylinder block.
Figure 70-100-110
B-05583
S6914
The end play can also be checked using a feeler gauge
[Figure 70-100-108].
The oil cooler (Item 1) [Figure 70-100-110] is installed on
Pry the crankshaft to the rear of the cylinder block and the left side of the engine. Coolant from the by-pass
measure the distance between the thrust washer and connection at the rear of the coolant pump passes
crankshaft. through a pipe to the oil cooler.

RECONDITIONING THE ENGINE (CONT'D) Thermostat Removal and Installation
Cooling System Description (Cont'd) Drain the engine coolant until it is below the thermostat
level.
Figure 70-100-111
Figure 70-100-112
1 1
P-55778
P-55778
The coolant then passes around the cylinders and in the

cylinder head. The coolant exits the cylinder head at the Remove the bolts (Item 1) [Figure 70-100-112] and

front and passes into the thermostat housing (Item 1) thermostat housing.
[Figure 70-100-111].
Installation: Make sure all gasket surfaces are clean.
If the thermostat is closed, the coolant goes directly Replace the gasket before installing the thermostat
through a by-pass to the inlet side of the water pump. If housing.
the thermostat is open, the thermostat closes the by-pass
and the coolant passes to the radiator. Figure 70-100-113
P-55780
Remove the housing and thermostat [Figure 70-100-

113].

RECONDITIONING THE ENGINE (CONT'D) Water Pump Removal
Thermostat Testing Remove the coolant from the cooling system.
Hang the thermostats in a suitable container filled with Figure 70-100-115

coolant.
1
Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
open.
1
If the thermostats do not operate correctly they must be 1
replaced.
NOTE: Identify thermostat temperature by the

stamping on the bypass valve.
1
Lubricating Oil Cooler Removal And Installation
Figure 70-100-114 S6913
1 1
from the water pump.

Remove the water pump.
2 Water Pump Installation
Clean the gasket surfaces and replace the gasket.
Install the water pump in the timing cover. The pump is a

tighten fit in the cover and is pulled into position by
tightening the bolts evenly.
1 1
P-55782
Install the water pump bolts (Item 1) [Figure 70-100-115]
and tighten to 22 N•m (16 ft-lb) torque.
Remove the eight mounting bolts (Item 1) and remove
the cooler (Item 2) [Figure 70-100-114].
Installation: Check oil level using the dipstick add oil as

needed.

Engine Lubrication System Description
Figure 70-100-116
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 100-118] to the cylinder block.
The oil passes to the main bearings of the crankshaft and

Pressure lubrication is supplied by a rotor type pump through passages in the crankshaft to the big end
(Item 1) [Figure 70-100-116] which is driven through an bearings. The pistons and the cylinder bores are

idler gear from the crankshaft gear. lubricated by splash and oil mist.
Engine oil from the oil pan sump passes through a Engine oil passes from the main bearings through
strainer (Item 2) [Figure 70-100-116] and pipe to the passages in the cylinder block to the journals of the
suction side of the pump. camshaft. Engine oil passes from the centre journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-100- shaft, at a reduced pressure, to feed the rocker bushing.
116], which is installed in the bottom left side of the The oil passes through a passage in the rocker shaft to
cylinder block. The relief valves opens if the oil pressure the bearings of the rocker levers. The valve stems, valve
is too high; this allows some of the engine oil to return to springs and the tappets are lubricated by splash and oil
the sump. mist.
Figure 70-100-117 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
1 The turbocharger is lubricated by oil after the filter. Oil is

supplied from a connection on the right side of the
cylinder block through an external pipe to the
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
S6449
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-100-117].

RECONDITIONING THE ENGINE (CONT'D) Oil Pan Removal And Installation
Engine Lubrication System Description (Cont'd) Figure 70-100-121
Figure 70-100-119 2
P-8740
P-08745
Remove the oil pan retaining bolts (Item 1) [Figure 70-
100-121].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-100-119]. These jets are connected to the oil Remove the pan (Item 2) and gasket [Figure 70-100-

pressure rail and spray lubricating oil inside the pistons to 121].
keep them cool.
Clean the pan in solvent and dry with compressed air.
Oil Filter Adapter Removal And Installation
Clean the block surface.
Figure 70-100-120
Installation: Place a new gasket on the oil pan. Place
two bolts on each side to position the oil pan correctly.
2 Install the remaining bolts. Tighten the bolts to 22 N•m
(16 ft-lb) torque [Figure 70-100-121].
1
1
S6915
Remove the oil filter.
Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-100-120].
Clean the filter adapter and the block mounting surfaces.
Using a new gasket, install the adapter (Item 2) [Figure

70-100-120] on the block.
Install the oil filter.

Oil Screen And Pick-up Tube

1
Figure 70-100-122
2
4
1
3
P-08744
Remove the oil pressure relief valve (Item 1) [Figure 70-

P-08834
100-123].
Remove the bolt (Item 1) that holds the bracket (Item 2) Remove the oil screen and pick-up tube.
[Figure 70-100-122] to the main bearing cap.
The oil pump is installed on the number 1 main bearing

Remove the bolts (Item 3) [Figure 70-100-122] from the cap.
pick-up tube flange.
NOTE: The pump can be removed with the main
Remove the pick-up tube (Item 4) [Figure 70-100-122] bearing cap if a spanner wrench is available
and gasket. that will allow the torque to be applied directly
to the main cap bolts.
Wash the assembly in solvent and dry with compressed
air. If there is no spanner wrench, the front timing case cover
must be removed. (See “Timing Cover Removal” on
Check the tube and strainer for cracks or other damage. page 70-100-20.)
Replace as necessary.
Figure 70-100-124
Loosely assemble the bracket (Item 2) [Figure 70-100-
122] with the pick-up tube to the main bearing cap.
Install the pick up tube gasket and mounting bolts (Item

3) [Figure 70-100-122].
Tighten the mounting bolts to 22 N•m (16 ft-lb) torque.
Tighten the bolt (Item 1) [Figure 70-100-122] for the pick-

up tube bracket. 2
Tighten the bolt to 22 N•m (16 ft-lb) torque.

1
Oil Pump Removal
NOTE: The oil pump has a channel in the body of the P-08835
pump. Oil from the front main bearing passes
down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft Remove the snap ring (Item 1), idler gear (Item 2)
bushing. [Figure 70-100-124], and washer.
Remove the oil pan. (See “Oil Pan Removal And Remove the bolts and oil pump.

Oil Pump Installation
Figure 70-100-125
B-05588
1
Check that there is a minimum of 0,076 mm (0.003 in)
P-08835 backlash between the idler gear and oil pump gear
[Figure 70-100-126].
Fill the pump with engine oil. End play for the idler gear should be 0,050 / 0,275 mm
(0.0019 / 0.0108 in).

If the number one main cap was removed, reinstall and
tighten to 250 N•m (185 ft-lb) torque. Install the oil screen and pick-up tube. (See Page 70-100-
44.)
Install the pump on the main cap and tighten to 22 N•m
(16 ft-lb) torque. Install the pressure relief valve.
Check the idler gear and bushing for wear. Install the oil pan. (See “Oil Pan Removal And
Lubricate with clean engine oil and install the washer,
idler gear (Item 1) and snap ring (Item 2) [Figure 70-100-
125].
Check the backlash between oil pump and idler gears.
There must be a minimum of 0,076 mm (0.003 in).

Oil Pump Disassembly And Assembly
Figure 70-100-127
B-05593
Check the rotor end play [Figure 70-100-129].
Rotor end play must be 0,038 - 0,089 mm (0.0014 -

B-05591
0.0035 in) for the inner rotor.
NOTE: If any part is worn enough to effect Rotor end play must be 0,025 - 0,076 mm (0.0010 -
performance replace the complete oil pump. 0.0029 in) for the outer rotor.

Remove the cover of the oil pump. Install the cover and tighten the bolts to 22 N•m (16 ft-lb)
torque.
Remove the outer rotor and thoroughly clean. Check for
cracks or other damage. Oil Pressure Relief Valve Disassembly And Assembly
Install the outer rotor and check the outer rotor to body Figure 70-100-130
clearance [Figure 70-100-127].
Clearance between the outer rotor and body must be

0,152 - 0,330 mm (0.0059 - 0.0129 in). 2
Figure 70-100-128
5
4
1
3
B-05606
Press the end plate (Item 1) in the valve body (Item 2)

and remove the snap ring (Item 3) [Figure 70-100-130].
Remove the end plate (Item 1), spring (Item 4), and
B-05592 plunger (Item 5) from the body (Item 2) [Figure 70-100-
130].
Check the inner rotor to outer rotor clearance [Figure 70- Clean the parts in solvent and dry with compressed air.
100-128].
Lubricate the bore of the valve body (Item 2), plunger
Clearance between the inner rotor and outer rotor must (Item 5) and the end plate (Item 1) [Figure 70-100-130]
be 0,040 - 0,127 mm (0.0015 - 0.005 in). with clean engine oil before assembly.

RECONDITIONING THE ENGINE (CONT'D) Engine Block Disassembly And Assembly
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-110-40.)
Figure 70-100-131
Remove the oil cooler. (See Removal And Installation on

Page 70-50-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
1
Remove the turbocharger. (See Turbo Charger Removal
Remove the fuel lift pump. (See Fuel Lift Pump Removal
P-08837
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the cylinder head. (See Cylinder Head Removal

on Page 70-110-6.)
The liners (Item 1) [Figure 70-100-131] are made of cast
iron. Production liners are a press fit and service liners Remove the timing case and gears. (See Timing Case
are a transion fit. Both types of liners are honed with And Gear Removal on Page 70-110-21.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the piston and connecting rod assemblies. (See
Pistons And Connecting Rods Removal on Page 70-110-
Figure 70-100-132 26.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-110-24.)
Remove the engine mounting bracket and flywheel. (See

1 Removal And Installation on Page 70-100-1.)
Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-110-36.)
P-08842
A bushing (Item 1) [Figure 70-100-132] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet alignment
Piston Cooling Jet Removal Figure 70-100-135
Figure 70-100-133
1 1
55,25 mm
(2.2”)
14 mm
(0.55”)
N-00535
P-08754
Insert a 1,70 mm (0.067 in) diameter rod of suitable
length, in the jet.
Remove the piston cooling jet assembly (Item 1) [Figure
70-100-133] from the engine block. The tip of the rod must extend out the top of the cylinder

in an area 55,25 mm (2.2 in) in height and 14 mm (0.55
Figure 70-100-134 in) of width to provide proper cooling jet alignment to cool
the pistons [Figure 70-100-135].
Inspection
Clean all passages of coolant and oil.

2
Check the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
3 cylinder block.
1
Check the camshaft bushing for wear. If the bushing
P-08836 needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up.
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-100-134] for damage.
Replace as needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-100-134] in
the block.
Install the mounting bolt (Item 2) [Figure 70-100-134]

and tighten to 9 N•m (8 ft-lb) torque.

Cylinder Liner Inspection
Figure 70-100-136
B-04066
Check the cylinder liner bore for out of round or wear

P-08837 beyond service limits [Figure 70-100-137]. The inside
diameter of the service liner should be 105,000 - 105,025
mm (4.1338 - 4.1348 in).
The condition of a cylinder liner is decided by:
A flex type hone can be used to clean up small scoring or

• The amount and location of polished areas. pitting.
• Wear. Damaged or worn liners must be replaced.
• Damage to the liner wall.
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [Figure 70-100-136]

for cracks, deep scratches and polished areas where the
honed finish is worn away.

RECONDITIONING THE ENGINE (CONT'D)
Cylinder Liner Removal
Figure 70-100-138

6
B-05556
NOTE: Where several liners are to be removed or a

very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) over the centre of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
100-138] is against the bottom of the recess.
Install the rod (Item 4) through the handle (Item 5)

[Figure 70-100-138].
Place the adapter (Item 6) [Figure 70-100-138] under

the cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.

RECONDITIONING THE ENGINE (CONT'D) Place the threaded rod (Item 4) through the handle (Item
5) and liner (Item 1) [Figure 70-100-139].
Cylinder Liner Installation
Adjust the rod until it is below the bottom of the block
surface.
Install the adapter (Item 6) [Figure 70-100-139] on the

IMPORTANT rod. Centre the adapter against the bottom of the block.
For the first five hours after the new liners have been Tighten the nut and washer.
installed:
• Do not operate at full load. Turn the handle and press the liner in the bore, stopping
• Do not operate at high speed. when approximately 50 mm (2 in) remain. Apply
• Do not allow engine to idle for extended periods. LOCTITE #603 to the outer surface below the flange and
I-2117-1196 to the flange recess.
Continue to press the liner into position. Remove the tool.

Figure 70-100-139
NOTE: Do Not hit the cylinder liners with a hammer.
4 They will be damaged.
5 Figure 70-100-140
3 2

1 1
2
B-0507
Check liner protrusion with a dial gauge [Figure 70-100-

140].
The liner can have 0,10 mm (0.004 in) protrusion or

recession from the block face.
6 Allow 15 minutes before measuring the bore. The liner

B-05555 will take 6 hours to reach full strength.
The inside diameter of the service liner should be

Clean the cylinder bore and the outside of the liner. 105,000 - 105,025 mm (4.1338 - 4.1348 in).
Lubricate the cylinder bore with engine oil. New piston rings must be used when the cylinder liners
have been replaced.
Start the liner (Item 1) [Figure 70-100-139] in the bore.
Make sure it is started straight. The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the [Figure 70-100-140].
bearing (Item 3) [Figure 70-100-139] in the recess at the
top.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor And Alternator Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-4
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-5
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
CONDENSER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW) . . . . . . . . . . 80-60-1
CONDENSER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE) . . . . . . . . . . . 80-61-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1


PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
EVAPORATOR / BLOWER UNIT (S/N A8GA12999 & BELOW, S/N A8GB12999 &
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EVAPORATOR / BLOWER UNIT (S/N A8GA13000 & ABOVE, S/N A8GB13000 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-91-1
EXPANSION VALVE (S/N A8GA12999 & BELOW,

S/N A8GB12999 & BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
EXPANSION VALVE (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE) . . . . . . . . 80-101-1
HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-2

Core Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-3

AIR CONDITIONING SYSTEM FLOW
Principles
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 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurises the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.)
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 80-10-2.) 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 80-10-2.)
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5)(See Chart on Page 80-10-2.) As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1 1
S6876
1
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

S6874 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is recommend-

ed to be turned on for at least 5 minutes week- 1
ly throughout the year to lubricate the internal
components.
Figure 80-10-2
P-27595
1
Pressure Switch: The pressure switch (Item 1) [Figure

80-10-4] is located on the receiver / drier assembly (Item
2) [Figure 80-10-3]. It will disengage the compressor
clutch if the pressure readings are too low or too high,
which indicates loss of refrigerant.
S6875
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
Figure 80-10-5
1
S6924
Blower Fan Switch: This is a three position switch (Item

1) [Figure 80-10-7]. When the blower fan switch is in the
OFF position the A/C will not engage.
P-27489

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
10-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.
Figure 80-10-6
P-27596
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

Components (Cont'd)
S/N A8GA13000 & Above, A8GB13000 & Above:
Figure 80-10-8
2 3 1
P-97010
1. Blower Fan Switch - This is a three position switch

(Item 1) [Figure 80-10-10]. When the blower fan
switch is in the OFF position the A/C will not engage.
S36335
2. Temperature Control - Turn clockwise to increase cab
temperature; anticlockwise to decrease.

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
10-8] is located under the dashboard inside the cab. The
3. Air Conditioning Switch (If Equipped) - Press the top
unit delivers the cold air for the A/C into the cab. The unit
of the switch (Item 3) [Figure 80-10-10] to turn the Air
also contains the blower fan, evaporator coil and
Conditioning ON - Press the bottom of the switch to
thermostat which are not serviceable.
turn the Air Conditioning OFF.
Figure 80-10-9
S36333
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-9] controls the amount of refrigerant entering the
evaporator coil.

Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-10-11
P-16398
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear

P-16398 gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-10-
11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety Items and one or the other is HFC R-134a refrigerant can be dangerous if not
absolutely required. properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
WARNING substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
In the event of a leak, wear safety goggles. Escaping
Any servicing work that involves release or addition
refrigerant can cause severe injuries to eyes. In
of R-134a to the system must be done by a
contact with a flame, R-134a refrigerant gives a toxic
competent refrigeration dealer who has the proper
gas.
W-2371-0611
equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611

REGULAR MAINTENANCE Compressor And Alternator Drive Belt Inspection
Filters Inspect the compressor drive belt for wear regularly. (See
SERVICE SCHEDULE on Page 10-50-1.)
Fresh Air Filters
Open the engine cover. (See Opening And Closing on
Figure 80-20-1 Page 10-160-1.)
1 Remove the belt cover.

1
Figure 80-20-3
2
1
P-97023A

The fresh air filter is located on the front of the operator
cab. Remove the two nuts (Item 1) and filter cover
S6874
(Item 2) [Figure 80-20-1].
Figure 80-20-2 Check the tension on the compressor belt (Item 1)

[Figure 80-20-3].
1 1
2
P-97025
Remove the two bolts and nuts (Item 1), the filter cover
(Item 2) and filter (Item 3) [Figure 80-20-2] (both sides).
Clean or replace the filter as necessary.

REGULAR MAINTENANCE (CONT'D) S/N A8GA13000 & Above, A8GB13000 & Above:
Cleaning The Condenser Figure 80-20-5
Open the engine cover. 2
S/N A8GA12999 & Below, A8GB12999 & Below:
Figure 80-20-4
1
S36349
1 Clean the condenser (Item 1) [Figure 80-20-5] using

water or air pressure.
P-52613 Loosen the nut (Item 2) [Figure 80-20-5] and tilt the

condenser forward.
Clean the condenser (Item 1) [Figure 80-20-4] using Figure 80-20-6

water or air pressure.
NOTE: Clean between the oil cooler and condenser.

1
2
S36350
Clean between the oil cooler (Item 1) and the condenser

(Item 2) [Figure 80-20-6].
Air Conditioning Lubrication
Run the air conditioning for about 5 minutes every week

to lubricate the internal components.

REGULAR MAINTENANCE (CONT'D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:


TROUBLESHOOTING
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor earth and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator / Blower
Unit.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction clean evaporator fins with
air or water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator /
switch (frozen Blower unit.

evaporator).
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on The high side pressure will be low and bubbles can be present Repair any leaks and
refrigerant. in sight glass on receive drier. recharge the refrigerant to
the correct level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture
excess refrigerant. Charge
to the correct refrigerant
level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic
clutch.
5. Oil on the clutch Clutch slips. Replace or clean the
surface. clutch surface.
6. Open coil. Clutch does not engage and there is not reading when a Replace clutch.
circuit tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the earth and connections. Repair.
earth.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 1,44 - 1,82 MPa (14,4 - 18,2 bar) (210 - 265 psi)
Low pressure side pressure: 0,1 - 0,22 MPa (1,0 - 2,2 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2.Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge

present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed ex- The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
pansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading can be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Replace Evaporator / Blower unit.
tion.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the fan.
formance. Operating.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil charge The high pressure side will be high. Evacuate system. Remove oil
from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
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.

Gauge Pressure Related Troubleshooting (Cont’d)

High pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge
present in sight glass on receiver drier. the refrigerant to the correct
level.
System pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2.Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
P-90410

Troubleshooting Tree (Cont’d)
P-90411

P-90412

P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP °C (°F) BAR (PSI) TEMP °C (°F) BAR (PSI)
-8,9 (16) 1,08 (15.69) 33,9 (93) 7,60 (110.20)
-7,8 (18) 1,17 (17.04) 34,4 (94) 7,73 (112.10)
-6,7 (20) 1,27 (18.43) 35 (95) 7,87 (114.10)
-5,6 (22) 1,30 (19.87) 37,8 (100) 8,57 (124.30)
-4,4 (24) 1,47 (21.35) 38,9 (102) 8,56 (128.50)
-3,3 (26) 1,58 (22.88) 40 (104) 9,16 (132.90)
-2,2 (28) 1,69 (24.47) 41,1 (106) 9,47 (137.30)
-1,1 (30) 1,80 (26.10) 42,2 (108) 9,78 (141.90)
0 (32) 1,92 (27.79) 43,3 (110) 10,10 (146.50)
1,1 (34) 2,04 (29.52) 44,4 (112) 10,43 (151.30)
2,2 (36) 2,16 (31.32) 45,6 (114) 10,76 (156.10)
3,3 (38) 2,29 (33.17) 46,7 (116) 11,11 (161.10)
4,4 (40) 2,42 (35.07) 47,8 (118) 11,45 (166.10)
5,6 (42) 2,55 (37.03) 48,9 (120) 11,81 (171.30)
6,7 (44) 2,70 (39.05) 50 (122) 12,18 (176.60)

7,2 (45) 2,76 (40.09) 51,1 (124) 12,55 (182.00)
10 (50) 3,14 (45.48) 52,2 (126) 12,93 (187.50)
12,8 (55) 3,53 (51.27) 53,3 (128) 13.31 (193.10)
15,6 (60) 3,96 (57.47) 54,4 (130) 13,71 (198.90)
18,3 (65) 4,42 (64.10) 57,2 (135) 14,73 (213.70)
21,1 (70) 4,91 (71.19) 60 (140) 15,82 (229.40)
23,9 (75) 5,43 (78.75) 62,8 (145) 16.95 (245.80)
26,7 (80) 5,98 (86.80) 65,6 (150) 18,13 (263.00)
29,4 (85) 6,58 (95.40) 68,3 (155) 19,38 (281.10)
32,2 (90) 7,20 (104.40) 71,1 (160) 20,69 (300.10)
32,8 (91) 7,33 (106.30) 73,9 (165) 22,07 (320.10)
33,3 (92) 7,46 (108.20) 76,7 (170) 23,50 (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 12,2 - 13,3°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4,4°C (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.
Example: Ambient Temperature = 32,2°C (90°F)

32,2°C (90°F)
+ 4,4°C (40°F)
54,4°C (130°F) condenser temperature = 1.38 MPa (13,8 bar), (200 psi)
Conditions and pressures will vary from system to system.

Poor A/C Performance Figure 80-30-3
Start the telescopic handler, engage the parking brake.

Engage the A/C system with the blower fan on high. Run
the telescopic handler at full RPM for approximately 15
minutes, with the cab door closed.
Figure 80-30-1

1
P-27746
Check the temperature at the louvers (Item 1) [Figure

80-30-1] and [Figure 80-30-2] with a thermometer
[Figure 80-30-3].
P-27747

The louver temperature should be between 2,2 - 11,6°C
(36 - 53°F) depending on the amount of humidity in the
Figure 80-30-2 air.
S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE If the louver temperature is too high (See
TROUBLESHOOTING on Page 80-30-1.)
1 Check the blower fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR / BLOWER
UNIT (S/N A8GA12999 & BELOW, S/N A8GB12999 &
BELOW) on Page 80-90-1.) or (See EVAPORATOR /
BLOWER UNIT (S/N A8GA13000 & ABOVE, S/N
A8GB13000 & ABOVE) on Page 80-91-1.)
Check the belt tension on the A/C compressor. (See

Compressor And Alternator Drive Belt Inspection on
Page 80-20-1.)
S36340
Check the A/C condenser for dirt or mud, and clean if
necessary. (See Cleaning The Condenser on Page 80-
20-2.)
Inspect the sight glass located on the receiver / drier for

air bubbles. (See Cleaning The Condenser on Page 80-
20-2.)

HVAC Repair And Leaks
Figure 80-30-4
S6876
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /

drier (Item 1) [Figure 80-30-4] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT'D) Figure 80-30-7
Electrical System S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE
Figure 80-30-5
S36336
1
Turn the blower fan switch (Item 1) [Figure 80-30-6] and
S6874 [Figure 80-30-7] to the first on position. The compressor
clutch should make a click sound, which indicates the
clutch is engaging.
Check to see if the compressor clutch (Item 1) [Figure
80-30-5] is engaging. Figure 80-30-8

Turn the Start key switch to the RUN position without
starting the machine.
Figure 80-30-6
1
P-52598
If the compressor clutch does not engage, check the fuse

S6924 (Item 1) [Figure 80-30-8]. Replace the fuse if needed.

Electrical System (Cont'd)
Figure 80-30-9
1
1
P-27738
With a multimeter, check the voltage to the compressor

P-52593 clutch at the main harness (Item 1) [Figure 80-30-11].
If there is no power at the clutch, check the wiring

Disconnect the connector (Item 1) [Figure 80-30-9] from harness for broken wires.
the compressor.

If there is no power at the clutch, reconnect the wiring
Figure 80-30-10 harness to the compressor clutch.
Figure 80-30-12
P-52597
S6876
With a multimeter check the resistance to the compressor
clutch connector (Item 1) [Figure 80-30-10].
Disconnect the machine harness (Item 1) [Figure 80-30-
If there is no resistance value replace the compressor 12] from the pressure switch.
clutch. (See COMPRESSOR on Page 80-50-1.)

Electrical System (Cont'd) S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW
Figure 80-30-13
1 1
P-27597
Figure 80-30-16
S6877
With the key switch to the run position (engine off) and
the blower fan switch on the first position. Use a

multimeter to check the main harness (Item 1) [Figure
80-30-13] for voltage.
There should be 12 volt. If there is no voltage, check the

harness for broken wires.
1
Figure 80-30-14
S36344
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-30-15] and [Figure 80-30-16] from the main
harness.
1
S6878
If there is voltage at the harness, check the resistance at

the pressure switch (Item 1) [Figure 80-30-14].
If there is no resistance value, check for a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-40-1.)
If good resistance value is observed, the pressure switch

is good.
Reconnect the main harness to the pressure switch.

Figure 80-30-17
P-27742
Check the main harness (Item 1) [Figure 80-30-17] for

voltage. The voltage should be 12 volt. If there is no

voltage, check the harness for broken wires.
Figure 80-30-18
P-27743
If there is voltage at the wiring harness, check the

thermostat wire (green) for resistance. The resistance
value should be 10 ohm at 20°C (68°F) [Figure 80-30-
18].
If there is no resistance, replace the entire blower fan

unit.


1
Figure 80-30-19
1
P-27745

voltage. The voltage should be 12 volt if there is no
voltage check the harness for broken wires.
S4598

Figure 80-30-20
P-27744
Disconnect the main wire harness connectors (Item 1)

[Figure 80-30-23] from the switch.
NOTE: Mark the wires for correct assembly.

S/N A8GA13000 & Above, S/N A8GB13000 & Above: 1
Figure 80-30-22
S36342

1 voltage. The voltage should be 12 volt if there is no
voltage check the harness for broken wires.
2
S36336
Remove the four screws (Item 1) [Figure 80-30-22].

Remove the panel (Item 2) [Figure 80-30-22].
Figure 80-30-23
S36341
Disconnect the main wire harness connector (Item 1)

[Figure 80-30-23] from the switch.

For All Models:
Figure 80-30-25
H C
M B
N-22288
If there is voltage at the main harness check the blower

fan switch [Figure 80-30-25] for resistance.

With the switch in the OFF position, there should be zero
resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-30-25].

also between the C terminal and the M terminal frame
[Figure 80-30-25].

also between the C terminal and the H terminal frame
[Figure 80-30-25].
If any of the above resistance tests fail, replace the

blower fan switch.


SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Figure 80-40-1
WARNING
gas.
W-2371-0611
1
NOTE: This test is run with the engine OFF, and the A/
2 C switch in the OFF position.
Figure 80-40-3
1
P-52599

Remove the access cover mounting bolt (Item 1) [Figure
80-40-1].
Remove the access cover (Item 2) [Figure 80-40-1].
Figure 80-40-2
N-23024
NOTE: Before reclaiming a refrigeration system, it is

1 recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-3]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
2 that can be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
P-27478
that are reclaimed and charged from your
MEL 1581 Recovery / Recycling / Recharging
Machine.
Locate the low pressure port (Item 1) and high pressure
port (Item 2) [Figure 80-40-2] on the back side of the Remove the protective cap and connect the refrigerant
compressor. identifier to the low pressure hose (Item 1) [Figure 80-
40-2].
Connect the refrigerant identifier to its power source.

SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation Procedure (Cont'd)
Figure 80-40-4
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
refrigeration equipment.
S6879 W-2373-0611
Follow the steps displayed on the refrigerant identifier Figure 80-40-5

screen [Figure 80-40-4].

Allow 2 minutes for the refrigerant identifier to display the
type of refrigerant and air content. An alarm will sound if
potentially flammable hydrocarbons are present and will
also indicate on the visual display.
Disconnect the refrigerant identifier from the A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.
If R134a is found, evacuate the system.

N-22291
Use an approved recovery / charging unit [Figure 80-40-

WARNING 5] to evacuate the system.
Connect the reclaimer to the A/C charge ports.

gas.
W-2371-0611

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-8
Reclamation Procedure (Cont'd)
Figure 80-40-6
2
N-22381
NOTE: The reclaimer unit, has a complete step by

P-25225 step set of instructions [Figure 80-40-8] to
follow for reclamation and recharging of the
A/C system. A trained technician should
Connect the Red hose (Item 1) [Figure 80-40-6] to the follow these instructions as they can vary
high pressure port and open the valve. slightly depending on the model and brand of

reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-40-6] to the
low pressure port and open the valve.
Figure 80-40-7
N-22292
Turn the reclaimer unit [Figure 80-40-7] to the ON

position and follow the on screen instructions.

Charging Procedure With A Manifold Gauge Set
Open the hood.
WARNING 2
refrigerant can cause severe injuries to eyes. In 1
gas.
W-2371-0611 S6880
Figure 80-40-9
Connect the Red hose (Item 1) [Figure 80-40-10] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-10] to the

low pressure port and open the valve.

1
Figure 80-40-11
1
1
P-52622
Check to see that the hand valves (Item 1) [Figure 80-

40-9] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure. S6882
(See Reclamation Procedure on Page 80-40-1.)
Connect the gauges to the A/C charge ports. Connect the Yellow hose (Item 1) [Figure 80-40-11] to
the vacuum pump.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Determine the problem with the A/C system and repair it.
Charging Procedure With A Manifold Gauge Set Figure 80-40-14

(Cont’d)
Figure 80-40-12
1 1
P-27485
P-52626 A thermistor vacuum gauge (Item 1) [Figure 80-40-14]

can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
Start the vacuum pump and open ISO-valve (Item 1) monitors and visually indicates the vacuum level.

[Figure 80-40-12] on the vacuum pump.
The thermistor vacuum gauge is used with the vacuum
Run the vacuum pump for at least 5 - 10 minutes to pump [Figure 80-40-14].
insure that a vacuum has been pulled on the system.
Start the vacuum pump and open ISO-valve on the
Close the ISO-valve (Item 1) [Figure 80-40-12] (which vacuum pump.
isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump. Be sure that both hand valves, and both charge port
valves are open.
Charging Procedure
Run the vacuum pump for at least 45 minutes to insure
Figure 80-40-13 that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
1 Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

gauge.
S6880
Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-40-13]. Let stand for 5-
10 minutes and recheck the pressure for changes.
If the pressure drops, this can be an indication of a leak

in the A/C system.

Charging Procedure (Cont’d) S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW
Figure 80-40-15
S6924
1 Figure 80-40-18
2
S6883
Place a refrigerant container with R134a (Item 1) on a

charging scale (Item 2) [Figure 80-40-15] and zero out

the scale. 1
Connect the yellow hose (Item 3) [Figure 80-40-15] from

the manifold gauge set to the valve on the refrigerant
tank.
Figure 80-40-16
S36336
2
Turn the A/C fan switch (Item 1) [Figure 80-40-17] and

[Figure 80-40-18] to HIGH position.
Start the machine, and run at medium speed.
Watch the scale and run system until the predetermined

1 amount of refrigerant is added to the A/C system.
The A/C system holds 0,800 kg (1.76 lb) of refrigerant.
S6884 Turn off the valve on the refrigerant container, and hand
valves on the manifold gauge set.
Open the valve on the refrigerant container (Item 1) and Turn off the engine and remove the A/C charging
open the low pressure hand valve (Blue) (Item 2) [Figure equipment from the machine.
80-40-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilises. Install access cover.

COMPRESSOR
Evacuate the A/C system. (See Reclamation Procedure

WARNING
on Page 80-40-1.)
Remove the alternator. (See Removal And Installation on
Page 60-30-1.)
gas.
W-2371-0611
Remove the compressor belt.

1
1
S6885 P-52609
Remove the compressor hoses (Item 1) [Figure 80-50-

Remove the two tensioner pulley mount belts (Item 1)
3].
[Figure 80-50-1]. Remove the pulley assembly.
Installation: Tighten the hoses to 29,8 N•m (22 ft-lb)
Figure 80-50-2
torque.
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
1
Figure 80-50-4
P-52608 1
Disconnect the connector (Item 1) [Figure 80-50-2] from

the compressor.
S6886
Mark the compressor hoses for correct installation.
Remove the mount bolts (Item 1) [Figure 80-50-4].
Remove the compressor.

COMPRESSOR (CONT'D) Oil Check
Oil The compressor oil should be checked as follows when

oil is being added to an in service machine.
Figure 80-50-5
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-40-1.)
1
Open the cab door and windows.
Run the blower fan at maximum speed.

P-27538
Run the compressor for at least 20 minutes at 800 - 1200
RPM.
The compressor (Item 1) [Figure 80-50-5] is factory filled
with 150 - 170 cc's of PAG oil (Poly Alkelene Glycol). Remove the compressor from the machine.

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver-drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, 30 cc (1 U.S. fl oz) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check (Cont'd)
Figure 80-50-6
1
P-27542
NOTE: After draining the oil through the drain hole

P-27539 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.

Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish colour, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-50-9
1
2
P-27545 1
Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole
(Item 2) [Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m

(9.4 - 10.8 ft-lb) torque.
P-27543
Add new compressor oil through the suction side

Installation: Add 150 - 170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor.

Clutch Disassembly And Assembly

1
Figure 80-50-10
32 MM 32 MM
(1.25”) (1.25”)
32 MM
(1.25”)
P-27524
1
The armature plate puller (Item 1) [Figure 80-50-12] can
P-27519 be constructed by drilling three 8 mm (0.315 in) holes in a
flat circular plate, located 31,75 mm (1.25 in) apart.
Remove the centre armature nut (Item 1) [Figure 80-50- Figure 80-50-13
10].

Assembly: Tighten the armature nut to 12 N•m (8 ft-lb).
Figure 80-50-11
1
P-27522
Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-50-13].
P-27520
To remove the armature plate (Item 1) [Figure 80-50-11]

from the clutch face you must make an armature plate
puller.

COMPRESSOR (CONT'D) The specified clearance for the clutch is 0,3 - 0,6 mm
(0.01 - 0.02 in) adjusting shims are available in the
Clutch Disassembly And Assembly (Cont'd) following thicknesses.
Figure 80-50-14 0,1 mm (0.0039 in)

0,3 mm (0.0118 in)
0,5 mm (0.0197 in)
Figure 80-50-16
P-27521
Attach a slide hammer puller to the armature puller tool

[Figure 80-50-14].
P-27525

Figure 80-50-15
Remove the snap ring (Item 1) [Figure 80-50-16] from
the pulley assembly.
Figure 80-50-17
2 1
P-27523
Remove the armature plate (Item 1) [Figure 80-50-15]

from the compressor clutch.
P-27526
Remove the shims (Item 2) [Figure 80-50-15] from the

armature shaft or armature plate. Remove the pulley from the compressor [Figure 80-50-
17].
Assembly: Insure that the clutch has the correct
clearance by adding the shims (Item 2) [Figure 80-50-
15].

Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-18
P-27529
Remove the harness retainer screw assembly (Item 1)

P-27527 [Figure 80-50-20].
Figure 80-50-21
The pulley assembly and bearing [Figure 80-50-18] must
be replaced as a complete unit.

Figure 80-50-19
1
2
1
P-27530
Remove the snap ring (Item 1) [Figure 80-50-21] from

P-27528 the coil.
Remove the lock (Item 1) and connector (Item 2) [Figure

80-50-19] from the compressor harness.

COMPRESSOR (CONT'D)
Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-22
P-27531
Remove the coil from the compressor [Figure 80-50-22].

Figure 80-50-23
P-27527
The compressor [Figure 80-50-23] must be replaced as

a complete unit.


CONDENSER (S/N A8GA12999 & BELOW, S/N Figure 80-60-2
A8GB12999 & BELOW)
Remove the refrigerant from the A/C system.

(See Reclamation Procedure on Page 80-40-1.) 1
WARNING
contact with a flame, R-134a refrigerant gives a toxic P-52611
gas.
W-2371-0611
Remove the A/C hose (Item 1) [Figure 80-60-2] from the
condenser.
Figure 80-60-1
Figure 80-60-3

1
P-52612
P-52614
condenser.
Remove the two nuts (Item 1) [Figure 80-60-3] from
each side of the condenser.
NOTE: Install caps and plugs on all fittings.
Tilt the condenser forward and remove.


CONDENSER (S/N A8GA13000 & ABOVE, S/N Figure 80-61-2
A8GB13000 & ABOVE)

(See Reclamation Procedure on Page 80-40-1.) 2
WARNING 1

contact with a flame, R-134a refrigerant gives a toxic S36353
gas.
W-2371-0611
Remove two nuts (Item 1) from the condenser mount
(Item 2) [Figure 80-61-2].
Figure 80-61-1
NOTE: One nut is hidden on [Figure 80-61-2].
3
Figure 80-61-3

1
1
2
S36351
Remove the tie straps (Item 1) [Figure 80-61-1] from the

condenser. S36352

Remove the nut (Item 1) [Figure 80-61-3] from the
condenser.
condenser.
Remove the A/C hose (Item 3) [Figure 80-61-1] from the
Tilt the condenser forward and remove.
condenser.


RECEIVER / DRIER Figure 80-70-2
Removal And Installation 1 1

WARNING
2
refrigerant can cause severe injuries to eyes. In P-52616
gas.
W-2371-0611 Remove the two hoses (Item 1) [Figure 80-70-2] from
the Receiver / Drier.
Figure 80-70-1 NOTE: Mark the hoses for correct installation.

Loosen the bolt (Item 2) [Figure 80-70-2] on the
mounting bracket.
S6876
Disconnect the connector (Item 1) [Figure 80-70-1] from

the pressure switch.


PRESSURE SWITCH Figure 80-80-2

(See “Reclamation Procedure” on Page 80-40-1.) 1
WARNING
refrigerant can cause severe injuries to eyes. In P-52616
gas.
W-2371-0611 Remove the pressure switch (Item 1) [Figure 80-80-2]
from the Receiver / Drier assembly.
Figure 80-80-1

2
S6876
Disconnect the connector (Item 1) from the pressure

switch (Item 2) [Figure 80-80-1].


EVAPORATOR / BLOWER UNIT (S/N A8GA12999 & Figure 80-90-2
BELOW, S/N A8GB12999 & BELOW)
Remove the refrigerant from the A/C system. 1

(See “Reclamation Procedure” on page 80-40-1)
WARNING
gas.
W-2371-0611 Temporarily remove the covering (Item 1) [Figure 80-90-
2] from the A/C hoses and expansion valve.
Figure 80-150-1
Figure 80-90-3
1
2

1
P-25221
P-25244

Remove the bolt (Item 1) and plate (Item 2) [Figure 80-
Figure 80-90-1 90-3]. Remove both A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-90-1].

BELOW, S/N A8GB12999 & BELOW) (CONT'D)
Figure 80-90-4
P-27599
1 Remove the front mounting bolt (Item 1) [Figure 80-90-

6].
P-27597
Place the evaporator / blower unit on the seat.
Disconnect the thermostat wiring connector (Item 1) Figure 80-90-7

[Figure 80-90-4].

Figure 80-90-5
2
1 1
P-27600
Remove the drain hose (Item 1) [Figure 80-90-7].

P-27598
Remove the evaporator / blower unit from the machine.

Remove the three mount bolts (Item 1) and earth wire
(Item 2) [Figure 80-90-5] from the back of the evaporator
unit.

ABOVE, S/N A8GB13000 & ABOVE)
Remove the refrigerant from the A/C system. (See

Reclamation Procedure on Page 80-40-1.)
1
WARNING
gas.
W-2371-0611
Remove the vent (Item 2) [Figure 80-91-2].
Figure 80-91-3
Figure 80-91-1

2
S36344
S36333

located under the dashboard.
1].

avoid contamination.
Remove the two heater hoses (Item 2) [Figure 80-91-1].

ABOVE, S/N A8GB13000 & ABOVE) (CONT’D)

1
Figure 80-91-4
1
S36347
Remove the evaporator / blower unit (Item 1) [Figure 80-

91-6].
S36345
Remove the two bolts (Item 1) [Figure 80-91-4] on the

right side of the evaporator / blower unit.
Figure 80-91-5
S36346
Remove the two bolts (Item 1) [Figure 80-91-5] on the

left side of the evaporator / blower unit outside the cab.

EXPANSION VALVE (S/N A8GA12999 & BELOW, Figure 80-100-3
S/N A8GB12999 & BELOW)
Remove the refrigerant from the A/C system. 1

(See “Reclamation Procedure” on Page 80-40-1)
WARNING
gas.
W-2371-0611
Temporarily remove the covering (Item 1) [Figure 80-
100-3] from the A/C hoses and expansion valve.
Figure 80-100-1
Figure 80-100-4

2
P-25221
P-25244

Remove the bolt (Item 1) and plate (Item 2) [Figure 80-
Figure 80-100-2 100-4]. Remove both A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-100-2].

EXPANSION VALVE (S/N A8GA12999 & BELOW,
S/N A8GB12999 & BELOW) (CONT'D)
Figure 80-100-5
P-27667
Remove the two mount bolts (Item 1) [Figure 80-100-5].

Remove the expansion valve.
Figure 80-100-6
P-27666
The expansion valve (Item 1) [Figure 80-100-6] is

replaced as a complete unit.

EXPANSION VALVE (S/N A8GA13000 & ABOVE, Figure 80-101-2
A8GB13000 & ABOVE)

1
WARNING
gas.
W-2371-0611
Remove the two evaporator fittings (Item 1) [Figure 80-
101-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 29,8
Figure 80-101-1

NOTE: Plug the evaporator tubelines to prevent
contamination.
Figure 80-101-3
1
2
S36333
1
Mark and remove both A/C hoses (Item 1) [Figure 80-

101-1].
S36348
Remove the two mount bolts (Item 1) [Figure 80-101-3].
Remove the expansion valve (Item 2) [Figure 80-101-3].
NOTE: The expansion valve (Item 2) [Figure 80-101-3]

is replaced as a complete unit.


HEATER ASSEMBLY Figure 80-170-2
The heater asembly is part of the evaporator / blower

unit. Remove the evaporator / blower unit. (See Removal
Remove the travel / signal levers. (See Removal And 1

Remove the instrument panel. (See Removal And P-25590

Remove the switch panel. (See Removal And Installation Remove the vent hoses (Item 1) [Figure 80-170-2] from
on Page 60-80-1.) the top of the assembly.
Remove the dash cover / steering column cover. Figure 80-170-3


Figure 80-170-1
P-25591
P-25589
Clamp the heater hoses [Figure 80-170-3].
Disconnect the connector (Item 1) [Figure 80-170-1].

HEATER ASSEMBLY (CONT'D) Fan Removal And Installation
Removal And Installation (Cont'd) Figure 80-170-6
Figure 80-170-4
P-25594
P-25592
Carefully remove the clip (Item 1) and cable (Item 2)
[Figure 80-170-6].
Remove the heater hoses (Item 1) [Figure 80-170-4]
from the heater assembly. Figure 80-170-7

Figure 80-170-5
1
1
1
P-25595
1
Remove the fan mounting bolts (Item 1) [Figure 80-170-
P-25593 7] and remove the fan.

and remove the heater assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-170-10
Core Removal And Installation
Figure 80-170-8
1
P-25604
1
Remove the two bolts (Item 1) [Figure 80-170-10] and

P-25602 save for later use.
Figure 80-170-11
Remove the two flange mounting nuts (Item 1) [Figure
80-170-8]. 1

1
Figure 80-170-9
1
1
P-25601
Remove the four screws (Item 1) [Figure 80-170-11]

P-25603 from the vent bracket.
Remove the flange / linkage assembly (Item 1) [Figure

80-170-9] from assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-170-14
Core Removal And Installation (Cont'd)
Figure 80-170-12
P-25607
2
Slide the core from the housing [Figure 80-170-14].

P-25605
Remove the end bracket (Item 1) and spacer (Item 2)

[Figure 80-170-12] from the assembly.

Figure 80-170-13
P-25606
Be sure to separate the bracket (Item 1) and tab (Item 2)

[Figure 80-170-13].

SPECIFICATIONS
(T40140) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
(T40170) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7

Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
860 of 895 SPEC-1 T40140, T40170 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
861 of 895 SPEC-2 T40140, T40170 Service Manual

(T40140) TELESCOPIC HANDLER SPECIFICATIONS
Each attachment and each Telescopic Handler have different Load

Capacity Charts. For example: An 84 inch bucket used on a T2250 will
WARNING have its own chart; that same 84 inch bucket when used on a T3571 will
have a different chart. Be sure you use the correct chart for your
attachment and Telescopic Handler combination.
Dimensions are given for machine equipped with standard tyres and can vary with other tyre types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Dimensional Specifications

(A) Overall length (with forks) 7304 mm (287.6 in)
(B) Overall length (with carriage) 6099 mm (240.1 in)
(C) Overall length (without attachment) -
(D) Overall length (to front tyres) 4589 mm (180.7 in)
(E) Overall height (with rotating beacon) 2701 mm (106.3 in)
(F) Overall height 2473 mm (97.4 in)
(G) Carriage rotation angle 125°
(I) Height to back of the machine -
(J) Ground clearance 503 mm (19.8 in)
(M) Wheelbase 2850 mm (112.2 in)
(O) Operator cab outside width 930 mm (36.6 in)
(P) Track width (front and rear) 1992 mm (36.6 in)
(Q) Width over standard tyres 2394 mm (94.3 in)
(R) External turning radius (with forks) 5748 mm (226.3 in)
(S) External turning radius (at tyres) 4260 mm (167.7 in)
(T) External turning radius (at counterweight) -
(U) Internal turning radius 1560 mm (61.4 in)
Carriage crowding angle 15°
Carriage tilting angle 110°
Width with stabilisers down 2475 mm (97.4 in)
Height to steering wheel 1804 mm (71.0 in)
Height of lifted stabilisers 1200 mm (47.2 in)
Operator cab inside width 920 mm (36.2 in)
Front wheel lifting when on stabilisers -
862 of 895 SPEC-10-1 T40140, T40170 Service Manual

(T40140) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)
Performance Specifications
Crowding force 5000 daN (11240.45 lb)

Drawbar pull 4800 daN (10790.83 lb)
Ground pressure on tyres 600 kPa (6 bar) (87.0 psi)
Ground pressure on stabilisers 1000 kPa (10 bar) (145.0 psi)
Rated operation capacity* 4000 kg (8818.5 lb)
Capacity (at max. height on stabilisers) 4000 kg (8818.5 lb)
Capacity (at max. height on tyres) 2500 kg (5511.6 lb)
Capacity (at max. reach on stabilisers) 1300 kg (2866.0 lb)
Capacity (at max. reach on tyres) 250 kg (551.2 lb)
Push force -
Tipping load -
Lifting height - on stabilisers 13610 mm (535.8 in)
Lifting height - on tyres 13430 mm (528.7 in)
Max. reach on stabilisers 9700 mm (381.9 in)
Max. reach on tyres 9800 mm (385.8 in)
Banking corrector 4° / 4°
Sideshift (max.) 1400 mm (55.1 in)

* Static and dynamic tests have been carried out and passed according to EN1459.
Weights
Weight (unladen) 10000 kg (22046.2 lb)

Front axle weight unladen 3790 kg (8355.5 lb)
Rear axle weight unladen 6210 kg (13690.7 lb)
Total weight with pallet frame and forks 10320 kg (22751.7 lb)
Front axle weight with pallet frame and forks 4370 kg (9634.2 lb)
Rear axle weight with pallet frame and forks 5950 kg (13117.5 lb)
Total weight with pallet frame, forks and 3500 kg 14320 kg (31570.2 lb)
(7716.2 lb) load
Front axle weight with pallet frame, forks and 12235 kg (26973.5 lb)
3500 kg (7716.2 lb) load
Rear axle weight with pallet frame, forks and 2085 kg (4596.6 lb)
3500 kg (7716.2 lb) load
Engine
Make / Model PERKINS / 1104D-44TA Turbo

Fuel Diesel
Cooling Liquid
Rated power (DIN 6271) at 2200 rpm 74,5 kW (100 hp)
Rated speed 2200 rpm
Maximum torque at 1400 rpm 410 N•m (302.4 ft-lb)
Number of cylinders 4
Displacement 4,4 L (1.16 U.S. gal)
Bore 105 mm (4.1 in)
Stroke 127 mm (5 in)
Ignition Diesel-compression

Controls
Engine Foot accelerator pedal

Starting Key-type starter switch and shutdown. Key activated air intake
heater
Front auxiliary Variable thumbwheel on joystick
Hydraulics lift and tilt Electro-hydraulic joystick
Hydraulics telescope in and telescope out Variable thumbwheel on joystick
Service brake Pedal-activated wet multi-disc on front axle
Secondary brake Hydrostatic transmission
Parking brake Hand lever activates spring-applied pressure release multi-disc
brake
Steering Proportional hydraulic steering via a conventional steering wheel
Speed range and reverse selection Left-hand multi-function lever on the central console
4WD / 2WD / parallel drive selection Three-position switch on the right-hand console
Auxiliary pressure release Button activated in cab
Drive System

Transmission Hydrostatic with electronic regulation
Main drive 2-speed hydrostatic motor
Traction
Standard tyres BFGOODRICH 400/80x24

Optional tyres DUNLOP 400/80x24 156B T37 TL
Tyre pressures 425 kPa (4,25 bar) (61.6 psi)
Low speed (forward / reverse) 8 km/h (5.0 mph)
High speed (forward / reverse) 30 km/h (18.6 mph)
Driving modes Direct drive / soft drive
Steering
Steering pump Casappa gear pump mounted on equipment pump

Steering modes 2WS / 4WS / CRAB
Brakes
Engine braking Hydrostatic

Parking and emergency brake Negative brake with hydraulic command
Service brake Oil-immersed disc

Fluid Capacities
Axle and reduction gears front / rear 11,9 / 11,4 L (3.14 / 3.0 U.S. gal)
Cooling system 17 L (4.5 U.S. gal)
Engine oil 8,5 L (2.2 U.S. gal)
Engine lubrication plus oil filter 8,5 L (2.2 U.S. gal)
Fuel tank 140 L (37.0 U.S. gal)
Hydraulic reservoir 77 L (20.3 U.S. gal)
Hydraulic system plus reservoir 145 L (38.3 U.S. gal)
Hydraulic System
Pump type Gear pump with LS valve

Pump capacity 105 L/min (27.7 U.S. gpm)
Relief valve pressure setting 26,5 MPa (265 bar) (3843.5 psi)
Auxiliary flow 80 L/min (21.1 U.S. gpm)
Electrical

Alternator 90 A - open
Battery 12 V - 105 Ah - 720 A cold cranking A at -18°C (0°F) - 180 min
reserve capacity
Starter 12 V - gear reduction type

Instruments
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Fuel gauge
Hydraulic fluid temperature gauge
Engine coolant temperature gauge
Sight level gauge
Indicators
Front and rear wheel alignment status
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Trailer turn indicators operational
Parking brake
Longitudinal Stability Indicator alarm active
Longitudinal Stability Indicator alarm neutralised
Windscreen wipers

Work lights
Flashing warning lights
Hazard warning lights
Transmission mode
Hydraulic function lock
Rear fog lights
Heater fan
End of high stroke for the winch
Boom-head hydraulic function locked
Boom-head hydraulic function in continuous mode
Warning lights
Hydraulic fluid temperature over 95°C (203°F)
Engine coolant over 103°C (217°F)
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
Environmental
Noise level LpA (EU Directive 2000/14/EC) 82 dB(A) Noise level LWA (EU Directive 2000/14/EC) 106 dB(A)
Operator position noise level 104 dB(A) Uncertainties YY dB(A)
(EU Directive 2006/42/EC)
Whole body vibration (ISO 2631-1) 0,8 m/s² Uncertainties 0,2 m/s²
(limit 0,5 m/s²)
Hand-arm vibration (ISO 5349-1) N/A Uncertainties N/A
(limit 2,5 m/s²)
Temperature Range
Operation and storage - 20°C / + 40°C (-4 /104°F)


(T40170) TELESCOPIC HANDLER SPECIFICATIONS
Each attachment and each Telescopic Handler have different Load

Capacity Charts. For example: An 84 inch bucket used on a T2250 will
WARNING have its own chart; that same 84 inch bucket when used on a T3571 will
have a different chart. Be sure you use the correct chart for your
attachment and Telescopic Handler combination.
Dimensions are given for machine equipped with standard tyres and can vary with other tyre types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Dimensional Specifications

(A) Overall length (with forks) 7415 mm (291.9 in)
(B) Overall length (with carriage) 6210 mm (244.5 in)
(C) Overall length (without attachment) 6107 mm (240.4 in)
(D) Overall length (to front tyres) 4589 mm (180.7 in)
(E) Overall height (with rotating beacon) 2701 mm (106.3 in)
(F) Overall height 2473 mm (97.4 in)
(G) Carriage rotation angle 125°
(I) Height to back of the machine -
(J) Ground clearance 503 mm (19.8 in)
(M) Wheelbase 2850 mm (112.2 in)
(O) Operator cab outside width 930 mm (36.6 in)
(P) Track width (front and rear) 1992 mm (78.4 in)
(Q) Width over standard tyres 2394 mm (94.3 in)
(S) External turning radius (at tyres) 4260 mm (167.7 in)
(T) External turning radius (at counterweight) -
(U) Internal turning radius 1560 mm (61.4 in)
Carriage crowding angle 15°
Carriage tilting angle 110°
Width with stabilisers down 2475 mm (97.4 in)
Height to steering wheel 1804 mm (71 in)
Height of lifted stabilisers 1200 mm (47.2 in)
Operator cab inside width 920 mm (36.2 in)
Front wheel lifting when on stabilisers -

Performance Specifications
Crowding force 5000 daN (11240 lb)

Drawbar pull 4800 daN (10791 lb)
Ground pressure on tyres 600 kPa (6 bar) (87 psi)
Ground pressure on stabilisers 1000 kPa (10 bar) (145 psi)
Rated capacity 4000 kg (8818 lb)
Capacity (at max. height on stabilisers) 2500 kg (5512 lb)
Capacity (at max. height on tyres) 1250 kg (2756 lb)
Capacity (at max. reach on stabilisers) 560 kg (1234.5 lb)
Capacity (at max. reach on tyres) 0 kg (0 lb)
Push force 4800 daN (10791 lbf)
Tipping load -
Lifting height - on stabilisers 17430 mm (686 in)
Lifting height - on tyres 17180 mm (676 in)
Max. reach on stabilisers 13670 mm (538 in)
Max. reach on tyres 13730 mm (540 in)
Banking corrector 4° / 4°
Sideshift (max.) 1400 mm (55 in)

* Static and dynamic tests have been carried out and passed according to EN1459.
Weights
Weight (unladen) 10970 kg (24185 lb)

Front axle weight unladen 4720 kg (10406 lb)
Rear axle weight unladen 625 kg (1378 lb)
Total weight with pallet frame and forks 10290 kg (22686 lb)
Front axle weight with pallet frame and forks 5325 kg (11740 lb)
Rear axle weight with pallet frame and forks 5965 kg (13151 lb)
Total weight with pallet frame, forks and 3500 kg 15290 kg (33709 lb)
(7716 lb) load
Front axle weight with pallet frame, forks and 13395 kg (29531 lb)
3500 kg (7716 lb) load
Rear axle weight with pallet frame, forks and 1895 kg (4178 lb)
3500 kg (7716 lb) load
Engine
Make / Model PERKINS / 1104D-44TA Turbo

Fuel Diesel
Cooling Liquid
Rated power (DIN 6271) at 2200 rpm 74,5 kW (100 hp)
Rated speed 2200 rpm
Maximum torque at 1400 rpm 410 N•m (302.4 ft-lb)
Number of cylinders 4
Displacement 4,4 L (1.16 U.S. gal)
Bore 105 mm (4.1 in)
Stroke 127 mm (5 in)
Ignition Diesel-compression

Controls
Engine Foot accelerator pedal

Starting Key-type starter switch and shutdown. Key activated air intake
heater
Front auxiliary Variable thumbwheel on joystick
Hydraulics lift and tilt Electro-hydraulic joystick
Hydraulics telescope in and telescope out Variable thumbwheel on joystick
Service brake Pedal-activated wet multi-disc on front axle
Secondary brake Hydrostatic transmission
Parking brake Hand lever activates spring-applied pressure release multi-disc
brake
Steering Proportional hydraulic steering via a conventional steering wheel
Speed range and reverse selection Left-hand multi-function lever on the central console
4WD / 2WD / parallel drive selection Three-position switch on the right-hand console
Auxiliary pressure release Button activated in cab
Drive System

Transmission Hydrostatic with electronic regulation
Main drive 2-speed hydrostatic motor
Traction
Standard tyres BFGOODRICH 400/80x24

Optional tyres DUNLOP 400/80x24 156B T37 TL
Tyre pressures 425 kPa (4,25 bar) (61.6 psi)
Low speed (forward / reverse) 8 km/h (5 mph)
High speed (forward / reverse) 30 km/h (18.6 mph)
Driving modes Direct drive / soft drive
Steering
Steering pump Casappa gear pump mounted on equipment pump

Steering modes 2WS / 4WS / CRAB
Brakes
Engine braking Hydrostatic

Parking and emergency brake Negative brake with hydraulic command
Service brake Oil-immersed disc

Fluid Capacities
Axle and reduction gears front / rear 11,9 / 11,4 L (3.1 / 3.0 U.S. gal)
Cooling system 17 L (4.5 U.S. gal)
Engine oil 8,5 L (2.25 U.S. gal)
Engine lubrication plus oil filter 8,5 L (2.25 U.S. gal)
Fuel tank 140 L (37 U.S. gal)
Hydraulic reservoir 77 L (20.34 U.S. gal)
Hydraulic system plus reservoir 145 L (38.3 U.S. gal)
Hydraulic System
Pump type Gear pump with LS valve

Pump capacity 105 L/min (27.7 gpm)
Relief valve pressure setting 26,5 MPa (265 bar) (3843.5 psi)
Auxiliary flow 80 L/min (21.1 gpm)
Electrical

Alternator 90 A - open
Battery 12 V - 105 Ah - 720 A cold cranking A at -18°C (0°F) - 180 min
reserve capacity
Starter 12 V - gear reduction type

Instruments
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Fuel gauge
Hydraulic fluid temperature gauge
Engine coolant temperature gauge
Sight level gauge
Indicators
Front and rear wheel alignment status
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Trailer turn indicators operational
Parking brake
Longitudinal Stability Indicator alarm active
Longitudinal Stability Indicator alarm neutralised
Windscreen wipers

Work lights
Flashing warning lights
Hazard warning lights
Transmission mode
Hydraulic function lock
Rear fog lights
Heater fan
End of high stroke for the winch
Boom-head hydraulic function locked
Boom-head hydraulic function in continuous mode
Warning lights
Hydraulic fluid temperature over 95°C (203°F)
Engine coolant over 103°C (217.4°F)
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
Environmental
Noise level LpA (EU Directive 2000/14/EC) 82 dB(A) Noise level LWA (EU Directive 2000/14/EC) 106 dB(A)
Operator position noise level 104 dB(A) Uncertainties YY dB(A)
(EU Directive 2006/42/EC)
Whole body vibration (ISO 2631-1) 0,8 m/s² Uncertainties 0,2 m/s²
(limit 0,5 m/s²)
Hand-arm vibration (ISO 5349-1) N/A Uncertainties N/A
(limit 2,5 m/s²)
Temperature Range
Operation and storage - 20°C / + 40°C (-4 / 104°F)


MACHINE TORQUE SPECIFICATIONS
Axle
N•M FT-LB
Axle To Frame Mounting Bolts 370-410 275-300
Brake Housing Hex Bolt 80 59
Brake Housing Spring Bolts 10 7
Brake Housing Stud 120 88
Differential Lock Retainer Bolt 13 10
Fender Mount Bolt 125-140 90-100
Housing Bolt 320 236
Housing Nut 190 140
King Pin Mount Bolts 190 140
Pinion Ring Gear Bolts 13 10
Planetary Cover Bolts 25 18
Planetary Gear Mount Bolts 120 88
Steering Cylinder Bolts 120 88
Tie Rod Jam Nut 250 185
Tie Rod Nut 220 160
Tie Rod Swivel End 406 300

Turn Stop Adjust Jam Nut 150 110
Wheel Nuts 300 221
Boom
N•m ft-lb
Extension Cylinder Base End 180 133
Extension Cylinder Rod End 255-285 188-210
Wear Pads Front 58 43
Wear Pads Rear 39 29
Drive Box
N•m ft-lb
Cover Bolts 60 44
Inner Housing Bolts 120 88
Mounting Flange Bolts 60 44
Drive Motor
N•m ft-lb
End Cap Bolts 115 85
Mounting Bolts 210 155
Mounting Plate Bolts 63 46

MACHINE TORQUE SPECIFICATIONS (CONT’D)
Engine
N•m ft-lb
A/C Compressor Mount Bolts 120 88
Alternator Mount Bolts 54 45
Starter Mount Bolts 54 45
Hydraulic Pump
N•M FT-LB
Filter Head 122 90
Flange Adapter 122 90
Guide Post Bolts 23 17
Mounting Bolts 106 78
Retaining Plate 13 10
Servo End Cap 13 10
Side Cover Bolts 32 24

TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90-100) (125 - 140)
0.625 170 - 190 240 - 190

(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
N•m 0.875 450 - 490 645 - 710
(ft-lb) (330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 -12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11-16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 8 - 14 N•m 30 - 41 N•m 49 - 68 N•m
(13 -18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-40-2
IMPORTANT Nut Nut
When repairing hydrostatic and hydraulic systems, Washer

Washer
clean the work area before disassembly and keep all O-ring
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system.
I-2003-0888
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or

B-07575 weather cracked rubber.
Always use two wrenches when loosening and tightening

When the fitting is tightened, you can feel when the fitting
hose or tubeline fittings.
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].

HYDRAULIC CONNECTION SPECIFICATIONS NOTE: If a torque wrench cannot be used, use the
(CONT'D) hex flat tightening method as an approximate
guideline.
Port Seal Fitting
NOTE: Port seal fittings are not recommended in all
Figure SPEC-40-3 applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE N•M

THREAD SIZE
WRENCH SIZE (FT-LB)
11/16" 9/16" - 18 30 (22)
15/16" 3/4" - 16 54 (40)
1-1/8" 7/8" - 14 81(60)
1-1/4" 1-1/16" - 12 114 (84)
1-1/2" 1-5/16" - 12 160 (118)
Nut Seals
to Fitting Figure SPEC-40-4

Nut Seals
to Port
2
Secondary O-ring Seal

1
P-13008
P-13571
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-3]. Do not use port seal fittings when a thread in orifice (Item
1) [Figure SPEC-40-4] is used in the port. The orifice
The hex portion of the nut does not contact the surface of can interfere with the fitting and prevent it from sealing.
the component when the nut is tight.
Use an O-ring boss fitting (Item 2) [Figure SPEC-40-4]
Use the following procedure to tighten the port seal as shown.
fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications
Use Bobcat Axle / Transmission Oil LS (P/N 6987724),

for the transfer case, planetaries and axle housings.
Use Bobcat Superior SH Hydraulic / Hydrostatic Oil

(P/N 6987721).
DO NOT use automatic transmission fluids in the

machine or permanent damage to the hydraulic /
hydrostatic system will result.
WARNING

Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
When temperatures below zero degree -18° (64,4°F) are

common, the machine must be kept in a warm building.
Extra warm-up time must be used each time the machine
is started during cold temperature conditions. Cold fluid
will not flow easily and it makes action on the hydraulic
function slower. Loss of fluid flow to the hydrostatic pump
can cause damage in less than 60 seconds.
WARNING
During cold weather (0°C [32°F] and below), do not
operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311


CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion


ALPHABETICAL INDEX
(T40140) TELESCOPIC HANDLER ELECTRICAL SYSTEM INFORMATION (S/N

SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1 A8GA13000 & ABOVE, S/N A8GB13000 &
(T40170) TELESCOPIC HANDLER ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-1
SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-7 EMERGENCY EXIT . . . . . . . . . . . . . . . 10-200-1
ACCUMULATOR . . . . . . . . . . . . . . . . . . 20-230-1 END BOOM . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
AIR CLEANER SERVICE . . . . . . . . . . . . 10-60-1 ENGINE AND ENGINE MOUNTS . . . . . . 70-60-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . 70-40-1 ENGINE COMPONENTS AND TESTING 70-70-1
AIR CONDITIONING SYSTEM FLOW . . 80-10-1 ENGINE COOLING SYSTEM . . . . . . . . . 10-70-1
AIR INTAKE COWLING . . . . . . . . . . . . . . 50-70-1 ENGINE COVER . . . . . . . . . . . . . . . . . . 10-160-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . 60-30-1 ENGINE COVER . . . . . . . . . . . . . . . . . . . 50-60-1
APPROVED BOOM STOP . . . . . . . . . . 10-150-1 ENGINE INFORMATION . . . . . . . . . . . . . 70-10-1
ATTACHMENT CARRIER . . . . . . . . . . . 10-110-1 ENGINE LUBRICATION SYSTEM . . . . . 10-90-1
AXLE AND DIFFERENTIAL (FRONT) . . 40-20-1 ENGINE SPEED CONTROL . . . . . . . . . . 70-20-1
AXLE AND DIFFERENTIAL (REAR) . . . . 40-21-1 ENGINE TIMING . . . . . . . . . . . . . . . . . . . 70-71-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . 40-40-1 ENGINE / HYDROSTAT ASSEMBLY . . . 70-80-1
AXLES (FRONT AND REAR) . . . . . . . . 10-120-1 EVAPORATOR / BLOWER UNIT (S/N
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 A8GA12999 & BELOW, S/N A8GB12999 &

BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
BCC MAIN CONTROLLER (S/N A8GA12001 &
ABOVE, S/N A8GB12001 & ABOVE) . . 60-170-1 EVAPORATOR / BLOWER UNIT (S/N
A8GA13000 & ABOVE, S/N A8GB13000 &
BOBCAT TELESCOPIC HANDLER ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . 80-91-1
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 1-14
EXPANSION VALVE (S/N A8GA12999 &
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . 50-30-1 BELOW,
BOOM TRAY . . . . . . . . . . . . . . . . . . . . . 50-160-1 S/N A8GB12999 & BELOW) . . . . . . . . . 80-100-1
BRAKE LIGHT SWITCH . . . . . . . . . . . . . 60-90-1 EXPANSION VALVE (S/N A8GA13000 & ABOVE,
BRAKE VALVE . . . . . . . . . . . . . . . . . . . 20-120-1 A8GB13000 & ABOVE) . . . . . . . . . . . . . 80-101-1
BUCKET POSITIONING CYLINDER . . . 20-30-1 EXTENSION CYLINDER . . . . . . . . . . . . 20-40-1
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 FAN MOTOR . . . . . . . . . . . . . . . . . . . . . 20-140-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . 80-50-1 FENDER . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
CONDENSER (S/N A8GA12999 & BELOW, S/N FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 1-10
A8GB12999 & BELOW) . . . . . . . . . . . . . 80-60-1 FLOW CONTROL VALVE . . . . . . . . . . . 20-190-1
CONDENSER (S/N A8GA13000 & ABOVE, S/N FLYWHEEL AND HOUSING . . . . . . . . . . 70-90-1
A8GB13000 & ABOVE) . . . . . . . . . . . . . . 80-61-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONVERSIONS . . . . . . . . . . . . . . . . SPEC-60-1 FRAME LEVEL SPEED SWITCH . . . . . 60-140-1
DASH COVER / STEERING COLUMN COVER FRAME LEVELING CYLINDER . . . . . . 20-100-1
(S/N A8GA12999 & BELOW, A8GB12999 &
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . 40-30-1
DASH COVER / STEERING COLUMN COVER FRONT WEIGHT . . . . . . . . . . . . . . . . . . 50-180-1
(S/N A8GA13000 & ABOVE, S/N A8GB13000 & FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10-80-1
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 1-13 GEAR PUMP . . . . . . . . . . . . . . . . . . . . . 20-130-1
DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 HEATER ASSEMBLY . . . . . . . . . . . . . . 80-170-1
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . 40-70-1 HYDRAULIC / HYDROSTATIC FLUID
ELECTRICAL SYSTEM INFORMATION (S/N SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-50-1
A8GA12999 & BELOW, S/N A8GB12999 & HYDRAULIC / HYDROSTATIC SYSTEM 10-100-
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1 1
884 of 895 INDEX-01

HYDRAULIC CONNECTION SPECIFICATIONS . PRESSURE SWITCH . . . . . . . . . . . . . . . 80-80-1
SPEC-40-1 QUICK-TACH CYLINDER . . . . . . . . . . . . 20-90-1
HYDRAULIC CONTROL VALVE . . . . . . 20-170-1 QUICK-TACH . . . . . . . . . . . . . . . . . . . . . . 50-90-1
HYDRAULIC FLUID RESERVOIR . . . . . 20-150-1 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
HYDRAULIC SYSTEM INFORMATION . . 20-10-1 REAR WEIGHTS . . . . . . . . . . . . . . . . . . 50-100-1
HYDROSTATIC DRIVE MOTOR . . . . . . . 30-30-1 RECEIVER / DRIER . . . . . . . . . . . . . . . . 80-70-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . 30-40-1 RECONDITIONING THE ENGINE . . . . 70-100-1
HYDROSTATIC SYSTEM INFORMATION . 30-10- REGULAR MAINTENANCE . . . . . . . . . . 80-20-1
1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . .1-9
INCHING SWITCH . . . . . . . . . . . . . . . . . 60-120-1
SERIAL NUMBER LOCATION . . . . . . . . . . .1-12
INSTRUMENT PANEL . . . . . . . . . . . . . . . 60-70-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . 40-80-1
INTERMEDIATE BOOM . . . . . . . . . . . . . 50-150-1
SERVICE MANUAL REVISION . . . . . . . . .SMR-1
JOYSTICK PANEL (S/N A8GA12999 & BELOW,
A8GB12999 & BELOW) . . . . . . . . . . . . . 50-130-1 SERVICE MANUAL REVISION . . . . . . . . .SMR-1
JOYSTICK PANEL (S/N A8GA13000 & ABOVE, SERVICE MANUAL REVISION . . . . . . . . .SMR-1
A8GB13000 & ABOVE) . . . . . . . . . . . . . 50-131-1 SERVICE SCHEDULE . . . . . . . . . . . . . . . 10-50-1
JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . 60-180-1 SERVICE SOFTWARE . . . . . . . . . . . . . 60-130-1
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . 20-20-1 STABILISER CONTROL VALVE . . . . . . 20-260-1
LIFTING AND BLOCKING THE TELESCOPIC STABILISER CYLINDER . . . . . . . . . . . . 20-250-1

HANDLER . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 STABILISER FRAME . . . . . . . . . . . . . . . 50-170-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LLMI / LLMC SYSTEM (S/N A8GA15000 & STEERING ANGLE ADJUSTMENT . . . . 40-60-1
ABOVE, S/N A8GB15000 & ABOVE) . . 60-160-1
STEERING CYLINDER (FRONT) . . . . . . 20-60-1
LONGITUDINAL STABILITY INDICATOR
CALIBRATION (S/N A8GA11001-14999, STEERING CYLINDER (REAR) . . . . . . . 20-61-1
S/N A8GB11001-14999) . . . . . . . . . . . . 60-150-1 STEERING MODE VALVE BLOCK . . . . 20-110-1
LUBRICATING THE TELESCOPIC HANDLER . . STEERING VALVE . . . . . . . . . . . . . . . . 20-160-1
10-130-1 STOPPING THE ENGINE AND LEAVING THE
MACHINE TORQUE SPECIFICATIONS . .SPEC- TELESCOPIC HANDLER . . . . . . . . . . . 10-190-1
20-1 SWITCH PANEL (S/N A8GA12999 & BELOW,
MAIN RELIEF VALVE . . . . . . . . . . . . . . . 20-80-1 A8GB12999 & BELOW) . . . . . . . . . . . . . . 60-80-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . . 1-1 SWITCH PANEL (S/N A8GA13000 - 14999,
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 A8GB13000 - 14999) . . . . . . . . . . . . . . . . 60-81-1
OIL COOLER / RADIATOR . . . . . . . . . . . 70-50-1 SWITCH PANEL (S/N A8GA15000 & ABOVE, S/N
A8GB15000 & ABOVE) . . . . . . . . . . . . . . 60-82-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . 30-10-1
SYSTEM CHARGING AND RECLAMATION .80-
OPERATOR CAB (S/N A8GA13000 & ABOVE, 40-1
S/N A8GB13000 & ABOVE) . . . . . . . . . . . 50-11-1
TELESCOPIC HANDLER STORAGE AND
OPERATOR CAB (ROPS / FOPS) . . . . . . 10-20-1 RETURN TO SERVICE . . . . . . . . . . . . . 10-180-1
OPERATOR CAB (S/N A8GA12999 & BELOW, S/ TILT CYLINDER . . . . . . . . . . . . . . . . . . . . 20-50-1
N A8GB12999 & BELOW) . . . . . . . . . . . . 50-10-1
TORQUE SPECIFICATIONS FOR BOLTS SPEC-
OPERATOR SEAT . . . . . . . . . . . . . . . . . . 50-20-1 30-1
PARKING BRAKE . . . . . . . . . . . . . . . . . 20-210-1 TOW VALVE . . . . . . . . . . . . . . . . . . . . . . 20-240-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . 40-50-1 TOWING THE TELESCOPIC HANDLER 10-40-1
PEDAL ASSEMBLY . . . . . . . . . . . . . . . . 60-110-1 TRANSPORTING THE TELESCOPIC HANDLER
PIVOT LINK . . . . . . . . . . . . . . . . . . . . . . 50-120-1 ON A TRAILER . . . . . . . . . . . . . . . . . . . . 10-30-1
PORT RELIEF VALVES . . . . . . . . . . . . . 20-180-1 TRAVEL / SIGNAL LEVER (S/N A8GA12999 &
PRESSURE REDUCING VALVE . . . . . . 20-220-1 BELOW, S/N A8GB12999 & BELOW) . . . 60-60-1
885 of 895 INDEX-02

TRAVEL / SIGNAL LEVER (S/N A8GA13000 &
ABOVE, S/N A8GB13000 & ABOVE) . . . 60-61-1
TROUBLESHOOTING . . . . . . . . . . . . . . 40-10-1
TROUBLESHOOTING . . . . . . . . . . . . . . 80-30-1
TYRE MAINTENANCE . . . . . . . . . . . . . 10-140-1
WEAR PADS (FRONT) . . . . . . . . . . . . . . 50-50-1
WEAR PADS (REAR) . . . . . . . . . . . . . . . 50-51-1
WIPER MOTOR (FRONT) . . . . . . . . . . . 60-100-1
WIPER MOTOR (REAR) . . . . . . . . . . . . 60-102-1
WIPER MOTOR (TOP) . . . . . . . . . . . . . 60-101-1
886 of 895 INDEX-03

887 of 895
INDEX-04
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: T40140, T40170 - 1

Date: 16 February 2010
Product: Telescopic Handler
Model: T40140, T40170
Manual No: 6986768 (02-10)

The following Sections are a revision to the above Service Manual.
10-30 70-50
10-50 70-80
20-80 80-20
20-130 80-40
20-140 80-50
20-170 80-100
20-180 80-120
20-210 80-121
40-20 80-150
40-21 80-151
50-10 80-160
50-11 80-161
50-130 80-170
50-131
50-140
50-141
60-10
60-11
60-60
60-70
60-71
60-80
60-90
60-91
60-160
888 of 895 SMR-1 T40140, T40170 Service Manual

889 of 895 SMR-2 T40140, T40170 Service Manual

ROUTE TO
ATTENTION
SERVICE MANAGER X
Revision No: T40140, T40170 - 2

Date: 01 March 2011
Model: T40140, T40170
Manual No: 6986768 (03-11)

60-91
60-92
60-180
60-190
60-200
890 of 895 SMR-1

891 of 895
SMR-2
ROUTE TO
ATTENTION
SERVICE MANAGER X
Revision No: T40140, T40170 - 3

Date: 27 May 2011
Model: T40140, T40170
Manual No: 6986768 (06-11)

complete revision
892 of 895 SMR-1

893 of 895
SMR-2
ROUTE TO
ATTENTION
SERVICE MANAGER X
Revision No: T40140, T40170 - 4

Date: 26 July 2012
Model: T40140, T40170
Manual No: 6986768 (07-12)

10-70
60-160
hydraulic schematics
electrical schematics
894 of 895 SMR-1

895 of 895
SMR-2

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Service Manual

T40140, T40170 Telescopic Handler

S/N A8GA11001 & Above

Dealer Copy -- Not for Resale

6986768 (08-08) Revised (08-12) Printed in Belgium © Bobcat Company 2012

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-16081 B-16078 B-6589

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 895 1-3 T40140, T40170 Service Manual

6 of 895 1-4 T40140, T40170 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Dealer Copy -- Not for Resale

BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

7 of 895 1-5 T40140, T40170 Service Manual

8 of 895 1-6 T40140, T40170 Service Manual

2. Check that ROPS mounting 9. Enclosure door latches must

3. The seat belt must be 10. Attachment locking pins must

Dealer Copy -- Not for Resale

5. Machine signs (decals) must 12. Check for correct function of

7. Check for correct function of 14. Inspect for fuel, oil or

9 of 895 1-7 T40140, T40170 Service Manual

18. Check the electrical charging 22. Check function or condition of

Dealer Copy -- Not for Resale

20. Inspect for loose or broken

10 of 895 1-8 T40140, T40170 Service Manual

Dealer Copy -- Not for Resale

• The Telescopic Handler Operator Training Course is

DANGER available through your local dealer or at

The dealer and owner / operator review the

WARNING recommended uses of the product when delivered. If the

11 of 895 1-9 T40140, T40170 Service Manual

The machine and some attachments have components

Flammable debris (leaves, straw, etc.) must be removed

The operator’s area, engine compartment and engine

Dealer Copy -- Not for Resale

All fuels, most lubricants and some coolants mixtures are

Do not use the machine where exhaust, arcs, sparks or

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

12 of 895 1-10 T40140, T40170 Service Manual

Hydraulic System Always clean the machine and attachment, disconnect

Stop the engine and let it cool before adding fuel. No

Dealer Copy -- Not for Resale

Do not use ether or starting fluids on any engine that has

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

Check the spark arrester exhaust system regularly to

13 of 895 1-11 T40140, T40170 Service Manual

Always use the serial number of the Telescopic Handler Figure 2

Telescopic Handler Serial Number