s550 6989494 Enus SM Bob Cat s550

Service Manual
Dealer Copy -- Not for Resale
Skid-Steer Loader
S/N A3NL11001 & Above
S/N A3NM11001 & Above
S/N AZN811001 & Above
S/N AZN911001 & Above
6989494enUS (07-19) (J) Printed in U.S.A. ©2019 Bobcat Company. All rights reserved.
iT4
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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
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1204 NA1193

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

NA1192 NA1205 NA1206
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1200 NA1191 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW35-0409
1-1 S550 Service Manual

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1-2 S550 Service Manual

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CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
5 of 1234 1-3 S550 Service Manual


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15


SAFETY
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach® attachment

correctly installed, functional mounting system wedges and
and in good condition. linkages must function

correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good
correctly adjusted, clean and condition.
lubricated.
SERVICE
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check all machine fluid

be legible and in the correct levels.
location.
7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).
8. Check for correct function of 16. Lubricate the loader.

the work lights.
FW SSL-0119 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire

approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
FW SSL-0119 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.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death.

operator. The handbook is available from your dealer
W-2003-0807
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

gives general safety information.
This notice identifies procedures which must be • The Service Manual and Parts Manual are available
followed to avoid damage to the machine. from your dealer for use by mechanics to do shop-
I-2019-0284 type service and repair work.
• The Skid-Steer Loader Operator Training Course is

available through your local dealer or at Bobcat.com/
training or Bobcat.com. This course is intended to
DANGER provide rules and practices of correct operation of the
skid-steer loader. The course is available in English
and Spanish versions.
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not • Service Safety Training Courses are available from
avoided, will result in death or serious injury. your Bobcat dealer or at Bobcat.com/training or
D-1002-1107 Bobcat.com. They provide information for safe and
correct service procedures.
• The Skid-Steer Loader Safety Video is available from

WARNING your Bobcat dealer or at Bobcat.com/training or
Bobcat.com.
The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1016 SM

SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
Call Before You Dig

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1016SM

FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
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. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
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
Check all electrical wiring and connections for damage. system, but the muffler and the exhaust gases are still
Keep the battery terminals clean and tight. Repair or hot.
replace any damaged part or wires that are loose or
frayed. Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
Battery gas can explode and cause serious injury. Use procedure in the Operation & Maintenance Manual for
the procedure in the Operation & Maintenance Manual cleaning the spark arrester muffler (if equipped).
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-1016 SM

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

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.
Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1016 SM

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Earlier or later models (identification made by serial
number) may use different parts, or there may be
different procedures to follow when performing a specific
service operation.
Loader Serial Number
Figure 1
P109275
1
The engine serial number (Item 1) [Figure 3] is located
on the side of the engine behind the alternator.

P109031F
The loader serial number plate (Item 1) [Figure 1] is

located on the outside of the loader frame.
Figure 2
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine

Combination NA3095
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order in which the loader is produced.

DELIVERY REPORT
Figure 4
NA3106
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.

The delivery report must be reviewed and signed by the
owner or operator and the dealer.

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL and
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
and SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS

BUCKET [1]
STEP
BUCKET
STEPS
OPERATOR CAB
LIFT (ROPS and FOPS) [2]
CYLINDER LIFT ARM
REAR
GRILLE
LIFT ARM
BACK-UP SUPPORT DEVICE
ALARM
REAR
LIGHT
REAR
DOOR TAILLIGHT TIRES [3] NA5800
NA5801
[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS - Roll-Over Protective Structure per ISO 3471 and FOPS - Falling-Object Protective Structure per ISO
3449, Level I. Level II is available.
[3] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.


SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . 10-30-5
TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
REMOTE START TOOL KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-2
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM (EARLIER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cooling System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
ENGINE COOLING SYSTEM (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91-1

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91-1
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER MODELS) . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
HYDRAULIC / HYDROSTATIC SYSTEM (LATER MODELS) . . . . . . . . . . . . . . . . . . . 10-121-1

Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-121-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-5
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-6
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1


LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-3
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-90556
P-85425
Lift the rear of the loader and install jackstands in the

B-7023A notched area of the frame [Figure 10-10-2].
Figure 10-10-3
WARNING

Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807 P-85985
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the axle tubes [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tires. Make sure the tires clear the floor or any
obstacles.
NOTE: The lift arms are raised for photo clarity.

WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
23 of 1234 10-10-1 S550 Service Manual


LIFT ARM SUPPORT DEVICE
Description
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
Figure 10-20-1

1
P109033
The lift arm support device (Item 1) [Figure 10-20-1] is

used to support the lift arms while working on a machine
with the lift arms up.
A decal (Item 2) [Figure 10-20-1] located on the right

side of the operator cab provides instructions for
installing and removing the lift arm support device.
The procedures are described in more detail on the

following pages. (See Installing on Page 10-20-2.) and
(See Removing on Page 10-20-3.)

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-3
Installing
DANGER
P109014
P-90328
AVOID DEATH Lower the lift arm support device to the top of the lift
• Disconnecting or loosening any hydraulic cylinder. Hook the free end of the spring (Item 1) [Figure
tubeline, hose, fitting, component or a part failure 10-20-3] to the lift arm support device to prevent
can cause lift arms to drop. interference with lift arm support device engagement.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Sit in the operator’s seat, fasten the seat belt, and lower
support. Replace if damaged.

the seat bar. Start the engine.
D-1009-0409
Figure 10-20-4
Remove attachment from the loader. (See Operation And
Maintenance Manual.)
Figure 10-20-2
2
2
1 1
3
P109015A P109016A
Raise the lift arms until the lift arm support device drops
P107247A P109013
onto the lift cylinder rod (Item 1) [Figure 10-20-4].
Lower the lift arms slowly until the lift arm support device
Put jackstands under the rear corners of the loader frame is held between the lift arm and the lift cylinder.
(Inset) [Figure 10-20-2].
Stop the engine, raise the seat bar, unbuckle the seat
Disconnect the spring (Item 3) from the lift arm support belt, and make sure lift and tilt functions are deactivated.
device retaining pin (Item 2). Support the lift arm support
device (Item 1) with your hand and remove the retaining Install the retaining pin (Item 2) [Figure 10-20-4] into the
pin [Figure 10-20-2]. rear of the lift arm support device below the lift cylinder
rod.

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-6
Removing
DANGER
P109012
P-90328
AVOID DEATH Raise the lift arms a small amount. The spring will lift the
• Disconnecting or loosening any hydraulic lift arm support device off the lift cylinder rod [Figure 10-
tubeline, hose, fitting, component or a part failure 20-6]. Fully lower the lift arms.
can cause lift arms to drop.
• Keep out of this area when lift arms are raised Stop the engine, raise the seat bar, unbuckle the seat
unless supported by an approved lift arm belt, and make sure lift and tilt functions are deactivated.

D-1009-0409
Disconnect the spring from the bracket.
Figure 10-20-5 Figure 10-20-7
1 1
2
P109017 P109013
Remove the retaining pin (Item 3) [Figure 10-20-5] from Raise the lift arm support device into storage position
the lift arm support device. and insert the retaining pin (Item 1) through the lift arm
support device and the bracket. Hook the spring (Item 2)
Connect the spring (Item 1) from the lift arm support [Figure 10-20-7] to the retaining pin.
device to the bracket (Item 2) [Figure 10-20-5] on the
bottom of the lift arm. Remove the jackstands.
Sit in the operator’s seat, fasten the seat belt, and lower
the seat bar. Start the engine.


OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. The seat belt must be
worn for rollover protection.
Inspect the cab, mounting, and hardware for damage.

Never modify the cab. Replace the cab and hardware if
damaged. See your dealer for parts.
ROPS - Roll-Over Protective Structure per ISO 3471 and

FOPS - Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
Level I
Protection from falling bricks, small concrete blocks,

and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines

involved in site clearing, overhead demolition or
forestry.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

OPERATOR CAB (CONT’D)
Raising WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See LIFT ARM • STOP ENGINE before raising or lowering cab.
SUPPORT DEVICE on Page 10-20-1.) W-2758-0908
Figure 10-30-1 NOTE: On some machines, the operator cab frame

can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3

P107247
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
P-85460
Figure 10-30-2
Hardware Installed Hardware Removed Lift on the grab handles and bottom of the operator cab
[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P100235A P100236A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONT’D) Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-4]. Remove your hand
Lowering from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Always stop the engine before raising or lowering the all the way down.
operator cab.
NOTE: Always use the grab handles to lower the

operator cab. WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
Hardware Removed Hardware Installed

P100953 P-85461
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
NOTE: The weight of the operator cab increases

when equipped with options and accessories P100236A P100235A
such as: cab door, heater, air conditioning. In

these cases, the operator cab may need to be Install the washers and nuts (both sides) [Figure 10-30-
raised slightly from the latch to be able to 5].
release the latch.
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
Remove the jackstands.

WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.

OPERATOR CAB (CONT’D) Special Applications Kit
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor. WARNING

Figure 10-30-6
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-8
P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed that deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7 NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.50 in)
2
thick polycarbonate front door and polycarbonate rear
window [Figure 10-30-8].
1 Polycarbonate top window (standard item) must be

installed for special applications to restrict material from
entering cab openings.
See your dealer for availability.

NA3275
Special Applications Kit Inspection And Maintenance
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30- • Inspect for cracks or damage. Replace if required.
7] is OFF when the door is closed, the key switch is • Prerinse with water to remove gritty materials.
turned to RUN, the seat bar is lowered, and the PRESS • Wash with a mild household detergent and warm
TO OPERATE LOADER button is pressed. water.
• Use a sponge or soft cloth. Rinse well with water and
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30- dry with a clean soft cloth or rubber squeegee.
7] is ON when the door is open, the key switch is turned • Do not use abrasive or highly alkaline cleaners.
to RUN, the seat bar is lowered, and the PRESS TO • Do not clean with metal blades or scrapers.
OPERATE LOADER button is pressed.
[DOOR] will appear in the data display (Item 2) [Figure

10-30-7] when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-9 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-10
NA1819
Available for special applications to prevent flying debris

and objects from entering the cab. Kit includes 19,1 mm

(0.75 in) thick laminated polycarbonate front door,
1
polycarbonate side windows, and polycarbonate rear
window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Door And Window Kit to
restrict material from entering cab openings.
P100984
• Inspect both emergency exit levers (Item 1) [Figure

10-30-10], linkages, and hardware for loose or
damaged parts.
• Repair or replace if necessary.


TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2

Rear Tie-Down Front Tie-Down
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 P107245A P107253A
break and cause personal injury.

W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1

P-85466F
Alternate Rear Tie-Down Alternate Front Tie-Down
P-85465F
P107246A P-85599C
A loader with an empty bucket or no attachment must be

loaded backward onto the transport vehicle [Figure 10- Use the following procedure to fasten the Bobcat loader
40-1]. to the transport vehicle to prevent the loader from moving
during sudden stops, or when going up or down slopes
The rear of the trailer must be blocked or supported (Item [Figure 10-40-2].
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up. 1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie-down

positions [Figure 10-40-2]. (Lift arms shown raised
for visual clarity.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.


TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires will not turn.) There might be slight wear to
the tires when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)


REMOTE START TOOL KIT - MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool Kit 3
MEL1566 - Service Tool Harness Communicator 1
(Computer Interface)
Figure 10-60-1
1
P16117
The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
P16114 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
The Remote Start Tool (Item 1) [Figure 10-60-1] is when testing pressures and flow rate.
required when the service technician is testing the
hydraulic / hydrostatic system, adjusting the steering NOTE: With the engine running; pushing and holding
linkage, and electrical diagnostics. the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.

REMOTE START TOOL - MEL1563 (CONT’D) Figure 10-60-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
2 1
P106653
Loaders equipped with an attachment harness (Item 1)

P16114 must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Remove the Service Tool Harness (Item 1) from the Connect the service tool harness to the ACD connector
cover (Item 2) [Figure 10-60-3]. and the loader harness connector.

Figure 10-60-4 NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool.
P106652
Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.
Connect the service tool harness control to the loader

harness connector.

REMOTE START TOOL - MEL1563 (CONT’D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The Service Tool Harness Communicator (Item 1) is P16115

required to connect Remote Start Tool to the Service PC

(Item 2) [Figure 10-60-6].
The Remote Start Tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.

REMOTE START TOOL - MEL1563 (CONT’D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
P106654
1
Figure 10-60-11
P106652
Figure 10-60-9
2

1
1
P106655
Connect the Remote Start Tool to the engine harness

P106653
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the Remote Start Tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (if equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (if equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT - MEL1563 (CONT’D) Figure 10-60-13
WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P16118
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock The traction lock switch (Item 1) [Figure 10-60-13] is
the keypad with a unique password (keyless) or used to turn traction lock ON or OFF. Push the switch to
otherwise disable the starter before working in the override position. The switch will illuminate to indicate
the engine area. traction lock OVERRIDE, in this position the wheels are
W-2457-1110 able to turn.

Figure 10-60-12 The maximum flow / variable flow switch (Item 2) [Figure
10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when testing pressures and flow rate.
NOTE: With the engine running; pushing and holding

1 the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
WARNING
P16116
• Use traction lock override switch for service work
with seat bar raised.
The Remote Start Tool (Item 1) [Figure 10-60-12] has
• Traction lock is engaged when light is OFF.
three rocker switches.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

REMOTE START TOOL KIT - MEL1563 (CONT’D)
Figure 10-60-14
P166657
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front

auxiliary pressure [Figure 10-60-14].

REMOTE START TOOL (SERVICE TOOL) KIT -
7217666
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool and
MEL1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7217666,

can be used to service newer loaders using the supplied
harness P/N 6689747.
A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7217666 (CONT’D)
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps

5 3
are:
7217666 - Remote Start Tool (Service Tool) Kit 6 4
Kit Includes:
1
7022042 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-1
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-2] has five buttons.
The STOP button (Item 2) [Figure 10-61-2] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader electrical system. The button will illuminate to
1
indicate the service tool is active.
The START button (Item 4) [Figure 10-61-2] is used to

start the loader engine.
P-76678
The traction lock button (Item 5) [Figure 10-61-2] is used
to turn traction lock ON or OFF. Push the button and the
The Remote Start Tool (Item 1) [Figure 10-61-1] is
button will illuminate indicating the traction lock is
required when the service technician is testing the
disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics.
The auxiliary button (Item 6) [Figure 10-61-2] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when testing pressures and flow rate.

7217666 (CONT’D)
Loader Service Tool Harness - 6689747

2
Figure 10-61-3
1
1
P16653
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The Loader Service Tool Harness (Item 1) [Figure 10- When the remote start procedure is completed, replace

61-3] is used to connect the Remote Start Tool (Service the loader connector cap (Item 1) [Figure 10-61-4] or
Tool) (Item 2) [Figure 10-61-3] to the electrical system on reconnect the attachment control harness to the loader
the loader. harness [Figure 10-61-5].
Figure 10-61-4
P106652
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT’D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
2
P-76450
1
P106655 The Computer Service Tool Harness (Item 1) [Figure 10-
61-7] is required to connect Remote Start Tool (Service
Tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)

connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The key switch must be in the off position or

the Remote Start Tool (Service Tool) will not
operate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7217666 (CONT’D)
Remote Start Procedure
WARNING
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P-85729
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock Loaders without an attachment control harness, remove
the keypad with a unique password (keyless) or the loader harness cap (Item 1) [Figure 10-61-9] and
otherwise disable the starter before working in connect the Loader Service Tool Harness from the
the engine area. Remote Start Tool (Service Tool).
W-2457-1110
NOTE: When using a Remote Start Tool (Service tool)

harness on loaders not equipped with an
The tool listed will be needed to do the following attachment control device, the Remote Start
procedure: Tool (Service Tool) harness attachment
control device connector must be capped.
7217666: Remote Start Tool (Service Tool) Kit
P-76450 P-85725

Loaders with an attachment control harness (7 pin or 14
10-61-8] is required when the operator cab is in the
pin), the attachment harness (Item 1) must be
raised position for service and the service technician
disconnected from the loader harness (Item 2) [Figure
needs to turn on the loader or start the engine. Example:
10-61-10].
adjusting the steering linkage.
Lift and block the loader. When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-10] or
Raise the lift arms (if required by the procedure) and
reconnect the attachment control harness to the loader
install an approved lift arm support device.
harness.
Raise the operator cab (if required by the procedure).

7217666 (CONT'D)
2
Figure 10-61-11
5 3
2
6 4
3
P-76439

1 10-61-12] has five buttons.
P106655
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.

connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when testing pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7217666 (CONT’D)
Figure 10-61-13
1 2
P106657
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure

10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
NOTE: To relieve the pressure at the rear or

secondary front auxiliary, (if equipped) press
the RUN button on the Remote Start Tool.
Then press the auxiliary (AUX) hydraulics
button on the Remote Start Tool and move the
AUXILIARY Hydraulic Switch to the right and
left several times.


SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures. WARNING
The service schedule is a guide for correct maintenance
of the Bobcat loader. AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Every 10 Hours (Before Starting The Loader)
• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System - Clean debris from radiator, hydraulic fluid cooler, air conditioning condenser (if equipped),
and rear grille. Check coolant level COLD and add premixed coolant as needed.
• Fuel Filter - Remove the trapped water.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges - Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks - Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) - Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm - Check for proper function.
• Tires - Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the
tire.
• Operator Cab - Check the fastening bolts, washers, and nuts. Check the condition of the cab.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Wheel Nuts - Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts
and tighten to correct torque.
• Safety Signs and Safety Treads - Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid - Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) - Clean or replace filters as needed.
SS SSL LF EXLF T3 MF EXMF iT4-0118

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 50 Hours
• Hydraulic Hoses and Tubelines - Check for damage and leaks. Repair or replace as needed.
• Final Drive Transmission (Chaincase) - Check fluid level and add as needed.
• Parking Brake, Foot Pedals, Hand Controls and Steering Levers, or Joysticks - Check for correct operation.
Repair or adjust as needed.
• Wheel Nuts - Check for loose wheel nuts and tighten to correct torque.
• Engine / Hydrostatic Drive Belt - Perform at first 50 hours, then as scheduled. Check for wear or damage. Adjust or
replace as needed.
• Engine Oil and Filter - Perform at first 50 hours, then as scheduled. Replace oil and filter.
Every 100 Hours
• Spark Arrester - Empty spark chamber.

• Battery - Check cables and connections.
• Engine Oil and Filter - Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours or Every 12 Months
• Fuel Filter - Replace filter.

• Engine / Hydrostatic Drive Belt - Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed.
• Bobcat Interlock Control System (BICS™) - Check the function of the lift arm bypass control.
• Engine Oil and Filter - Replace oil and filter.
• Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap - Replace the charge filter and the reservoir breather
cap.
• Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.
• Hydraulic / Hydrostatic Filter - Replace the hydraulic / hydrostatic filter.

• Hydraulic Reservoir - Replace the fluid.
• Final Drive Transmission (Chaincase) - Replace the fluid.
• Engine Valves - Adjust the engine valve clearance.
Every 24 Months
• Coolant - Replace the coolant.
SS SSL LF EXLF T3 MF EXMF iT4-0118

ENGINE AIR CLEANER Figure 10-80-3
Replacing Filters
Figure 10-80-1
1
2
1
3 P107255
Remove the outer filter (Item 1) [Figure 10-80-3] and

NA3271 discard.
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
Replace the air filters only when necessary. The service DO NOT use compressed air.

indicator (Item 1) will FLASH. Press the Information
button (Item 3) until the display screen shows the service Install new outer filter. Push in until the filter contacts the
codes. Service code [M0117] (Air Filter Plugged) will base of the housing. Install the cover and secure the
show in the display screen (Item 2) [Figure 10-80-1] latches [Figure 10-80-2].
when air filter replacement is necessary.
Close the rear door.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Outer Filter
Stop the engine and open the rear door.
Figure 10-80-2
2
1
P107254
Open the latches (Item 1) and remove the cover (Item 2)

[Figure 10-80-2].

ENGINE AIR CLEANER (CONT’D) Figure 10-80-5
Replacing Filters (Cont’d)
Inner Filter
Replace the inner filter only under the following 2

conditions: 1
• Replace the inner filter every third time the outer filter
is replaced.
• After the outer filter has been replaced, start the

engine and operate at full rpm. If service code
[M0117] (Air Filter Plugged) is still displayed in the
data display, replace the inner filter.
P107254

Install the cover (Item 2) and secure the latches (Item 1)
Remove the cover [Figure 10-80-2] and the outer filter [Figure 10-80-5].
[Figure 10-80-3].
Figure 10-80-4

1
P107256
Remove the inner filter (Item 1) [Figure 10-80-4].
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new inner filter. Push in until the filter contacts the
base of the housing.
Install the outer filter [Figure 10-80-3].

ENGINE COOLING SYSTEM (EARLIER MODELS) Cooling System Identification
Check the cooling system every day to prevent over- NOTE: Identification of the cooling system used on
heating, loss of performance, or engine damage. your machine is necessary to perform the
correct cleaning procedure.
Maintenance Platform
Figure 10-90-2
Figure 10-90-1
Earlier Model Later Model
P109009B P109569A
Earlier models have a square coolant tank. Later models

P107266 have a rectangular coolant tank [Figure 10-90-2].

Cleaning
A maintenance platform [Figure 10-90-1] is available to
facilitate access when cleaning the engine cooling
See the SERVICE SCHEDULE for the correct service
system.
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
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

ENGINE COOLING SYSTEM (EARLIER MODELS) Loaders Without Air Conditioning
(CONT’D)
Cleaning (Cont’d) Figure 10-90-5
Loaders With Air Conditioning
Figure 10-90-3
1
1
2 2
2
3
P107980
Use low air pressure or water pressure to clean the top of

the hydraulic fluid cooler (Item 1) [Figure 10-90-5].
P107267
All Loaders

the air conditioning condenser (Item 1) [Figure 10-90-3]. Unhook the two rubber straps (Item 2) [Figure 10-90-5].
The area between the air conditioning condenser and the Figure 10-90-6
hydraulic fluid cooler will require occasional cleaning.
Remove the bolts (Item 2) and the brackets (Item 3)
[Figure 10-90-3].
Figure 10-90-4
1
2
1
3
2
P107270
Raise the hydraulic fluid cooler (Item 1) until the support

bar (Item 2) drops into position to support the hydraulic
fluid cooler. Use low air pressure or water pressure to
P107276
clean the top of the radiator (Item 3) [Figure 10-90-6].
NOTE: Be careful when raising and lowering the air Raise the support bar (Item 2) [Figure 10-90-6] slightly
conditioning condenser so that the air and lower the hydraulic fluid cooler.
conditioning condenser does not fall on the
hydraulic fluid cooler and damage the fins. Fasten the two rubber straps [Figure 10-90-5].
Raise the air conditioning condenser (Item 1) and use Check the cooling system for leaks.
low air pressure or water pressure to clean the top of the
hydraulic fluid cooler (Item 2) [Figure 10-90-4]. Install the rear grille and close the rear door.
Lower the air conditioning condenser. Install the brackets

and the bolts [Figure 10-90-3].

ENGINE COOLING SYSTEM (EARLIER MODELS)
(CONT’D)
Checking And Adding Coolant IMPORTANT

Check the engine coolant level every day before starting AVOID ENGINE DAMAGE
the engine for the work shift. Always use the correct ratio of water to antifreeze.
Stop the engine, open the rear door, and remove the rear Too much antifreeze reduces cooling system
grille. (See REAR GRILLE on Page 50-60-1.) efficiency and may cause serious premature engine
damage.
Figure 10-90-7
Too little antifreeze reduces the additives which
Earlier Model Later Model protect the internal engine components; reduces the
boiling point and freeze protection of the system.
1 Always add a premixed solution. Adding full strength

1 concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
2 Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-90-7].

P109009B P109570A
Install the coolant fill cap [Figure 10-90-7].

Coolant must be between the top and bottom level
markers (Item 2) [Figure 10-90-7] when the engine is NOTE: The coolant fill cap must be tightened until the
cold. cap clicks.
NOTE: The loader is factory filled with propylene Install the rear grille and close the rear door.
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to test the condition of propylene

glycol in your cooling system.
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Remove the coolant fill cap (Item 1) [Figure 10-90-7] to

add coolant.
The correct mixture of coolant to provide a -37°C (-34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.

ENGINE COOLING SYSTEM (EARLIER MODELS) Recycle or dispose of used coolant in an environmentally
(CONT’D) safe manner.
Removing And Replacing Coolant Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-5.)
interval. (See SERVICE SCHEDULE on Page 10-70-1.) The correct mixture of coolant to provide a -37°C (-34°F)
Stop the engine, open the rear door, and remove the rear of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
grille. (See REAR GRILLE on Page 50-60-1.) of water.
WARNING IMPORTANT
AVOID INJURY
AVOID ENGINE DAMAGE
Do not remove engine coolant cap when the engine
Always use the correct ratio of water to antifreeze.
is hot. You can be seriously burned.
W-2607-0804
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-90-8 damage.
Earlier Model Later Model Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
1
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
2
Add premixed coolant, 47% water and 53% propylene
P109009B P109570A
the lower level marker on the tank (Item 2) [Figure 10-90-
8].
Remove the coolant fill cap (Item 1) [Figure 10-90-8].
Figure 10-90-9
NOTE: The coolant fill cap must be tightened until the
cap clicks.
Install the rear grille and close the rear door.
Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
Check the coolant level when cool. Add coolant as

1 needed. (See Checking And Adding Coolant on Page 10-
90-3.)
P107272
Remove the coolant drain plug (Item 1) [Figure 10-90-9]

located to the left of the oil filter. Drain the coolant into a
container. Install and tighten the plug.

ENGINE COOLING SYSTEM (LATER MODELS) Cleaning
Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Maintenance Platform Stop the engine, open the rear door, and remove the rear
Figure 10-91-1
WARNING
W-2019-0907
P107266 Loaders With Air Conditioning

Figure 10-91-2
A maintenance platform [Figure 10-91-1] is available to
facilitate access when cleaning the engine cooling
system.
1
P109573

the air conditioning condenser (Item 1) [Figure 10-91-2].
Unhook the two rubber straps (Item 2) [Figure 10-91-2].
NOTE: The air conditioning condenser fits into two

slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains
connected to the brackets when raising and
lowering.

ENGINE COOLING SYSTEM (LATER MODELS) Fasten the two rubber straps [Figure 10-91-2].
(CONT’D)
NOTE: The air conditioning condenser can be lifted
Cleaning (Cont’d) out of the two slotted brackets by removing
the clips. This allows greater access to clean
Loaders With Air Conditioning (Cont’d) the hydraulic fluid cooler and radiator
assembly.
Figure 10-91-3
Loaders Without Air Conditioning
Figure 10-91-5
3
1
P109572

Raise the air conditioning condenser (Item 1) and rotate
the support bar (Item 2) into position. Use low air P109571
pressure or water pressure to clean the top of the
hydraulic fluid cooler and radiator assembly (Item 3) Use low air pressure or water pressure to clean the top of
[Figure 10-91-3]. the hydraulic fluid cooler and radiator assembly (Item 1)
[Figure 10-91-5].
Return the support bar to storage position and lower the
air conditioning condenser. All Loaders
Figure 10-91-4 Check the cooling system for leaks.
1
2
P121162
Ensure the air conditioning condenser is installed into the

two slotted brackets [Figure 10-91-4]. (Right side
shown.)
Ensure the clips (Item 1) are properly installed over the

two slotted brackets (Item 2) [Figure 10-91-4]. (Right
side shown.)

ENGINE COOLING SYSTEM (LATER MODELS)
(CONT’D)
Checking And Adding Coolant IMPORTANT

Check the engine coolant level every day before starting AVOID ENGINE DAMAGE
the engine for the work shift. Always use the correct ratio of water to antifreeze.
Stop the engine, open the rear door, and remove the rear Too much antifreeze reduces cooling system
grille. (See REAR GRILLE on Page 50-60-1.) efficiency and may cause serious premature engine
damage.
Figure 10-91-6
Too little antifreeze reduces the additives which
Earlier Model Later Model protect the internal engine components; reduces the

1 concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
2 Add premixed coolant, 47% water and 53% propylene
the upper level marker on the tank [Figure 10-91-6].

P109009B P109570A

Coolant must be between the top and bottom level
markers (Item 2) [Figure 10-91-6] when the engine is NOTE: The coolant fill cap must be tightened until the
cold. cap clicks.
NOTE: The loader is factory filled with propylene Install the rear grille and close the rear door.
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to test the condition of propylene

glycol in your cooling system.
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Remove the coolant fill cap (Item 1) [Figure 10-91-6] to

add coolant.
The correct mixture of coolant to provide a -37°C (-34°F)

of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.

ENGINE COOLING SYSTEM (LATER MODELS) Recycle or dispose of used coolant in an environmentally
(CONT’D) safe manner.
Removing And Replacing Coolant Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-5.)
interval. (See SERVICE SCHEDULE on Page 10-70-1.) The correct mixture of coolant to provide a -37°C (-34°F)
Stop the engine, open the rear door, and remove the rear of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
grille. (See REAR GRILLE on Page 50-60-1.) of water.
WARNING IMPORTANT
AVOID INJURY
AVOID ENGINE DAMAGE
Do not remove engine coolant cap when the engine
Always use the correct ratio of water to antifreeze.
is hot. You can be seriously burned.
W-2607-0804
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-91-7 damage.
Earlier Model Later Model Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
1
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
2
Add premixed coolant, 47% water and 53% propylene
P109009B P109570A
the lower level marker on the tank (Item 2) [Figure 10-91-
7].
Remove the coolant fill cap (Item 1) [Figure 10-91-7].
Figure 10-91-8
NOTE: The coolant fill cap must be tightened until the
cap clicks.

Check the coolant level when cool. Add coolant as

1 needed. (See Checking And Adding Coolant on Page 10-
91-3.)
P107272
Remove the coolant drain plug (Item 1) [Figure 10-91-8]

located to the left of the oil filter. Drain the coolant into a
container. Install and tighten the plug.

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.
The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0% five percent biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.

Apply the following guidelines if biodiesel blend fuel is
NOTE: Biodiesel blend fuel may also be used in this
used:
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed
• Ensure the fuel tank is as full as possible at all times
with ultra low sulfur petroleum based diesel.
to prevent moisture from collecting in the fuel tank.
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5
• Ensure that the fuel tank cap is securely tightened.
blended diesel fuel must meet ASTM
specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
E.U. Standard (EN590)
immediately.
Use only clean, high quality diesel fuel that meets the
• Drain all water from the fuel filter daily before
EN590 specifications listed below:
operating the machine.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10
• Do not exceed engine oil change interval. Extended
ppm) sulfur maximum
oil change intervals can cause engine damage.
• Diesel fuel with cetane number of 51.0 and above.
• Before vehicle storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer, and
NOTE: Biodiesel blend fuel may also be used in this
operate the engine for at least 30 minutes.
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
NOTE: Biodiesel blend fuel does not have long term
with ultra low sulfur petroleum based diesel.
stability and should not be stored for more
This biodiesel blend fuel is commonly
than 3 months.
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807

NA1202
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].
1 Install and tighten the fuel cap (Item 1) [Figure 10-100-

1].
WARNING
P107257
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the fill cap (Item 1) [Figure 10-100-1]. 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) Replacing Filter
Fuel Filter See the SERVICE SCHEDULE for the correct service
Removing Water
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Remove the fuel filter (Item 2) [Figure 10-100-3].
Stop the engine and open the rear door. Clean the area around the filter base. Put clean oil on the
seal of the new filter. Install the filter and hand tighten.
Figure 10-100-3
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.)
WARNING
2 AVOID INJURY OR DEATH
sparks or lighted tobacco away from fuel and oil.

1 explosion or fire.
W-2103-0508
P107258
Loosen the drain (Item 1) [Figure 10-100-3] at the Start the engine and allow to operate for one minute.
bottom of the filter to remove trapped water from the filter.
Securely tighten the drain.

WARNING
WARNING AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
AVOID INJURY OR DEATH death. Fluid leaks under pressure may not be visible.
Always clean up spilled fuel or oil. Keep heat, flames, Use a piece of cardboard or wood to find leaks. Do
sparks or lighted tobacco away from fuel and oil. not use your bare hand. Wear safety goggles. If fluid
Failure to use care around combustibles can cause enters skin or eyes, get immediate medical attention
explosion or fire. from a physician familiar with this injury.
W-2103-0508 W-2072-0807
Close the rear door. Stop the engine and check for leaks at the filter.

FUEL SYSTEM (CONT’D) Figure 10-100-5
Removing Air From The Fuel System
After replacing the filter or if the fuel tank has run out of
fuel, the air must be removed from the fuel system before
starting the engine. 1
WARNING
death. Fluid leaks under pressure may not be visible. P107259
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid Squeeze the hand pump (priming bulb) (Item 1)
enters skin or eyes, get immediate medical attention [Figure 10-100-5] until fuel flows from the vent with no
from a physician familiar with this injury. air bubbles.
W-2072-0807
Close the vent (Item 1) [Figure 10-100-4].

Figure 10-100-4

WARNING
1
explosion or fire.
W-2103-0508
P107258
Open the air vent plug (Item 1) [Figure 10-100-4] on the

fuel filter base.

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE CRANKCASE OIL
engine for the work shift. Recommended SAE Viscosity Number
Figure 10-110-1
1 2
P107260 Refer to temperature range anticipated before next

oil change

Must use API Category CI-4 or better, or ACEA E7 or
Park the loader on a level surface. Stop the engine. Open
better
the rear door and remove the dipstick (Item 2) [Figure
10-110-1]. Do not use API Category FA-4 engine oil
[1] Bobcat Synthetic Oil – SAE 5W-40
Keep the oil level between the marks on the dipstick. Do
not overfill.
Bobcat engine oils are recommended for use in this
Remove the oil fill cap (Item 1) [Figure 10-110-1] to add machine. If Bobcat engine oil is not available, use a good
engine oil. quality engine oil that meets API Service Category of
CI-4 or better, or ACEA E7 or better [Figure 10-110-2].
WARNING
AVOID INJURY OR DEATH IMPORTANT
sparks or lighted tobacco away from fuel and oil. AVOID ENGINE DAMAGE
Failure to use care around combustibles can cause Use of API Service Category FA-4 engine oil is not
explosion or fire. approved and may cause irreversible damage to the
W-2103-0508 engine.
I-2384-0916

ENGINE LUBRICATION SYSTEM (CONT’D) Install the cover and the cover mounting bolts [Figure 10-
110-3]. Tighten both bolts.
Removing And Replacing Oil And Filter
Figure 10-110-5
2
1
Figure 10-110-3
P107261
2
Open the rear door, remove the oil filter (Item 3) [Figure
10-110-5], and clean the filter base.

Put clean oil on the new filter gasket, install the new filter,
P107954A P107264
and hand tighten. Use genuine Bobcat filter only.
Remove the oil fill cap (Item 1) [Figure 10-110-5].

The oil drain hose is located behind a cover (Item 1)
under the rear of the loader (Inset) [Figure 10-110-3]. Put oil in the engine and replace the fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Loosen one cover mounting bolt and remove the other
bolt (Item 2) [Figure 10-110-3] to allow the cover to Start the engine and allow to operate for several minutes.
swing open. Stop the engine and check for leaks at the filter.
Figure 10-110-4 Remove the dipstick (Item 2) [Figure 10-110-5] and

check the oil level.
Add oil as needed if oil level is not at the top mark on the
dipstick. Install the dipstick and close the rear door.
WARNING
explosion or fire.
P107265
W-2103-0508
Remove the oil drain cap (Item 1) [Figure 10-110-4] from

the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
Install and tighten the oil drain cap [Figure 10-110-4].

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER Hydraulic / Hydrostatic Fluid Chart
MODELS)
Figure 10-120-3
Checking And Adding Fluid
HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG)
before starting the work shift. AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms, and
put the attachment flat on the ground or tilt the Bob-
Tach® fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid

(Unlike biodegradable fluids that are vegetable based,
Bobcat biodegradable fluid is formulated to prevent
oxidation and thermal breakdown at operating
P107282 temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure Use only recommended fluid in the hydraulic system
10-120-1]. Keep the fluid level within the operating range. [Figure 10-120-3]. (See Hydraulic System on Page
SPEC-10-4.)
Open the rear door and remove the rear grille. (See
REAR GRILLE on Page 50-60-1.)
Figure 10-120-2 WARNING

1 Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508
P107976
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-120-1].
Install the fill cap [Figure 10-120-2], install the rear grille,
and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER (Earlier Models with Square Coolant Tank) - Unhook
MODELS) (CONT’D) the two rubber straps (Item 2) [Figure 10-120-5].
Removing And Replacing Hydraulic Fluid Figure 10-120-6

Replace the fluid if contaminated or after major repair.
Always replace the hydraulic / hydrostatic filter and the 1

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic / 2
Hydrostatic Filter on Page 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.)
P107270
Figure 10-120-4
(Earlier Models with Square Coolant Tank) - Raise the
hydraulic fluid cooler (Item 1) until the support bar (Item
2) [Figure 10-120-6] drops into position to support the

1 hydraulic fluid cooler. This procedure will aid in draining
the hydraulic fluid.
Figure 10-120-7
P107976
Figure 10-120-5
P107955A
Remove the right side access cover bolts (Item 1)

[Figure 10-120-7] and remove the access cover. (Lift
arms shown raised for visual clarity.)
2
P107267
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4].

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER Figure 10-120-9
MODELS) (CONT’D)
Removing And Replacing Hydraulic Fluid (Cont’d)
NOTE: The hose used to drain the hydraulic reservoir

is located under the fan motor.
Figure 10-120-8 1
1 P107977
2 Remove and clean the hydraulic fill screen (Item 1)

[Figure 10-120-9]. Use low air pressure to dry the
2
screen.
P109760A P115527A
Install hydraulic fill screen and add the correct fluid to the
Remove the clamp (Item 1). Pinch off the hose (Item 2) reservoir until the fluid level is within the operating range

[Figure 10-120-8] near the fitting and disconnect hose of the sight gauge. (See Capacities on Page SPEC-10-
from the fitting. Route the hose out the side of the loader 5.) and (See Checking And Adding Fluid on Page 10-
and drain the fluid into a container. 120-1.)
Connect the hose to the fitting when the fluid stops Install the hydraulic fill cap [Figure 10-120-4].
draining. Install the clamp.
Recycle or dispose of used fluid in an environmentally
safe manner. Start the engine and operate the loader hydraulic
controls.
WARNING WARNING
Always clean up spilled fuel or oil. Keep heat, flames, AVOID INJURY OR DEATH
sparks or lighted tobacco away from fuel and oil. Diesel fuel or hydraulic fluid under pressure can
Failure to use care around combustibles can cause penetrate skin or eyes, causing serious injury or
explosion or fire. death. Fluid leaks under pressure may not be visible.
W-2103-0508 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
Install the side access cover and bolts [Figure 10-120-7].
from a physician familiar with this injury.
W-2072-0807
(Earlier Models with Square Coolant Tank) - Raise the
support bar supporting the hydraulic fluid cooler and
lower the hydraulic fluid cooler. Fasten the two rubber Stop the engine and check for leaks.
straps [Figure 10-120-5].
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER Lubricate the O-ring (Item 1) [Figure 10-120-11] on new
MODELS) (CONT’D) filter with clean oil.
Removing And Replacing Hydraulic / Hydrostatic Install new filter ensuring that filter is fully seated in the
Filter housing.
See the SERVICE SCHEDULE for the correct service Remove the filter cap O-rings (Item 3) [Figure 10-120-
interval. (See SERVICE SCHEDULE on Page 10-70-1.) 11] and discard.
Stop the engine, open the rear door, and remove the rear Install new filter cap O-rings and lubricate with clean oil.
NOTE: The filter cap O-rings are not the same size.
Clean the top of the filter housing. Take care to install each O-ring in the correct
location.
Figure 10-120-10
Install the filter cap and rotate clockwise to engage the
1 bolts [Figure 10-120-10]. Alternate tightening the bolts to
draw the cap down evenly. Tighten the bolts to 27 - 41
N•m (20 - 30 ft-lb) torque.
WARNING

P109054
explosion or fire.
W-2103-0508
Loosen the bolts (Item 1) and rotate the filter cap (Item 2)
[Figure 10-120-10] counterclockwise until the cap clears
the bolts.
Start the engine and operate the loader hydraulic
controls.
Slowly pry the filter cap off the housing by hand.
Figure 10-120-11
WARNING
1
2 penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
3 W-2072-0807
Stop the engine and check for leaks at the filter.

P109072A P109073A
Remove the filter (Item 2) [Figure 10-120-11] and
discard.

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER Figure 10-120-14
MODELS) (CONT’D)
Removing And Replacing Hydraulic Charge Filter

Figure 10-120-12
P109622A
Remove the filter (Item 1) [Figure 10-120-14] and

discard.
Clean the surface of the filter housing and the filter base
where they contact the filter seal.
P109069A

Put clean oil on the seal of the new filter. Install the filter
on the filter base [Figure 10-120-14].
Remove the left side access cover bolts (Item 1) [Figure
10-120-12] and remove the access cover. (Lift arms Install and tighten the filter housing to 65 - 70 N•m (48 -
shown raised for visual clarity.) 52 ft-lb) torque [Figure 10-120-13].
NOTE: Identification of the hydraulic charge filter

used on your machine is necessary to
perform the correct replacement procedure.
Figure 10-120-13
P109622
Put a suitable container below the filter housing and

remove the filter housing (Item 1) [Figure 10-120-13].

HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER Replacing Reservoir Breather Cap
MODELS) (CONT”D)
See the SERVICE SCHEDULE for the correct
Removing And Replacing Hydraulic Charge Filter replacement interval. (See SERVICE SCHEDULE on
(Cont’d) Page 10-70-1.)
All Models Stop the engine, open the rear door, and remove the rear
safe manner. Figure 10-120-15
WARNING 1
explosion or fire.
W-2103-0508
Install the side access cover and bolts [Figure 10-120-

12].
P107976

controls. Remove the breather cap (Item 1) [Figure 10-120-15]
and discard.
Install new breather cap.

WARNING
W-2072-0807


HYDRAULIC / HYDROSTATIC SYSTEM (LATER Hydraulic / Hydrostatic Fluid Chart
MODELS)
Figure 10-121-3
Checking And Adding Fluid
HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG)
before starting the work shift. AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms, and
put the attachment flat on the ground or tilt the Bob-Tach
fully back if no attachment is installed.
Stop the engine.
Figure 10-121-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid

(Unlike biodegradable fluids that are vegetable based,
Bobcat biodegradable fluid is formulated to prevent
oxidation and thermal breakdown at operating
P107282 temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure Use only recommended fluid in the hydraulic system
10-121-1]. Keep the fluid level within the operating range. [Figure 10-121-3]. (See Hydraulic System on Page
SPEC-10-4.)
Open the rear door and remove the rear grille. (See
REAR GRILLE on Page 50-60-1.)
Figure 10-121-2 WARNING

1 Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508
P107976
Remove the fill cap (Item 1) [Figure 10-121-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-121-1].
Install the fill cap [Figure 10-121-2], install the rear grille,
and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM (LATER Figure 10-121-5
MODELS) (CONT’D)
Removing And Replacing Hydraulic Fluid 1

Replace the fluid if contaminated or after major repair.
Always replace the hydraulic / hydrostatic filter and the

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-121-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-121-5.).
P107955A
grille. (See REAR GRILLE on Page 50-60-1.) Remove the right side access cover bolts (Item 1)
[Figure 10-121-5] and remove the access cover. (Lift
Figure 10-121-4 arms shown raised for visual clarity.)
NOTE: The hose used to drain the hydraulic reservoir

is located on the right side of the fan motor on

later models.
1
Figure 10-121-6
1
P107976
2
Remove the hydraulic fill cap (Item 1) [Figure 10-121-4]. 2
P109760A P115527A
Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-121-6] near the fitting and disconnect hose
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.
Connect the hose to the fitting when the fluid stops

draining. Install the clamp.

HYDRAULIC / HYDROSTATIC SYSTEM (LATER Install hydraulic fill screen and add the correct fluid to the
MODELS) (CONT’D) reservoir until the fluid level is within the operating range
of the sight gauge. (See Capacities on Page SPEC-10-
Removing And Replacing Hydraulic Fluid (Cont’d) 5.) and (See Checking And Adding Fluid on Page 10-
121-1.)
safe manner. Install the hydraulic fill cap [Figure 10-121-4].
WARNING Start the engine and operate the loader hydraulic

controls.
Failure to use care around combustibles can cause WARNING
explosion or fire.
W-2103-0508
Install the side access cover and bolts [Figure 10-121-5]. penetrate skin or eyes, causing serious injury or
Figure 10-121-7 Use a piece of cardboard or wood to find leaks. Do

W-2072-0807
Stop the engine and check for leaks.

1
P107977
Remove and clean the hydraulic fill screen (Item 1)

[Figure 10-121-7]. Use low air pressure to dry the
screen.

HYDRAULIC / HYDROSTATIC SYSTEM (LATER Lubricate the O-ring (Item 1) [Figure 10-121-9] on new
MODELS) (CONT’D) filter with clean oil.
Removing And Replacing Hydraulic / Hydrostatic Install new filter ensuring that filter is fully seated in the
Filter housing.
See the SERVICE SCHEDULE for the correct service Remove the filter cap O-rings (Item 3) [Figure 10-121-9]
interval. (See SERVICE SCHEDULE on Page 10-70-1.) and discard.
Stop the engine, open the rear door, and remove the rear Install new filter cap O-rings and lubricate with clean oil.
NOTE: The filter cap O-rings are not the same size.
Clean the top of the filter housing. Take care to install each O-ring in the correct
location.
Figure 10-121-8
Install the filter cap and rotate clockwise to engage the
1 bolts [Figure 10-121-8]. Alternate tightening the bolts to
draw the cap down evenly. Tighten the bolts to 27 – 41
N•m (20 – 30 ft-lb) torque.
WARNING

P109054
explosion or fire.
W-2103-0508
Loosen the bolts (Item 1) and rotate the filter cap (Item 2)
[Figure 10-121-8] counterclockwise until the cap clears
the bolts.
controls.
Slowly lift the filter cap off the housing by hand.
Figure 10-121-9
WARNING
1
2 penetrate skin or eyes, causing serious injury or
3 W-2072-0807

P109072A P109073A
Remove the filter (Item 2) [Figure 10-121-9] and discard.

HYDRAULIC / HYDROSTATIC SYSTEM (LATER All Models
MODELS) (CONT’D)
Recycle or dispose of used fluid and filter in an
Removing And Replacing Hydraulic Charge Filter environmentally safe manner.

Stop the engine.

WARNING
Figure 10-121-10 AVOID INJURY OR DEATH
1 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Install the side access cover and bolts [Figure 10-121-

10].

controls.

P109069A WARNING
Remove the left side access cover bolts (Item 1) [Figure AVOID INJURY OR DEATH
10-121-10] and remove the access cover. (Lift arms Diesel fuel or hydraulic fluid under pressure can
shown raised for visual clarity.) penetrate skin or eyes, causing serious injury or
Figure 10-121-11 Use a piece of cardboard or wood to find leaks. Do
W-2072-0807

1 (See Checking And Adding Fluid on Page 10-121-1.)
P115526
Place a suitable container under the filter. Remove the

filter (Item 1) [Figure 10-121-11] and clean the filter
base.
Put clean oil on the new filter gasket. Install the new filter,
and tighten the filter to 37 - 45 N•m (27 - 33 ft-lb) torque.

HYDRAULIC / HYDROSTATIC SYSTEM (LATER
MODELS) (CONT’D)
Replacing Reservoir Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Figure 10-121-12

P107976
Remove the breather cap (Item 1) [Figure 10-121-12]

and discard.
Install new breather cap.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Fluid
Checking And Adding Fluid See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Park the loader on a level surface and stop the engine.
The chaincase contains the final drive sprockets and Remove the check plug (Item 1) [Figure 10-130-1] from
chains, and uses the same type fluid as the hydraulic / the front of the chaincase housing.
hydrostatic system. (See Hydraulic / Hydrostatic Fluid
Chart on Page 10-120-1.) Figure 10-130-2
Park the loader on a level surface and stop the engine.
Figure 10-130-1

P107281
Pump the fluid out of the chaincase [Figure 10-130-2].

P107956
(Lift arms shown raised for visual clarity.)

Remove the check plug (Item 1) [Figure 10-130-1] from safe manner.
the front of the chaincase housing. (Lift arms shown
raised for visual clarity.) Add fluid through the check plug hole until fluid flows from
the hole. (See Capacities on Page SPEC-10-5.)
If fluid can be reached with the tip of your finger through
the hole, the fluid level is correct. Install and tighten the plug [Figure 10-130-1].
If the level is low, add fluid through the check plug hole
until fluid flows from the hole.
Install and tighten the plug [Figure 10-130-1]. WARNING

WARNING Always clean up spilled fuel or oil. Keep heat, flames,

AVOID INJURY OR DEATH explosion or fire.
Always clean up spilled fuel or oil. Keep heat, flames, W-2103-0508
explosion or fire.
W-2103-0508


BOB-TACH (HAND LEVER) Figure 10-140-2
Inspection And Maintenance

1
Figure 10-140-1
Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
The wedges (Item 1) [Figure 10-140-2] must extend

P-85513A
through the holes in the attachment mounting frame.
The spring loaded wedges (Item 1) must contact the

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-140-1]. frame (Item 2) [Figure 10-140-2].

The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-140-3

The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages, and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)


BOB-TACH (POWER) Figure 10-141-2
This machine may be equipped with a Power Bob-Tach®.

1
Figure 10-141-1 2
1
Both wedges must
contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
2
The wedges (Item 1) [Figure 10-141-2] must extend
through the holes in the attachment mounting frame.
NA3094
The spring loaded wedges (Item 1) must contact the

Push and hold the BOB-TACH WEDGES “UP” switch lower edge of the holes in the attachment mounting
(Item 1) until wedges are fully raised. Push and hold the frame (Item 2) [Figure 10-141-2].

BOB-TACH WEDGES “DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down. If the wedges do not contact the lower edge of the holes
[Figure 10-141-2], the attachment will be loose and can
The levers and wedges must move freely. come off the Bob-Tach.
Figure 10-141-3
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages, and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Inspect for cracked welds. Contact your dealer for repair

or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)


LUBRICATING THE LOADER Lubricate the following:
Lubrication Locations Figure 10-150-2

Record the operating hours each time you lubricate the

Bobcat loader.
1
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. (See Operation and

Maintenance Manual.)
Stop the engine.

P109023
Figure 10-150-1
1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-2].
1
Figure 10-150-3

2 5
6 7
8
3
4 P109019A
The grease fitting locations [Figure 10-150-1] are shown

P109034
in more detail in the following figures.
2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

150-3].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-6
Lubrication Locations (Cont’d)
Figure 10-150-4
5
3
P109022
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

P109030
150-6].
Figure 10-150-7
3. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-
150-4].

Figure 10-150-5
4
P107960
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-31308A
150-7].
4. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-5].

LUBRICATING THE LOADER (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-150-8
P107961
7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-

8].

If Equipped With Power Bob-Tach
Figure 10-150-9
P107959
8. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10-

150-9].


TIRE MAINTENANCE Rotating
Wheel Nuts Check the tires regularly for wear, damage, and pressure.
See the SERVICE SCHEDULE for the correct service Figure 10-160-2
Figure 10-160-1
NA1023A
P107283
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires

to the front [Figure 10-160-2].
Follow the torques specified below for the wheel nuts
[Figure 10-160-1]: The same size tires must be used on each side of the
loader. If different sizes are used, each tire will turn at a
When installing wheel nuts, tighten to 217 N•m (160 different rate and cause excessive wear. The tread bars
ft-lb) torque. of all the tires must face the same direction.
When checking wheel nut torque, set the torque Recommended tire pressure must be maintained to avoid
wrench to 190 N•m (140 ft-lb) to prevent excessive tire wear, loss of stability, and loss of handling
overtightening. capability. Check for correct pressure before operating
the loader. (See Tires on Page SPEC-10-6.)

TIRE MAINTENANCE (CONT’D)
Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and safe equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

rubber lubricant before mounting the tire.
Avoid excessive pressure that can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.
WARNING

Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010

SPARK ARRESTER MUFFLER
Cleaning Procedure WARNING

interval. (See SERVICE SCHEDULE on Page 10-70-1.) Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Do not operate the loader with a defective exhaust flammable material. Failure to obey warnings can
system. cause injury or death.
W-2068-1285
IMPORTANT
WARNING
This machine is factory equipped with a U.S.D.A.
Forestry Service Approved spark arrester exhaust Stop engine and allow the muffler to cool before
system that must be maintained for proper function. cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
• WITH MUFFLER W-2011-1285
The muffler spark chamber must be emptied
every 100 hours of operation to keep it in working
Figure 10-170-1
condition.
• WITH SELECTIVE CATALYST REDUCTION (SCR)

AND / OR DIESEL OXIDATION CATALYST (DOC)
Do not remove or modify the DOC or SCR.

The SCR must be maintained according to the 1
instructions in the Operation & Maintenance
Manual for proper function.
• WITH DIESEL PARTICULATE FILTER (DPF)

The DPF must be maintained according to the
instructions in the Operation & Maintenance
Manual for proper function.
P107280
(If this machine is operated on flammable forest,
brush or grass cover land, the engine must be
equipped with a spark arrester and maintained in
Remove the plug (Item 1) [Figure 10-170-1] from the
working order. Failure to do so will be in violation of
muffler.
California state law section 4442 PRC. Refer to local
laws and regulations for spark arrester
requirements.)
I-2350-1114
WARNING
When the engine is running during service, the
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
WARNING cause injury or death.
W-2006-1209

Start the engine and operate for approximately 10
When an engine is running in an enclosed area, fresh
seconds while a second person, wearing safety glasses,
air must be added to avoid concentration of exhaust
holds a piece of wood over the outlet of the muffler. This
fumes. If the engine is stationary, vent the exhaust
will force contaminants out through the cleanout hole.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine. Install and tighten the plug. Close the
W-2050-0807
rear door.


PIVOT PINS
Figure 10-180-1
1
P109020A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure

10-180-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 -

40 ft-lb) torque.


LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, perform the
procedures below to return the loader to service:
You may decide to store your Bobcat loader for an
extended period of time. Perform the procedures below • Check the engine oil and hydraulic fluid levels; check
for storage: coolant level.
• Thoroughly clean the loader including the engine • Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in position.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check tire inflation and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the
tires. • Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods. • Start the engine and operate for a few minutes while

observing the instrument panels and systems for
• Put fuel stabilizer in the fuel tank and operate the correct operation.
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors. • Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer, and operate the engine for at
least 30 minutes.
• Drain and flush the cooling system. Refill with

premixed coolant.
• 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 the battery in a
cool dry location above freezing temperatures and
charge the battery periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that the machine is in

storage condition.


STOPPING THE ENGINE AND LEAVING THE LOADER (Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
Procedure personnel.
Stop the loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Fully lower the lift arms and put the attachment flat on the Deluxe Instrumentation Panel allows
ground. operation of the loader without using a
password. (See Password Lockout Feature on
Figure 10-200-1 Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-200-3

P-90525B P-85737A P-85735A
Set the engine speed control to the low idle position Exit the loader using grab handles, safety tread, and
[Figure 10-200-1]. steps (maintaining a three-point contact) [Figure 10-200-
3].
Engage the parking brake.
Figure 10-200-2
WARNING
1 1
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
P-90688A P-90214C
position to make sure the lift, tilt and traction
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) [Figure The seat bar system must deactivate these functions
10-200-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.


EMERGENCY EXIT
The front opening on the operator cab and rear window There are two different procedures for removing the rear
provide exits. window from your machine:
Rear Window Identification 1. This window is equipped with latches [Figure 10-210-
1].
Figure 10-210-1
2. This window is equipped with a rubber cord and tag
Latches Rubber Cord [Figure 10-210-1].
NOTE: Use these procedures to remove the rear

window only under emergency conditions.
2 Damage to machine may occur.
1
P-85309B P-64994G
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-210-2 Figure 10-210-4

1
P-85309A P-64994F
Turn both latches (Item 1) [Figure 10-210-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-210-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-210-3 Figure 10-210-5
P-85459A P-85459A
Exit through the rear of the operator cab [Figure 10-210- Exit through the rear of the operator cab [Figure 10-210-
3]. 5].

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 10-210-6
Figure 10-210-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 10-210-8] up and out

[Figure 10-210-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
OR
Figure 10-210-7
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.
Turn both knobs (Item 1) [Figure 10-210-7]

counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.

EMERGENCY EXIT (CONT’D) Front Door Reassembly
Front Door Reassemble the front door using the following

instructions if the door was opened using the emergency
NOTE: Use this procedure to remove the front door exit procedure.
only under emergency conditions. Damage to
machine may occur. Figure 10-210-10
Figure 10-210-9 1
P-85781A
P-90725

NOTE: Later models route the washer fluid hose
differently and will not require this step.
Turn both latches (Item 1) [Figure 10-210-9] down until
they disengage from the door frame. Disconnect electrical connector (Item 2) and washer fluid
hose (Item 1) (if equipped) [Figure 10-210-10].
Push the door out of the operator cab door frame and exit
through the opening. Figure 10-210-11
2
3
P-85588A P-85589A
Rotate and pull the clip (Item 1) out of the gas spring
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 10-210-11].
Remove the door hinges from the loader.

EMERGENCY EXIT (CONT’D)
Front Door (Cont’d)
Front Door Reassembly (Cont’d)
Figure 10-210-12
P-90685

Orient the latches as shown (Item 1) and install the door
hinges (Item 2) [Figure 10-210-12] on the door. (Bottom
hinge shown.)
Figure 10-210-13
P-90686A
Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
against door and rotate latch (Item 1) [Figure 10-210-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity.)
Install door on loader. Install the gas spring socket on the

ball stud fitting. Install the clip into the hole in the gas
spring socket. Rotate the clip to lock into position [Figure
10-210-11].
Connect electrical connector and washer fluid hose (if

equipped) [Figure 10-210-10].

SEAT BELT Figure 10-220-1

1
WARNING 3
Failure to properly inspect and maintain the seat belt

can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function. 2 4
Inspect the seat belt system thoroughly at least once

each year, or more often if the machine is exposed to
severe environmental conditions or applications.
Any seat belt system that shows cuts, fraying, extreme or

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware, or any other obvious
problem should be replaced immediately. 5
The items below are referenced in [Figure 10-220-1].

NA3113
1. Check the webbing. If the system is equipped with a

retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt, and stiffness.
2. Check the buckle and latch for correct operation.

Make sure latch plate is not excessively worn or
deformed and buckle is not damaged or casing
broken.
3. Check the retractor web storage device (if equipped)

by extending webbing to determine if it looks correct,
and that it spools out and retracts webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun, or extreme dust or dirt. If the
original color of the webbing in these areas is
extremely faded and / or the webbing is packed with
dirt, the webbing strength may have deteriorated.
5. Check the hardware on both sides of the seat.

Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.
See your dealer for seat belt system replacement parts

for your machine.


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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7

CYLINDER (LIFT) (AZN811740 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-8
CYLINDER (TILT) (AZN811740 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28

Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24

Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-12

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-15
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-16
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
OIL COOLER (EARLIER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
OIL COOLER (LATER MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK (S/N A3NL11001 - A3NL12242) . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

BOB-TACH (POWER) BLOCK (S/N A3NL12243 & ABOVE) . . . . . . . . . . . . . . . . . . . . 20-121-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly (FFI/FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2
Disassembly And Assembly (FFH/FH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
AUTOMATIC RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Checking The Pressure In The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-5
Adding Nitrogen To The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-7


HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH NO OPTIONS
S550 (S/N A3NL11001 AND ABOVE)
(S/N A3NM11001 AND ABOVE)
(S/N AZN811001 AND ABOVE)
(PRINTED AUGUST 2012) Printable Version Click Here
V-1527legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 35 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CHARGE PUMP -
2 36
SIGHT GUAGE 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
19 PULL BUTTON ACTIVATED
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT HYDRAULIC PUMP . . . . . . . Gear Type
37
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 64,7 L/min (17.1 U.S. gpm) at High Engine Idle
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO 38 VARIABLE CAPACITY DISPLACEMENT
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP
DOWN BUT NOT DURING BOOM UP
5 SPRING LOADED FILTER BY-PASS 39 RELIEF/REPLENISHING VALVE - HIGH
21 ANTICAVITATION VALVE
VALVE: 172 kPa (1,7 bar) (25 psi) PRESSURE: 34500 kPa (345 bar) (5000 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa 40
2827 kPa (28,3 bar) (410 psi) at High
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) Engine Idle With 60 ° C (140 ° F) Fluid
PORT – Factory Hydraulic Oil
23 SPRING LOADED FILTER BY-PASS VALVE:
7 RELIEF VALVE - MAIN: 41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
23787 - 24476 kPa (238 - 245 bar) With
Dealer Copy -- Not for 345 kPa (3,45 bar) (50 psi) Spring
Resale
24 FIXED CAPACITY DISPLACEMENT
(3450 - 3550 psi) at Front Quick Couplers
HYDRAULIC MOTOR
25 FILTER - HYDRAULIC (CANISTER)
8 RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 26 SENSOR – CHARGE PRESSURE
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE

PORT (OPTIONAL): BLEED-OFF VALVE
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE
10 SOLENOID ACTIVATED DIRECTIONAL 29 FLUSHING RELIEF VALVE
CONTROL VALVE - AUXILIARY
11 LOAD CHECK VALVE
30 DRIVE MOTOR SHUTTLE VALVE
31 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT
14 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC MOTOR
CONTROL VALVE - LIFT CONTROL
15 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 34 NOT USED FOR THIS MODEL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1527legend (8-30-12)
115 of 1234
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR 27
29
Male
30
Female
OUT
HYDRAULIC CONTROL VALVE
32
9
A B 10
10
Auxiliary Spool
6A
R
HYDROSTATIC PUMP 38 T
11
8
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
TILT CYLINDERS
8
39
Tilt Spool
13
M4
M3
12
D C
11
40
LIFT CYLINDERS
8 14
B A
Lift Spool
M2 M1
39
11 20 17
15 ?
IN 18
7 6 17
2
16
T
38 1
41 Oil Cooler
19
37 HYDRAULIC RESERVOIR
4 (VENTED)
VARIABLE SPEED HYDRAULIC 2
FAN MOTOR W/ INTEGRATED FILTER
5
36
HYDRAULIC
1
FILTER 3
25
26 23
B A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
DRAIN/RETURN MANIFOLD
Printable Version Click Here
32
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH NO OPTIONS
30 (S/N AZN811001 AND ABOVE)
29
DRIVE MOTOR
116 of 1234 (PRINTED AUGUST 2012)
Printed In U.S.A. 7204247 (A)

MANUAL WITH ALL OPTIONS
S550 (S/N A3NL11001 - A3NL12242)
(S/N AZN811001 - AZN811512)
(PRINTED NOVEMBER 2017) Printable Version Click Here
V-1528legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 38 VARIABLE CAPACITY DISPLACEMENT 62 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE - Female
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal) 39 SOLENOID ACTIVATED DIRECTIONAL
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) RELIEF/REPLENISHING VALVE - HIGH 63
2 SIGHT GUAGE PRESSURE: 34500 kPa (345 bar) (5000 psi) CONTROL VALVE - Male
19 PULL BUTTON ACTIVATED 64 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT RELIEF VALVE - CHARGE INLET:
40 CONTROL VALVE - BUCKET POSITION
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 2827 kPa (28,3 bar) (410 psi) at High
VALVE (ON/OFF)
Normally Closed Engine Idle With 60 ° C (140 ° F) Fluid
20 LIFT CYLINDER SPOOL - MADE TO 65 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM 41 CHECK VALVE – COLD WEATHER BY-PASS
PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP With 345 kPa (3,45 bar) (50 psi) Spring 66
5 SPRING LOADED FILTER BY-PASS CONTROL VALVE - FLOW CONTROL
21 ANTICAVITATION VALVE 42 NOT USED ON THIS MODEL SPOOL
VALVE: 172 kPa (1,7 bar) (25 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE –
43 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa NOT USED ON THIS MODEL VALVE
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) PILOTED ACTIVATED DIRECTIONAL
44 NOT USED ON THIS MODEL 68
PORT – Factory Hydraulic Oil CONTROL VALVE - UNLOADING
7 RELIEF VALVE - MAIN: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 45 NOT USED ON THIS MODEL SPOOL
23787 - 24476 kPa (238 - 245 bar) 24 FIXED CAPACITY DISPLACEMENT Dealer Copy -- Not for Resale 69 HIGH FLOW HYDRAULIC PUMP Gear Type
(3450 - 3550 psi) at Front Quick Couplers 46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR VALVE – HYDRAULIC POWERED BOB-TACH 36,4 L/min (9.6 U.S. gal) at High Engine Idle
25 FILTER - HYDRAULIC (CANISTER) With Build-up Valve 207 kPa (2,07 bar) (30 psi) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
26 SENSOR – CHARGE PRESSURE 47 FILTER - BOB-TACH VALVE 71 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi)
48 RESTRICTION - 2,03 mm (0.08 in)
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE 72 CHECK VALVE - With 34,5 kPa (0,34 bar)
49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
27579 kPa (276 bar) (4000 psi) CONTROL VALVE (TWO COIL) 73 RIDE CONTROL VALVE
28 SENSOR – HYD. TEMPERATURE
10 SOLENOID ACTIVATED DIRECTIONAL 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
29 FLUSHING RELIEF VALVE 74 HIGH PRESSURE CHAMBER
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 552 kPa) (5,5 bar)
11 LOAD CHECK VALVE (80 psi) Spring 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 SHUTTLE VALVE
31 HIGH PRESSURE SHUTTLE 53 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi)
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT psi) Spring And With 0,33 mm (0.013 in) Orifice
CONTROL VALVE - LIFT CONTROL 55 RESTRICTION - 0,51 mm (0.020 in)
33 PILOT ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 RESTRICTION - 0,51 mm (0.020 in)
CONTROL VALVE - BICS CONTROL 34 NOT USED FOR THIS MODEL PILOT ACTIVATED DIRECTIONAL
16 57
FILTER - BICS CONTROL VALVE CONTROL VALVE - REAR AUXILIARY
(SCREEN) 35 SOLENOID ACTIVATED DIRECTIONAL 58 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE – Brake Valve
36 CHARGE PUMP - CONTROL VALVE - TWO COIL
49,2 L/min (13.0 U.S. gpm) at High Engine Idle NOTE: Unless otherwise specified
60 RESTRICTOR - 0,8 mm (0.031 in) springs have NO significant
HYDRAULIC PUMP . . . . . . . Gear Type pressure value.
37 LOAD SHUTTLE VALVE - BLEED OFF
Printed in U.S.A. 64,7 L/min (17.1 U.S. gpm) at High Engine Idle 61 V-1528legend (11-17-17)
117 of 1234
Male
DRIVE MOTOR 27
29
Male
30
72
Female
31
OUT
32 LIFT CYLINDERS
RIDE CONTROL
(FIELD INSTALLED OPTION)
9
REAR AUXILIARY VALVE
(OPTIONAL)
FEMALE MALE
REAR QUICK COUPLERS 9 75 74
A B 10 73
33 ? ?
61
10
Auxiliary Spool
63 6A
62
? ? 59
R BUCKET POSITIONING
HYDROSTATIC PUMP 38 VALVE (OPTIONAL)
T
60 11 E1 E2 A1 A2
8 E3
BOBCAT INTERLOCK CONTROL 64

SYSTEM (BICS)
B 65
TILT CYLINDERS
58 8
39 ? 66
Tilt Spool 67
57 13 D2
M4
P in P out T
2-SPEED VALVE M3
12
(OPTIONAL) D C
11
A1 T
40
POWER BOBTACH CYLINDER
LIFT CYLINDERS 68 C2
(OPTIONAL)
8 14
POWER BOBTACH C1 D1
B A
A
P VALVE (OPTIONAL)
Lift Spool
M2 M1
51
35
50 52 54
39
11 20 17
49 15 ?
TILT CYLINDERS
IN 18
53
7 6 17
56 2
55 16
D 48
T
38 1
47 46
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
70 71 FILTER 3
25
69 ? 23
26
B 33 A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
31
S550 (S/N A3NL11001 -A3NL12242)
30
(S/N AZN811001 - AZN811512)
DRIVE MOTOR
29
118 of 1234 (PRINTED NOVEMBER 2017)

MANUAL WITH ALL OPTIONS S550
(S/N A3NL12243 - A3NL12730)
(S/N AZN811513 - AZN811551)
V-1528legend
LEGEND
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
43 NOT USED ON THIS MODEL 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa VALVE
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi)
44 NOT USED ON THIS MODEL 68 PILOTED ACTIVATED DIRECTIONAL
23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
PORT: 27579 kPa (276 bar) (4000 psi)
10 SOLENOID ACTIVATED DIRECTIONAL 50 NOT USED ON THIS MODEL
CONTROL VALVE - AUXILIARY 51 CHECK VALVE
11 LOAD CHECK VALVE 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL
54 NOT USED ON THIS MODEL
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 NOT USED ON THIS MODEL
16 57
37 61 LOAD SHUTTLE VALVE - BLEED OFF
Printed in U.S.A. 64,7 L/min (17.1 U.S. gpm) at High Engine Idle V-1528legend (11-17-17)
119 of 1234
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A B A
Male
30 B A
B
A
B A
1
A
72
A A
P B B A
A
0 2
Female
A B B A
A B
31 A
OUT
B B
A C
32 B
A
RIDE CONTROL LIFT CYLINDERS
B
A
B A
9
A REAR AUXILIARY VALVE
(OPTIONAL) A
A A
A
2 A3 A0
A
FEMALE A A
MALE A
A B
B
75 74
1
A B A
REAR QUICK COUPLERS B A
9
1 A A
A B
A B B A
A 10 73
33
B B A B B
A A
B B B
61 A
A B
P
B
PB
10
A A
A BA CA Auxiliary Spool
B A A A C
B
63 6A A B
62 B
B A
T
A A
T
A B B
P A A P
A B
A B A B B A A B A
B
A
A
B
A
59 T1 P T2
A
R A A B
BUCKET POSITIONING
HYDROSTATIC PUMP 38 B A VALVE (OPTIONAL)
A
A T B
A 60 A P T
A C
11 E1 E2 A1 A2
B
A B
A
8 E3
A
B
B
B
A
B A

A B
A
A B
A SYSTEM (BICS)
A B
B P A
65
P
B A
A
58 B A
8 A
B
B
39 A P
P A T
66
A B
1 2 3 4
Tilt Spool 67
57
A A A
A
B
B 13 A B
D2
A B B A
M4
P in
B P out
A
T A B
A
2-SPEED VALVE C C
M3
12 B
B
(OPTIONAL) D B
C
0 6
A
5 A
A B
11
A A P T
B B
B
A B
B A A
A A A
A1
A
T

A A
B
A B
40
B
A
A B
68
A
A
POWER BOBTACH CYLINDER A B

C2
14
A B A
(OPTIONAL)
B
B A 8
A B A A POWER BOBTACH C1 D1
P B BA A B A
A B A BB A
B
BA
B
VALVE (OPTIONAL)
P B
A A P A
B A
A
C C A B 1 2 3
Lift Spool
M2
A B B A
A
M1
54 53 A B
35 B
B
A
T
A
0 5 4 P A
A A
B B A
39 49
A
11 20 17
B
55 2 5
B
15
B A
A B B
A
B A
TILT CYLINDERS
1 4 3 IN B
B
18
D A 7 6 A
17 A
A
2
A
B
A
A
B
B A
A
16
A B B
A
T
A
38 A
A
A
P A
A
1 PA
47 46 B
41 Oil Cooler
A
A B
A B
19
4 (VENTED)
A B
5 B A
A
36
HYDRAULIC A 1
70
A
71 FILTER
A
3
B A
B
C P
A B 25 B
B
69 23
A
A
26
A
B
A
C 2
A
B
B 33 A
A
A WORKING CIRCUIT
24 A
1
1 21 CHARGE
A A
B
PRESSURE
A
2 A3 A0 P DR
22 DRAIN / RETURN
A
A
A
32
B
28
C A
A
A
31
2 0
B
A A
S550 (S/N A3NL12243 - A3NL12730)

1
30 A
29
DRIVE MOTOR (S/N AZN811513 - AZN811551)
(PRINTED NOVEMBER 2017)
120 of 1234
Printed In U.S.A. 7204247 (C)
V-1652legend
LEGEND
VALVE (ON/OFF)
(Fan Speed Regulator): 10797 – 12300 kPa NOT USED ON THIS MODEL VALVE
44 NOT USED ON THIS MODEL 68
PORT: 27579 kPa (276 bar) (4000 psi)
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE (TWO COIL)
CONTROL VALVE – Ride Control (OPTIONAL)
29 FLUSHING RELIEF VALVE 74 ACCUMULATOR – Ride Control (OPTIONAL)
CONTROL VALVE - AUXILIARY 51 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE 75 ORIFICE WITH CHECK VALVE:
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL 2,54 mm (0.10 in)
53 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 76 ORIFICE: 1,60 mm (0.063 in)
31 HIGH PRESSURE SHUTTLE
CONTROL VALVE - TILT CONTROL
54 CHECK VALVE 77 FAN REVERSING VALVE (OPTIONAL)
16 57
FILTER - BICS CONTROL VALVE CONTROL VALVE - REAR AUXILIARY RELIEF VALVE:
(SCREEN) 35 SOLENOID ACTIVATED DIRECTIONAL 58 22753 kPa (228 bar) (3300 psi)
121 of 1234
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A
30
B A
B A A Male
B B A
1
A
72
A A
P B B A
A
0 2
Female
A B B A
74
A B
31 RIDE CONTROL (OPTION)

OUT
A
T2 ACC
A
B B
A C
HYDRAULIC CONTROL VALVE NOTE: Cushioned Lift Cylinder
T
B
B
75 Pistons On Later Models Only.
32 B
A
B
A
LIFT CYLINDERS
76 P
A
P
A
9
A
B A
P
A REAR AUXILIARY VALVE A A
(OPTIONAL) A
A
2 A3 A0
A
FEMALE A A
MALE A
A B
B
73
A B A
REAR QUICK COUPLERS B A

9
CR2 CR CB
1
A A
A B B
A
B
B
A B
B
B
A
A
10
33 B
A
B
A
B
61 A
A B
P
B
PB
10
A A
A BA CA Auxiliary Spool
B A A A C
B
63 6A A B
62 B
B A
T
A A
T
A B B
P A A P
A B
A B A B B A A B A
B
A
A A
B
59 T1 P T2
R A A B
BUCKET POSITIONING
HYDROSTATIC PUMP
A
38 A
A T
B
B
A VALVE (OPTIONAL)
A
A 60 A P T
A C
11 E1 E2 A1 A2
B
A B
A
8 E3
A
B
B
A
B
B A

A B
A
A B
A SYSTEM (BICS)
A B
B P A
65
P
B A
A
58 B A
8 A
B
B
39 A P
P A T
66
A
A B
1 2 3 4
Tilt Spool A A
67
A
57 B 13
B
A B
D2
A B B A
M4
P in
B P out
A
T A B
A
2-SPEED VALVE C C
M3
12 B
B
(OPTIONAL) D B
C
0 6
A
5
A
A B
11
A A P T
B B
B
A B
B A A
A A
A1

A
T A
A
A
A
B B
40
B
A
A B
68
A
A
POWER BOBTACH CYLINDER A B

C2
14
A B A
(OPTIONAL)
B B A 8
A
POWER BOBTACH C1 D1
P
B BA A
B B A A
A
A B A BB BA
B
BA
P VALVE (OPTIONAL)
B
A A P A
A B A
C C A B 1 2 3
Lift Spool
M2
A B B A
A
M1
54 53 A B
35 B
B
A
T
A
0 5 4 P A
A A
B B A
39 49 A
20 B
55 2 5 B
A
11 17
15
B A
A B B
A
1 4 3
B
B
A
18 TILT CYLINDERS
IN B
D A 7 6 A
17 A
A 2
48 A
A
A
B
16
A
T
B 47 B
38 A
A
A
A
1 PA
46
B
41 Oil Cooler
A B
19
A B
VARIABLE SPEED 4 (VENTED)
HYDRAULIC FAN MOTOR W/ 2
A B
INTEGRATED FILTER (Show n 5 B A

A
36 With OPTIONAL Reversing

Valve)
HYDRAULIC
A 1
70
A
71 FILTER A 3
B
A
B
A B
C P
25 23
69
B
B
A
A
26 A
B
A
C
T
1 4 B
2
B 33 A
A
P A
B
WORKING CIRCUIT
3 2 A
A
1 A
21 CHARGE
24 PRESSURE
1
A A
B
2 A3 A0
A
77 22 DRAIN / RETURN
DR P
A
A
A
32
B
28 Printable Version Click Here
C A
A
A
31
B
2 0
A A
1
B

A
30
29
DRIVE MOTOR

122 of 1234
Printed In U.S.A. 7204247 (E)
SJC WITH NO OPTIONS
(PRINTED AUGUST 2012) Printable Version Click Here
V-1529legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 35 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
36 CHARGE PUMP -
2 SIGHT GUAGE
19 PULL BUTTON ACTIVATED 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT HYDRAULIC PUMP . . . . . . . Gear Type
37
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 64,7 L/min (17.1 U.S. gpm) at High Engine Idle
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO
38 VARIABLE CAPACITY DISPLACEMENT
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP
DOWN BUT NOT DURING BOOM UP
5 SPRING LOADED FILTER BY-PASS 39 RELIEF/REPLENISHING VALVE - HIGH
VALVE: 172 kPa (1,7 bar) (25 psi) PRESSURE: 34500 kPa (345 bar) (5000 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa 40
2861 kPa (28,6 bar) (415 psi) at High
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) Engine Idle With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN: 41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
23787 - 24476 kPa (238 - 245 bar) With
Dealer Copy -- Not for 345 kPa (3,45 bar) (50 psi) Spring
Resale
(3450 - 3550 psi) at Front Quick Couplers
HYDRAULIC MOTOR 42 SOLENOID ACTIVATED DIRECTIONAL
25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – FORWARD/REVERSE
8 RELIEF/ANTICAVITATION VALVE - 43 FILTER
PORT: 27579 kPa (276 bar) (4000 psi) 26 SENSOR – CHARGE PRESSURE
44 SERVO PISTON – Swash Plate
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE
10 SOLENOID ACTIVATED DIRECTIONAL 29 FLUSHING RELIEF VALVE
CONTROL VALVE - AUXILIARY
11 LOAD CHECK VALVE
30 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - LIFT CONTROL 33 NOT USED FOR THIS MODEL
CONTROL VALVE - BICS CONTROL 34 NOT USED FOR THIS MODEL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1529legend (8-30-12)
123 of 1234
Male
DRIVE MOTOR 27
29
Male
30
Female
OUT
32
9
A B 10
10
Auxiliary Spool
6A
R
HYDROSTATIC PUMP 38 T
11
42
8
X1 43 BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
TILT CYLINDERS
X2 8
39
Tilt Spool
13
MA
MB 43
12
A B
11
MG
40
LIFT CYLINDERS
G 8 14
A B
MB
Lift Spool
MA 43
?
20
39
X2 11 17
15 ?
44 18
IN
X1 ? 7 6 17
43 2
42 16
T
38 R 1
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
FILTER 3
25
26 23
B A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
DRAIN/RETURN MANIFOLD Printable Version Click Here

32
SJC WITH NO OPTIONS
30 (S/N AZN811001 AND ABOVE)
29
DRIVE MOTOR
124 of 1234 (PRINTED AUGUST 2012)

SJC WITH ALL OPTIONS
S550 (S/N A3NL11001 - A3NL12242)
(S/N AZN811001 - AZN811512)
V-1530legend
LEGEND
VALVE (ON/OFF)
With 345 kPa (3,45 bar) (50 psi) Spring PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP 66
21 ANTICAVITATION VALVE 42 SOLENOID ACTIVATED DIRECTIONAL SPOOL
CONTROL VALVE – FORWARD/REVERSE
FILTER VALVE
(Fan Speed Regulator): 10797 – 12300 kPa
44 SERVO PISTON – Swash Plate 68
PORT: 27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
PORT (OPTIONAL):
10 SOLENOID ACTIVATED DIRECTIONAL 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 552 kPa) (5,5 bar)
11 LOAD CHECK VALVE (80 psi) Spring 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 SHUTTLE VALVE
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT psi) Spring And With 0,33 mm (0.013 in) Orifice
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 RESTRICTION - 0,51 mm (0.020 in)
16 57
36 CHARGE PUMP - CONTROL VALVE - TWO COIL NOTE: Unless otherwise specified
49,2 L/min (13.0 U.S. gpm) at High Engine Idle
125 of 1234
Male
DRIVE MOTOR 27
29
Male
30
72
Female
31
OUT
32 LIFT CYLINDERS
RIDE CONTROL
9
(OPTIONAL)
FEMALE MALE
A B 10 73
33 ? ?
61
10
Auxiliary Spool
63 6A
62
? ? 59
T
60 11 E1 E2 A1 A2
42
8 E3
X1 43 BOBCAT INTERLOCK CONTROL 64
SYSTEM (BICS)
44 B 65
TILT CYLINDERS
X2
58 8
39 ? 66
Tilt Spool 67
57 13 D2
MA
P in P out T
2-SPEED VALVE MB 43
(OPTIONAL)
12
A B
11
A1 T
MG
40
POWER BOBTACH CYLINDER
LIFT CYLINDERS 68 C2
G
(OPTIONAL)
8 14
POWER BOBTACH C1 D1
A B
A
P VALVE (OPTIONAL)
MB
Lift Spool
MA 43
51
35
50 52 54 20
?
39
X2 11 17
49 15 ?
44 18 TILT CYLINDERS
IN
53
X1 ? 7 6 17
43 56 2
42 55 16
D 48
T
38 R 1
47 46
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
70 71 FILTER 3
25
69 ? 23
26
B 33 A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
SJC WITH ALL OPTIONS Printable Version Click Here
31
S550 (S/N A3NL11001-A3NL12242)
30
(S/N AZN811001 - AZN811512)
29
DRIVE MOTOR
126 of 1234 (PRINTED NOVEMBER 2017)

S550 (S/N A3NL12243 - A3NL12730)
(S/N AZN811513 - AZN811551)
V-1530legend
LEGEND
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
43 FILTER 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa VALVE
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi)
44 SERVO PISTON – Swash Plate 68 PILOTED ACTIVATED DIRECTIONAL
23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
PORT: 27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE 49 (5.0 psi) Spring
PORT (OPTIONAL): SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 51 CHECK VALVE
11 LOAD CHECK VALVE 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL
54 NOT USED ON THIS MODEL
16 57
37 61 LOAD SHUTTLE VALVE - BLEED OFF
Printed in U.S.A. 64,7 L/min (17.1 U.S. gpm) at High Engine Idle V-1530legend (11-17-17)
127 of 1234
Male
DRIVE MOTOR 27
29
Male
30
72
Female
31
OUT
32
RIDE CONTROL LIFT CYLINDERS
9
(OPTIONAL)
FEMALE MALE
A B 10 73
33
61
10
Auxiliary Spool
63 6A
62
59
T
60 11 E1 E2 A1 A2
42
8 E3
SYSTEM (BICS)
44 B 65
TILT CYLINDERS
X2 58 8
39 66
Tilt Spool 67
57 13 D2
P in P out T
2-SPEED VALVE
MA
43
MB
12
(OPTIONAL) A B
MG
11
A1 T
40 Dealer Copy -- Not for Resale LIFT CYLINDERS 68

POWER BOBTACH CYLINDER C2
G
(OPTIONAL)
8 14
POWER BOBTACH C1 D1
A B
A VALVE (OPTIONAL)
P
MB
Lift Spool
MA 43 53
54
35
20
39 49
X2 11 17
55
15
44 TILT CYLINDERS
IN 18
X1
D 7 6 17
43 2
42 16
T
38 R 1
47 46
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
70 71 FILTER 3
25
69 23
26
B 33 A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
28
31
30
S550 (S/N A3NL12243 - A3NL12730)
29
(S/N AZN811513 - AZN811551)
DRIVE MOTOR

128 of 1234
V-1653legend
LEGEND
VALVE (ON/OFF)
FILTER VALVE
(Fan Speed Regulator): 10797 – 12300 kPa
44 SERVO PISTON – Swash Plate 68
PORT: 27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi) CONTROL VALVE (TWO COIL) 73 SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 50 NOT USED ON THIS MODEL CONTROL VALVE – Ride Control (OPTIONAL)
29 FLUSHING RELIEF VALVE 74 ACCUMULATOR – Ride Control (OPTIONAL)
CONTROL VALVE - AUXILIARY 51 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL 75 ORIFICE WITH CHECK VALVE:
12 ANTICAVITATION VALVE 2,54 mm (0.10 in)
31 HIGH PRESSURE SHUTTLE 53 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 76 ORIFICE: 1,60 mm (0.063 in)
54 CHECK VALVE
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT 77 FAN REVERSING VALVE (OPTIONAL)
16 57
129 of 1234
Male
DRIVE MOTOR 27
29
30 Male
Female
31 74
OUT RIDE CONTROL (OPTION)
HYDRAULIC CONTROL VALVE T2 ACC NOTE: Cushioned Lift Cylinder
75 Pistons On Later Models Only.
32 T
LIFT CYLINDERS
76
9
P
(OPTIONAL)
FEMALE MALE
REAR QUICK COUPLERS 9 73
A B 10 CR2 CR CB
33
61
10
Auxiliary Spool
63 6A
62
59
T
60 11 E1 E2 A1 A2
42
8 E3
SYSTEM (BICS)
44 B 65
X2
58 8
39 66
Tilt Spool 67
57 13 D2
MA
P in P out T
2-SPEED VALVE MB 43
12
(OPTIONAL) A B
MG
11
A1 T
40 POWER BOBTACH CYLINDER

Dealer Copy -- Not for Resale 68
(OPTIONAL) C2
G 8 14
POWER BOBTACH
C1 D1
A B VALVE (OPTIONAL)
A
P
MB
Lift Spool
MA 43 51 50
35
20
49
39
X2 52 11 17
15
44 18 TILT CYLINDERS
IN
D
X1 7 6 17
43 48 2
42 47 16
T
38 R 1
46
41 Oil Cooler
19
VARIABLE SPEED 4 (VENTED)
HYDRAULIC FAN MOTOR W/ 2
INTEGRATED FILTER (Show n 5
36 With OPTIONAL Reversing
Valve)
HYDRAULIC
1
FILTER 3
25 23
26
1 4
B 33 A
3 2 WORKING CIRCUIT
21
CHARGE
24 PRESSURE
77 22
DR P DRAIN / RETURN
32 DRAIN/RETURN MANIFOLD
31
30
DRIVE MOTOR
29
130 of 1234
Printed In U.S.A. 7204248 (E)
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS
WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).
DRAIN CIRCUITS - Dotted Line -

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.)

FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

Connected). electric signal with pressure.
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
PRESSURE SWITCH - Switch

activates when pressure reaches
specified level.
MUFFLER (silencer) - Reduces

noise.

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).
DOUBLE ACTING HYDRAULIC

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.
CONTROL VALVE ACTIVATED BY A

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).
MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).


NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).
NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.
TOW VALVE - Normally in closed

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-80-1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
Lift bypass control valve stuck. 12

Lift arm bypass control valve stem bent or broken. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-
50-1.)
8. Using the loader for more than its rated capacity. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace lift arm bypass control valve assembly.


CYLINDER (LIFT) Figure 20-20-2
Testing
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 2
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P106658
Lower the lift arms. Stop the engine. Raise the seat bar.
Install a plug (Item 1) [Figure 20-20-2] in the hose and
Figure 20-20-1 tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.

Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2]. Remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
P106656
Test only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the cylinder.

CYLINDER (LIFT) (CONT’D) Figure 20-20-4
Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the lower fan duct. (See Fan Duct Removal And
Installation on Page 70-50-3.)
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P106659
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the bolt and nut (Item 1) [Figure 20-20-4] from
I-2003-0888 the pin on the rod end of the cylinder.
Figure 20-20-3 Installation: Tighten the bolt and nut to 48 - 54 N•m (35 -
40 ft-lb) torque.

Figure 20-20-5
P106656
Remove both hydraulic hoses from the cylinder (Item 1) P106660

[Figure 20-20-3].
Remove the pin (Item 1) [Figure 20-20-5] from the rod

end of the cylinder.

Removal And Installation (Cont'd)

1
Figure 20-20-6
1
1
P106668
Remove the two bolts (Item 1) [Figure 20-20-8].

P106665
Figure 20-20-9
Remove the bolt (Item 1) [Figure 20-20-6].

1

Figure 20-20-7
2
1 P106666
2
Remove the two bolts (Item 1) and reposition the upper

P106664 plate (Item 2) [Figure 20-20-9].
Remove the bolt (Item 1) and remove the lower plate

(Item 2) [Figure 20-20-7].

Figure 20-20-10
P106667
1
Remove the pin (Item 1) [Figure 20-20-12] from inside
P106661 the loader frame.
Remove the bolt and nut (Item 1) [Figure 20-20-10] from

the pivot pin at the base end of the cylinder. WARNING

Installation: Tighten the bolt and nut to 48 - 54 N•m (35 -
40 ft-lb) torque. AVOID INJURY OR DEATH
Figure 20-20-11 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
1
P106662
Drive the pin (Item 1) in to the loader frame. Remove the

cylinder (Item 2) [Figure 20-20-11].

CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Tubeline 9. Spacer
2. Plug 10. Back-up Ring
3. O-ring 11. Head
4. Grease Fitting 12. Rod Seal
5. Tube 13. Wiper
6. Nut 14. Rod
7. Seal
8. Piston
1
4
2
3

5
6
3
7
10 3 3
8
11
9
12
13
14 4
NA6578S

Disassembly
4
Clean the outside of the cylinder before disassembly. 3
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Figure 20-20-13 P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].
Figure 20-20-15
1

2
1
P-81032
Insert the Adjustable Gland Nut Wrench into the holes

(Item 1) [Figure 20-20-13] to loosen the head. 3
Remove the head and the rod assembly from the P-48038
cylinder. Put the rod end in a vise.

Remove the seal (Item 1) and O-ring (Item 2) from the
piston (Item 3) [Figure 20-20-15].
NOTE: If the fiber surface (Item 3) [Figure 20-20-15]

on the piston becomes damaged, the
complete piston must be replaced.

Disassembly (Cont’d)
Figure 20-20-16
1
2
P-81039
1
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-
P-48039 18].
Remove the O-ring (Item 1), back-up ring (Item 2) and

the O-ring (Item 3) [Figure 20-20-16].

Figure 20-20-17
2 1
P-81036A
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-17].

Assembly
3
Clean all parts in solvent and dry with compressed air. 1
Inspect the cylinder parts for wear or damage. Replace 2

any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during

installation.
Use the following tools to assemble the cylinder:

P-48038
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor Install the O-ring (Item 1) and seal (Item 2) on the piston
MEL1075 - Adjustable Gland Nut Wrench (Item 3) [Figure 20-20-20].
Figure 20-20-21
Figure 20-20-19

N-22358
P-7424
Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-19]. approximately three minutes [Figure 20-20-21].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Cont’d)
Figure 20-20-22
P-7425
Install the rod seal in the head [Figure 20-20-24].

P-7427
Figure 20-20-25
Install the rod seal on the rod seal tool [Figure 20-20-22].

NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-20-23
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
20-25] toward the outside of the head.
N20613
Rotate the handles to collapse the rod seal [Figure 20-

20-23].

Assembly (Cont’d)
Figure 20-20-26
2
2
81039
3
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-
P-48039 20-28].
Tighten the plug to 50 N•m (37 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-20-26].

Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-20-26]. Figure 20-20-29
Figure 20-20-27
1
2
3 1
1
P-81032
P-48036
(Item 1) [Figure 20-20-29] to tighten the head. Tighten
Install the head (Item 1), spacer (Item 2) and the piston the head until it is flush with the end of the housing.
(Item 3) [Figure 20-20-27] on the rod.
Grease the piston where the nut contacts the piston. Do

not get grease on the threads.
Provide an adequate support for the cylinder before

tightening.
NOTE: Clean and dry the rod threads. Install a NEW

NUT with preapplied Loctite®.
Install the nut (Item 4) [Figure 20-20-27].
Tighten the nut to 1152 N•m (850 ft-lb) torque.

CYLINDER (TILT) Figure 20-21-2
Testing
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar.
1
WARNING 2

penetrating the skin. This can cause serious injury
P106670
immediately.
W-2145-0290
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Figure 20-21-1

Operate the controls that rolls the Bob-Tach back.

1
Repeat procedure to test the other cylinder.
P106669

the cylinder.

CYLINDER (TILT) (CONT’D) Figure 20-21-5
Remove the attachment from the Bob-Tach. Roll the Bob-

Tach forward.
2
Figure 20-21-3 1
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-21-

5] from the cylinder.
Remove the base end pivot bolt and washer (Item 2)

[Figure 20-21-5].

P-85554 Figure 20-21-6

the rod end pivot pin.
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb) 1

torque.
Figure 20-21-4
P-85648
Remove the nut and washer (Item 1) [Figure 20-21-6]

from the base end pivot pin.
Installation: Tighten the nut to 258 - 264 N•m (190 - 195

ft-lb) torque.
P-85649
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

CYLINDER (TILT) (CONT’D) Base End Pivot Pin Removal And Installation
Removal And Installation (Cont'd) Remove the tilt cylinder from the cylinder base pin. (See
Removal And Installation on Page 20-21-2.)
Figure 20-21-7
Figure 20-21-8
1
P106673
P106671
Slide the cylinder from the base pin and remove the
cylinder [Figure 20-21-7]. Using a 22 mm (0.875 in) drift, drive the taper pin (Item 1)

[Figure 20-21-8] from the track side of the loader out of
the lift arm.
Figure 20-21-9
P-85567
Inspect the pivot pin and replace as needed [Figure 20-

21-9].

CYLINDER (TILT) (CONT’D)
1. Tube
2. Grease Fitting
3. O-ring
4. Plug
5. Nut
6. Seal
7. Piston
2
8. Back-up Ring
9. Head
10. Rod Seal
11. Wiper 1
12. Rod
13. Bushing
3
4
5
6
3 3
4

7
3
8
3
9
10
11
2
12
13
NA6577S

Disassembly 3
Clean the outside of the cylinder before disassembly. 2

1
MEL1074 - O-ring Seal Hook
Figure 20-21-10 P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
1 Figure 20-21-13

1
P-53073
Remove the bushing (Item 1) [Figure 20-21-10]. 3
Figure 20-21-11
P-48073

1
P-81032

(Item 1) [Figure 20-21-11] to loosen the head.
Remove the head and the rod assembly from the


Figure 20-21-14
1
3
1
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-21-

P-48039 16].
Remove the O-ring (Item 1). Remove the O-ring (Item 2)

and back-up ring (Item 3) [Figure 20-21-14].

Figure 20-21-15
2 1
P-81036A
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-21-15].

Assembly
2
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace 1

any damaged parts.

installation. 3

P-48073
Figure 20-21-19
Figure 20-21-17

N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-21-20
P-7425

P-7427
Figure 20-21-23

Figure 20-21-21
N-22359
N20613

21-21].

Assembly (Cont’d)
Figure 20-21-24
1
2
2
3
81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

P-48039 21-26].
Tighten the small plug to 20 N•m (15 ft-lb) torque.

Tighten the large plug to 50 N•m (37 ft-lb) torque.

[Figure 20-21-24]. Put the base end of the cylinder in a vise.
Figure 20-21-25
1
2
P-48071
Install the head (Item 1) and the piston (Item 2) [Figure

20-21-25] on the rod.


tightening.


CYLINDER (TILT) (CONT’D)
Assembly (Cont’d)
Figure 20-21-27
1
P-81032

(Item 1) [Figure 20-21-27] to tighten the head. Tighten

the head until it is flush with the end of the housing.
Figure 20-21-28
P-53073
Install the bushing (Item 1) [Figure 20-21-28]. Make sure

the bushing is aligned with the grease channel in the
cylinder.

CYLINDER (LIFT) (AZN811740 & ABOVE) Figure 20-22-2
Testing
WARNING
penetrating the skin. This can cause serious injury 2
immediately.
W-2145-0290
P106658
Lower the lift arms. Stop the engine. Raise the seat bar.
Install a plug (Item 1) [Figure 20-22-2] in the hose and
Figure 20-22-1 tighten.

Operate the controls that lower the lift arms.

Repeat the procedure to test the other cylinder.
P106656

the cylinder.

CYLINDER (LIFT) (AZN811740 & ABOVE) (CONT’D) Figure 20-22-4
Remove the lower fan duct. (See Fan Duct Removal And
IMPORTANT
1
P106659
damage the system. Remove the bolt and nut (Item 1) [Figure 20-22-4] from
I-2003-0888 the pin on the rod end of the cylinder.
Figure 20-22-3 Installation: Tighten the bolt and nut to 48 - 54 N•m (35 -
40 ft-lb) torque.

Figure 20-22-5
P106656
Remove both hydraulic hoses from the cylinder (Item 1) P106660

[Figure 20-22-3].

end of the cylinder.


1
Figure 20-22-6
1
1
P106668

P106665
Figure 20-22-9
Remove the bolt (Item 1) [Figure 20-22-6].

1

Figure 20-22-7
2
1 P106666
2
Remove the two bolts (Item 1) and reposition the upper

P106664 plate (Item 2) [Figure 20-22-9].
Remove the bolt (Item 1) and remove the lower plate

(Item 2) [Figure 20-22-7].

Figure 20-22-10
P106667
1
Remove the pin (Item 1) [Figure 20-22-12] from inside
P106661 the loader frame.

the pivot pin at the base end of the cylinder. WARNING

40 ft-lb) torque. AVOID INJURY OR DEATH
Figure 20-22-11 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
1
P106662
Drive the pin (Item 1) in to the loader frame. Remove the

cylinder (Item 2) [Figure 20-22-11].

CYLINDER (LIFT) (AZN811740 & ABOVE) (CONT'D)
1. Tube 6. O-ring
2. Grease Fitting 7. Spacer
3. Nut 8. Head
4. Piston 9. Wiper
2 5. Seal 10. Rod
1
3
4
5
6
7
6

5
6
6
8
5
9
10
NA14140S

CYLINDER (LIFT) (AZN811740 & ABOVE) (CONT'D) Figure 20-22-14
Disassembly 3 1
Clean the outside of the cylinder before disassembly.

MEL1076 - Adjustable Gland Nut Wrench

Put the base end of the cylinder in a vise. 2

P131804
Figure 20-22-13
Remove the nut (Item 1), piston (Item 2), and spacer
(Item 3) [Figure 20-22-14].
1
Figure 20-22-15

2
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the 2

notch (Item 2) [Figure 20-22-13] to loosen the head.
P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-
22-15] from the piston.

2 1
Figure 20-22-16
P131810
Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

P131809 22-18] from the inside of the head.
Figure 20-22-19
Remove the O-ring (Item 1) [Figure 20-22-16] from the
spacer. 1

Figure 20-22-17
1
1
2
P131811
Remove the O-rings (Item 1) and back-up ring (Item 2)

P131805 [Figure 20-22-19] from the outside of the head.
Remove the head (Item 1) [Figure 20-22-17] from the

rod.

Assembly
2
Inspect the cylinder parts for wear or damage. Replace

any damaged parts.

installation.
1
P131807
MEL1396-2 - Piston Ring Compressor Install the seal (Item 1) and O-ring (Item 2) [Figure 20-
MEL1076 - Adjustable Gland Nut Wrench 22-21] on the piston.
Figure 20-22-22
Figure 20-22-20

N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-22-23
1
2
N20613

P131811 22-25].
Figure 20-22-26
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-22-23] onto the outside of the head.

Figure 20-22-24
P-7425

P-7427


Assembly (Cont’d)
1
Figure 20-22-27
P131809
Install the O-ring (Item 1) [Figure 20-22-29] in the

P131810 spacer.
Figure 20-22-30

1
Figure 20-22-28
P131808
Install the spacer (Item 1) [Figure 20-22-30] on the rod.

P131805
Install the head (Item 1) [Figure 20-22-28] onto the rod.

Assembly (Cont’d)
Figure 20-22-31
1
P131804

P131806
Install the piston (Item 1) [Figure 20-22-31] on the rod. Put the base end of the cylinder in a vise.

Figure 20-22-32 Figure 20-22-34
1
2
P131816 P131818
Provide an adequate support for the cylinder before Install the head and rod assembly (Item 1) into the
tightening. cylinder tube and thread the head into the cylinder. Install
the Adjustable Gland Nut Wrench (Item 2) [Figure 20-22-
NOTE: Clean and dry the rod threads. Apply thread 34] onto the head. Tighten to 550 N•m (405 ft-lb) torque.
locking adhesive (Item 1) [Figure 20-22-32].


CYLINDER (TILT) (AZN811740 & ABOVE) Figure 20-23-2
Testing
Remove the attachment. Roll the Bob-Tach fully back.

1
WARNING 2

P106670
immediately.
W-2145-0290
Install a plug (Item 1) [Figure 20-23-2] in the hydraulic
hose and tighten.
Figure 20-23-1

Operate the controls that rolls the Bob-Tach back.

(Item 2) [Figure 20-23-2], remove the cylinder for repair.
1
Repeat procedure to test the other cylinder.
P106669

(Item 1) [Figure 20-23-1] from the base end of the
cylinder.

CYLINDER (TILT) (AZN811740 & ABOVE) (CONT'D) Figure 20-23-5
Remove the attachment from the Bob-Tach. Roll the Bob-

Tach forward
2
Figure 20-23-3 1
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-23-

5] from the cylinder.
Remove the base end pivot bolt and washer (Item 2)

[Figure 20-23-5].

P-85554 Figure 20-23-6


torque.
Figure 20-23-4
P-85648
Remove the nut and washer (Item 1) [Figure 20-23-6]

from the base end pivot pin.

ft-lb) torque.
P-85649

CYLINDER (TILT) (AZN811740 & ABOVE) (CONT'D) Base End Pivot Pin Removal And Installation
Removal And Installation (Cont'd) Remove the tilt cylinder from the cylinder base pin. (See
Figure 20-23-7
Figure 20-23-8
1
P106673
P106671
Slide the cylinder from the base pin and remove the
cylinder [Figure 20-23-7]. Using a 22 mm (0.875 in) drift, drive the taper pin (Item 1)

[Figure 20-23-8] from the track side of the loader out of
the lift arm.
Figure 20-23-9
P-85567
Inspect the pivot pin and replace as needed [Figure 20-

23-9].

CYLINDER (TILT) (AZN811740 & ABOVE) (CONT'D)
2 1. Tube 6. O-ring
2. Grease Fitting 7. Head
1
3. Nut 8. Wiper
4. Piston 9. Rod
5. Seal 10. Bushing
3
4
5
6

6
5
6
7
5
8
9
2
6
10
NA14141S

Disassembly 1

MEL1076 - Adjustable Gland Nut Wrench
Figure 20-23-10 2
P131889
1 Remove the nut (Item 1), and piston (Item 2) [Figure 20-
23-11].
Figure 20-23-12

2
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the

notch (Item 2) [Figure 20-23-10] to loosen the head. 2

cylinder. Put the rod end in a vise. P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

23-12] from the piston.

Disassembly (Cont’d) 1
Figure 20-23-13
1
1
2
P131811

P131805 [Figure 20-23-15] from the outside of the head.
Remove the head (Item 1) [Figure 20-23-13] from the

rod.

Figure 20-23-14
2 1
P131810
Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

23-14] from the inside of the head.

Assembly
2

any damaged parts.

installation.
1
P131807
MEL1396-2 - Piston Ring Compressor Install the seal (Item 1) and O-ring (Item 2) [Figure 20-
MEL1076 - Adjustable Gland Nut Wrench 23-17] on the piston.
Figure 20-23-18
Figure 20-23-16

N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-23-19
1
2
N20613

P131811 23-21].
Figure 20-23-22
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-23-19] onto the outside of the head.

Figure 20-23-20
P-7425

P-7427


Assembly (Cont’d) 1
Figure 20-23-23
P131806
Install the piston (Item 1) [Figure 20-23-25] on the rod.

P131810
Figure 20-23-26
23-23] toward the outside of the head. 1

Figure 20-23-24
P131816

tightening.
P131805
NOTE: Clean and dry the rod threads. Apply thread
locking adhesive (Item 1) [Figure 20-23-26].
Install the head (Item 1) [Figure 20-23-24] onto the rod.

CYLINDER (TILT) (AZN811740 & ABOVE) (CONT'D)
Assembly (Cont’d)
Figure 20-23-27
1
P131889

Figure 20-23-28
P131818
Install the head and rod assembly (Item 1) into the

cylinder tube and thread the head into the cylinder. Install
the adjustable gland nut wrench (Item 2) [Figure 20-23-
28] onto the head. Tighten to 550 N•m (405 ft-lb) torque.

CYLINDER (BOB-TACH) Figure 20-24-2
Testing
WARNING 1

P106674
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-24-2] from the

Power Bob-Tach cylinder base end port.
WARNING Figure 20-24-3

explosion or fire. 1
W-2103-0508
Figure 20-24-1
P106675
Install a plug in the hose (Item 1) [Figure 20-24-3] and

tighten.
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

P106772 (Front Accessory Panel).
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-24-3], remove the cylinder for repair.
[Figure 20-24-1].
Push and hold BOB-TACH “WEDGES UP” switch until

levers are in the unlocked position (Wedges fully raised).

CYLINDER (BOB-TACH) (CONT’D)
Figure 20-24-4
P106672
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-24-4].

Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -
24 ft-lb) torque.
Install plugs in the hoses and cap on fittings.
Figure 20-24-5
1
1
P106676
Remove the bolts and washers (Item 1) [Figure 20-24-5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

lb) torque.
Remove the cylinder from the lever pivots.

1. Tube
2. Nut
3. Seal
4. O-ring
5. Piston
6. Spacer
7. Back-up Ring
8. Head
9. Seal
10. Wiper
11. Rod 1
2
4
5
3

6
4
7
4
9
10
11
NA2603S

CYLINDER (BOB-TACH) (CONT’D) Figure 20-24-7
Disassembly 2
4 3
1
Figure 20-24-6 P-16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-24-7].
Figure 20-24-8
1
3

2 1
1
P-81032

(Item 1) [Figure 20-24-6] to loosen the head.
Remove the head and the rod assembly from the P-16295


Figure 20-24-9
2
1
4
3
N-20611
Remove the wiper seal (Item 1), rod seal (Item 2), back-
up ring (Item 3), O-ring (Item 4), and O-ring (Item 5)

[Figure 20-24-9] from the head.

Assembly
3 1
Clean all parts in solvent and dry with compressed air. 2

any damaged parts.

installation.

P16295
Figure 20-24-12
Figure 20-24-10

N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-24-13
P-7425

P-7427
Figure 20-24-16

Figure 20-24-14
N-22359
N20613

24-14].

Assembly (Cont’d)
Figure 20-24-17
1 1
2
1
P-81032
3
P101716 (Item 1) [Figure 20-24-19] to tighten the head. Tighten
the head until it is flush with the end of the housing.

[Figure 20-24-17].
Figure 20-24-18
3
1 2 4
P-81064
Install the head (Item 1), spacer (Item 2) and the piston
(Item 3) [Figure 20-24-18] on the rod.


tightening.


MAIN RELIEF VALVE
Description
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic fluid to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader.

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1
Testing
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine. 1
I-2024-0284
WARNING P106632
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
cause injury or death.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the

loader.
WARNING Start the engine and run at low idle.
Figure 20-30-2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
The tools listed will be needed to do the following

procedure:
2
MEL10003 or MEL1744 - Hydraulic Tester 1
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure on Page 10-10-

1.)
NA3267
NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the Press the AUXILIARY HYDRAULICS Button (Item 1)
hydraulic tester without using any type of once to engage the auxiliary hydraulics. The light (Item 2)
quick coupler on the connection to the tester. [Figure 20-30-2] will be on.

Testing (Cont’d)
Figure 20-30-3
1
1
P106632
1 Warm the fluid to 60°C (140°F) by turning the restrictor

P106677 control (Item 1) [Figure 20-30-4] clockwise on the tester
until it reads 6895 kPa (69 bar) (1000 psi).
After activating the auxiliary hydraulics, press the NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
continuous flow control switch (Item 1) [Figure 20-30-3] psi).

to allow constant auxiliary hydraulic fluid flow to the front
female coupler (female coupler is pressurized). Turn the restrictor control (Item 1) [Figure 20-30-4]
counterclockwise to obtain free flow.
To stop continuous auxiliary hydraulic fluid flow, press the
front auxiliary hydraulic switch (Item 1) [Figure 20-30-3] Check the free flow specification. (See Hydraulic System
a second time. on Page SPEC-10-4.)
NOTE: When the operator is seated and raises the NOTE: If free flow is below specification perform the
seat bar, the Auxiliary Hydraulic System direct pump test.
(Front and Rear) will deactivate.
Start turning the restrictor clockwise, causing more
If no flow is indicated on the tester, the hoses are restriction on the flow. The fluid flow should drop off
connected wrong. With the hoses connected correctly, slightly until the pressure reaches approximately 21374
increase the engine speed to full rpm. kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
kPa (237,9 - 241,3 bar) (3450 - 3500 psi) the flow should
be at 0 L/min (0 U.S. gpm). DO NOT exceed 25510 kPa
(255 bar) (3700 psi). Turn the restrictor (Item 1) [Figure
20-30-4] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
If pressure does not match the above information, the

main relief valve needs to be adjusted.
After adjusting the main relief valve, retest the main relief
valve.

MAIN RELIEF VALVE (CONT’D)
Adjusting
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5

2
P106708
Loosen the locknut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
Retest the main relief valve after adjusting.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve.


1
IMPORTANT
2
damage the system.
I-2003-0888
P107745A
Clean the area around the control valve. Remove the O-rings and back-up rings from the main
relief valve [Figure 20-30-7].
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.
relief valve is located in the same place on all

of the loaders. Install new O-rings and back-up rings. Install the main
relief valve [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Test the relief valve. (See Testing on Page 20-30-2.)
P106708
Remove the main relief valve (Item 1) [Figure 20-30-6].


HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P107871
The hydraulic control valve is located inside the main

frame on the right hand side, below the operator’s cab.

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.
The auxiliary function is operated by pilot pressure.

There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handle / lever. The activated
solenoid sends pilot pressure fluid to one side of the
spool and forces the spool to shift.
The hydraulic control valve also contains a main relief

valve which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) Drain the hydraulic reservoir. (See Removing And
(CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.) OR (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 121-2.).
Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
DANGER Remove the control linkage. (See Linkage Removal And
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.
Clean area around control valve.
Open rear door.

P-90328
AVOID DEATH Figure 20-40-2

• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
• Keep out of this area when lift arms are raised 3
unless supported by an approved lift arm

D-1009-0409
1
WARNING 2
the lift arms are secured by an approved lift arm P106820

support device can allow the lift arms or attachment Remove the two bolts (Item 1), fill hose (Item 2) and the
to fall and cause injury or death. vent hose (Item 3) [Figure 20-40-2].
W-2059-0598
Remove the fuel inlet assembly.
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm

support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-40-3
2
1
P106832
Remove the hose (Item 1) [Figure 20-40-5] that routes

from the control valve to the filter.
P106822
Remove the tubeline (Item 2) [Figure 20-40-5] that
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed

Figure 20-40-6
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-40-3].
Figure 20-40-4 1
1
2
3
1
P106833
1
1 Remove the auxiliary hydraulic tubelines (Item 1) [Figure

20-40-6].
P106831
Disconnect the wire harness (Item 1) [Figure 20-40-4]

from the control valve.
Remove the hose (Item 2) [Figure 20-40-4] that routes

from the control valve to the drain manifold.
Remove the tubeline (Item 3) [Figure 20-40-4] that

routes from the control valve to the brake valve.

(CONT’D)
Figure 20-40-7
2
3
P106836
1 Remove the hose (Item 1) [Figure 20-40-9] that routes

from the control valve to the junction block at the rear of
P106834 the machine.
Remove the lift arm bypass drain hose (Item 2) [Figure

Remove the bolt (Item 1) [Figure 20-40-7] and tubeline 20-40-9] from the control valve.

clamp.
Remove the hose (Item 3) [Figure 20-40-9] that runs
Figure 20-40-8 from the control valve to the outlet fitting of the hydraulic
pump.
P-106835
Remove the three tubelines (Item 1) [Figure 20-40-8]

that route from the control valve to the junction block at
the rear of the loader.

HYDRAULIC CONTROL VALVE (STANDARD) Mount Bracket Removal And Installation
(CONT’D)
Figure 20-40-12
Figure 20-40-10
1 1
P-90280
P106837 Support the mounting bracket (Item 1) [Figure 20-40-12].
Figure 20-40-13
Remove the clips and pins (Item 1) [Figure 20-40-10]

from the linkage.
Figure 20-40-11
1
1
1
P110095
Remove the two control valve mount bolts (Item 1)

P-106838 [Figure 20-40-13].
Remove the control valve bracket from the loader.

Support the control valve and remove the two bolts (Item
1) [Figure 20-40-11].
Remove the control valve from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT’D)
Identification Chart
Figure 20-40-14
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2
D2
A1
H3 E1
B1
F3 MR

F1 H1 J1 J3
C1
NA5826
ITEM DESCRIPTION ITEM DESCRIPTION

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Female Coupler E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Male Coupler F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J3 Lift Arm Bypass Orifice
(276 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24131 kPa (241 bar)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa
(3500 psi)
(276 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)

(CONT’D)
Lift Load Check Valve Removal And Installation
IMPORTANT 1
damage the system.
I-2003-0888
P107873
Figure 20-40-15
Remove the lift load check valve (Item 1) [Figure 20-40-
16] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.

Figure 20-40-17
1
1
P107872
2
Remove the charge tubeline (Item 1) [Figure 20-40-15]
from the BICS™ valve fitting on the top of the lift load
check valve. 3
4
P107716

[Figure 20-40-17].
Inspect the spring (Item 3) and free movement in the load

check valve (Item 4) [Figure 20-40-17].
Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-40-17].

(CONT’D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
Figure 20-40-18 1
2
1 4
2
3
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-19].
P107874 Inspect the orifice (Item 3) [Figure 20-40-19] in the

poppet to make sure it is not plugged.

At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-40-
the tilt section load check valve (Item 1) [Figure 20-40- 19] and lubricate with oil before installing. Tighten the
18]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

the auxiliary section load check valve (Item 2) [Figure
20-40-18].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-22

Rod End)
Figure 20-40-20
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-40-22].

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-20]. Figure 20-40-23
Figure 20-40-21
1
2
2
1
4
P107952
3
P107624
port relief / anti-cavitation relief valve.
20-40-21]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-23] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-40-21] in the needed.
Installation: Tighten the port relief anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-40- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
21] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-26

Installation (Tilt, Base End)
Figure 20-40-24
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-26]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-40-24] from the base end of the tilt section. Figure 20-40-27
Figure 20-40-25
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief anti-cavitation relief

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-40-28
P107628
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-30].
P107628
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-28] Figure 20-40-31

from the auxiliary circuit of the control valve.
Figure 20-40-29
1
1
P107629
2
P107630 Remove the O-ring (Item 1) [Figure 20-40-31] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
[Figure 20-40-29] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-32
P107628

P107628

Figure 20-40-33
2
P107629


(CONT’D)
Plug Removal And Installation
Figure 20-40-36
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-38].
P107631
Figure 20-40-39
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-36].

Figure 20-40-37
1
P107633

plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

plug.

HYDRAULIC CONTROL VALVE (STANDARD) End Cap Block Removal And Installation
(CONT’D)
Figure 20-40-42
Rubber Boot Removal And Installation
Figure 20-40-40
1
2
1
1 P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-42] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-40-40] on

the rubber boot retainer plate. Figure 20-40-43
Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-41
1
2
1 P107666
Disconnect the tubeline (Item 1) [Figure 20-40-43] from

the end cap block.
P107664
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-41].

HYDRAULIC CONTROL VALVE (STANDARD) Lift Spool And Detent Removal And Installation
(CONT’D)
End Cap Block Removal And Installation (Cont’d) procedure:
Figure 20-40-44 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap block from the control valve. (See
End Cap Block Removal And Installation on Page 20-40-
14.)
Figure 20-40-45
2
1
P107773 1
Remove the end cap block mount screw (Item 1) [Figure

20-40-44].

11,6 N•m (95 - 105 in-lb) torque.
P107776
Remove the end cap block (Item 2) [Figure 20-40-44]

from the control valve. Remove the O-ring (Item 1) [Figure 20-40-45].
Installation: Replace the O-ring, and lubricate the O-ring

lightly with grease or oil before installation of the end cap
block.
Figure 20-40-46
P107775
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-46] from the lift spool.

(CONT’D)
Lift Spool And Detent Removal And Installation

(Cont’d)
Figure 20-40-47
P107846
NOTE: Do not remove the sleeve detent (Item 1) or

1 retaining ring (Item 2) [Figure 20-40-49] from
the spool centering block. If removed, the
P107779 sleeve detent must be inserted with the
original orientation.

Remove the four screws (Item 1) [Figure 20-40-47] from Figure 20-40-50
the spool centering block.
Figure 20-40-48
2
2
P107845A
1
P107778 NOTE: If removed, use the following for correct

installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-40-50]
Remove the spool centering block (Item 1) [Figure 20- so it faces the opening of the spool centering
40-48]. block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
Remove the O-ring (Item 2) [Figure 20-40-48]. [Figure 20-40-50] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

(CONT’D)

(Cont’d)
Figure 20-40-51
P107739
2
Clamp the linkage end of the spool in a vise [Figure 20-
40-53].
1
P107790 NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly (Item 1) and O-ring (Item
2) [Figure 20-40-51] from the control valve.
Figure 20-40-52
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-54
2
1
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-40-52]

from the linkage end of the valve.
P107674A
Install the spring tool (Item 1) [Figure 20-40-54] over the

centering spring.
NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-40-54] from the centering
spring, as it is under spring pressure.

(CONT’D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-55
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly

2 (Item 2) [Figure 20-40-57].
P107674 Figure 20-40-58

Remove the spring assembly / spring tool (Item 1) from
the spool (Item 2) [Figure 20-40-55]. 2
3 1
NOTE: The detent adapter has two detent balls (Item 4
3) held under pressure from a detent spring
(Item 4) [Figure 20-40-57]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-40-56
P107677
1 Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-58].
P107675
Remove the detent adapter (Item 1) [Figure 20-40-56]

from the spring assembly.

(CONT’D)

(Cont'd)
Figure 20-40-59
1
N-18967
Clamp the collar (Item 1) [Figure 20-40-61] in a vise.
Figure 20-40-62
N-18918

Remove the stud from the end of the spool [Figure 20-
40-59]. 3
Figure 20-40-60 2
P107677
Apply grease on all the detent component surfaces

15,2 mm before assembly [Figure 20-40-62].
(0.60 inch)
Install the spring (Item 1) and detent balls (Item 2) into
B-14712B the adapter (Item 3) [Figure 20-40-62] and compress
with the detent pliers (Item 1) [Figure 20-40-63].
Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-60].

(CONT’D)

(Cont'd)
Figure 20-40-63
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-40-65].
N-18968A Remove the spring tool.
Check the alignment of the detent adapter and the

Install the detent adapter to the collar [Figure 20-40-63]. washer.
NOTE: The collar and the detent adapter are held Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the NOTE: The adapter must fit in the center of the
detent adapter and collar together to prevent washer.
the detent balls and spring from falling out.
Figure 20-40-66
Figure 20-40-64
2
P107790
P107675
Lubricate and install a new O-ring (Item 1) [Figure 20-40-

Install the spring tool (Item 1) [Figure 20-40-64] over the 66].
washer, spring, collar, and detent adapter.
Lubricate and install a new O-ring (Item 2) [Figure 20-40-
66].
Install the lift spool assembly (Item 3) [Figure 20-40-66]

in the spool bore.

(CONT’D)

(Cont'd)
Figure 20-40-67
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

2 20-40-69] on the lift spool.
P107779 Figure 20-40-70

Install the spool centering block (Item 1) [Figure 20-40-
67].
Install the four mounting screws (Item 2) [Figure 20-40-

67].
1
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-68
P107776
1
Install an O-ring (Item 1) [Figure 20-40-70] on the control

valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-40-68] on the

linkage end of the valve.

(CONT’D)

(Cont'd)
Figure 20-40-71
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
P107664A The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap block (Item 1) and the mount bolt (Item 2) [Figure 20-40-73] lock solenoids and tighten to
(Item 2) [Figure 20-40-71]. 52 - 61 N•m (38 - 45 ft-lb) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-71].

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-72
P107666
Connect the tubeline (Item 1) [Figure 20-40-72].

(CONT’D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap block. (See End Cap
Block Removal And Installation on Page 20-40-14.) 2
Figure 20-40-74
1
P107778
Remove the spool centering block (Item 1) [Figure 20-

1 40-76] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

2
76] and lubricate the O-ring lightly with grease or oil
P107777 before installation of the spool centering block.

Figure 20-40-77
20-40-74] from the tilt spool.
Installation: Install the spacer (Item 1) and an O-ring

2
(Item 2) [Figure 20-40-74].
Figure 20-40-75
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure

20-40-77].
1
P107779 77] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Remove the four screws (Item 1) [Figure 20-40-75] from


11,6 N•m (95 - 105 in-lb) torque.

(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-78
1
P107647
Remove the bolt (Item 1) [Figure 20-40-80] holding the

centering spring to the spool.
P107781
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-40-78].

Remove the spring tool from the spring assembly.
Assembly: Always use a new spool seal.
Figure 20-40-81
Figure 20-40-79
2 1
3
1 4
N-18944B
P107646
Inspect the adapter (Item 1), collar (Item 2), spring (Item
Put the linkage end of the spool in the vise [Figure 20- 3), and washer (Item 4) [Figure 20-40-81].
40-79].
NOTE: Protect spool before clamping in vise.

centering spring.

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-40-82
1
3 2
4
1
2
4
P107783
Remove the spring (Item 1) and center spring retainer

3 (Item 2) [Figure 20-40-83] from the auxiliary spool.
P107782
20-40-83] from the auxiliary spool.
(Item 2) [Figure 20-40-82] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure
20-40-83] must be replaced, replace the
Remove the spacer (Item 3) and O-ring (Item 4) [Figure retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
NOTE: If the centering spring retainer (Item 2) [Figure [Figure 20-40-83].
retainer on the opposite end also. Figure 20-40-84
Installation: Lubricate and install an O-ring (Item 4)

[Figure 20-40-82].
P107784
Remove the auxiliary spool (Item 1) [Figure 20-40-84].

(CONT’D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-85 1
2
1
2
2
P107798
1
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-86] from the solenoid stem.
P107876
Use an ohmmeter to measure the solenoid coil
resistance.
Remove the screws (Item 1) [Figure 20-40-85] from both

solenoids. The correct resistance for the coil is 5.1 ohm.
Remove the solenoids (Item 2) [Figure 20-40-85] from Installation: Lubricate and install new O-rings (Item 1)
the control valves. and back-up rings (Item 2) [Figure 20-40-86].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9

in-lb) torque.

(CONT’D)
Solenoid Removal And Installation
Figure 20-40-87
1
1
2
P107876
Remove the solenoid stem (Item 1) [Figure 20-40-89].
P107875 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-87] from the Figure 20-40-90

solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-87]. 3

2
Figure 20-40-88
N-18694

[Figure 20-40-90] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-88] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-90] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-40-91
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure

20-40-93] is threaded for easier removal and installation.
P107785
Figure 20-40-94
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-40-

91]. 1 3
2
Figure 20-40-92
P107767
Remove the O-ring (Item 1) [Figure 20-40-94].
Remove and inspect the spring (Item 2) and BICS™

P107786 valve (Item 3) [Figure 20-40-94].
Remove the lift lock valve (Item 1) [Figure 20-40-92]

from the back of the control valve.
Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-95
2
1
P107937

P107788
Figure 20-40-98
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-95].

1 3
Remove the tilt spool lock solenoid (Item 2) [Figure 20-
2
40-95].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-96
P107767

valve (Item 3) [Figure 20-40-98].
1
P107789
Remove the tilt lock valve (Item 1) [Figure 20-40-96]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-40-101
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-99
P107787
1
P107693 Remove the main relief valve (Item 1) [Figure 20-40-

101].
Remove the fitting (Item 1) [Figure 20-40-99] from the Figure 20-40-102

valve.
Figure 20-40-100 1
1
2
P107745A
P-51437 Remove the O-ring (Item 1) and back-up rings (Item 2)

[Figure 20-40-102] from the main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
100].
NOTE: This orifice is not removable from the valve

casting.

HYDRAULIC CONTROL VALVE (STANDARD) Later Models
(CONT’D)
Figure 20-40-105
Check Valve Removal And Installation
Figure 20-40-103
1
1
2
P107625
P107693 Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-40-105].
Remove the tubeline (Item 1) [Figure 20-40-103]. Remove the O-ring (Item 1) [Figure 20-40-105].

Figure 20-40-104 Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-
lb) torque.
P107786
Remove the check valve fitting (Item 1) [Figure 20-40-

104] from the hydraulic control valve.


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P107847
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operator’s cab. D-1009-0409

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions. WARNING
The lift and tilt functions in the hydraulic control valve are
operated using electronic control handles / levers that Never work on a machine with the lift arms up unless
send an electronic signal to the electronic actuators to the lift arms are secured by an approved lift arm
move the lift and tilt spools in the control valve. support device. Failure to use an approved lift arm
The auxiliary function is operated by pilot pressure. to fall and cause injury or death.
There is one solenoid located by each side of the spool. W-2059-0598
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure fluid to one side of the
spool and forces the spool to shift.
The hydraulic control valve also contains a main relief

IMPORTANT
valve which is adjustable.
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)

support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.) 1
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.) OR (See
121-2.)
P106822
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
The fixed end main valve hose assembly is connected to
Clean area around control valve. a fixed end fitting on the control valve. The hose is routed
to the junction block at the rear of the loader where it
Open rear door. feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
Figure 20-41-2 1) [Figure 20-41-3].

3 Figure 20-41-4
1
1
2
1
2
P106714
P-90269
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-41-2] off to the side. Disconnect the wire harness connectors (Item 1) [Figure
20-41-4] from the control valve.
Cover the fuel tank inlet.
Disconnect the hose (Item 2) [Figure 20-41-4] that
routes from the control valve to the drain manifold.

routes from the control valve to the inlet fitting of the
hydraulic pump.

(CONT’D)
Figure 20-41-5
2 2
1
2
1 P-90272
Remove the tubeline clamp (Item 1) [Figure 20-41-7].
P107219 Disconnect the two tubelines (Item 2) [Figure 20-41-7]

that route from the control valve to the front auxiliary
hydraulics.

routes from the control valve to the brake valve. Figure 20-41-8

routes from the control valve to the fan motor.
Figure 20-41-6
1
1
P-90273
Remove the tubeline clamp (Item 1) [Figure 20-41-8].
P-90271

routes from the top of the control valve to the hydraulic
filter.

(CONT’D)
Figure 20-41-9
1 1
1
P-90276
1 Disconnect the hose (Item 1) [Figure 20-41-11] that

routes from the bottom of the control valve to the outlet
P-90274 fitting of the hydraulic pump.
Figure 20-41-12
Disconnect the three tubelines (Item 1) [Figure 20-41-9]

that route from the control valve to the junction block at
the rear of the loader.
Figure 20-41-10
1
1
2
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-12].
P-90275

routes from the control valve to the junction block at the
rear of the machine.
Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-41-10] from the control valve.

(CONT’D)
Actuator Removal And Installation (In Loader)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-2.) Remove the two bolts (Item 1) [Figure 20-41-14] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.

Figure 20-41-15
Figure 20-41-13
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-41-15] away from

Disconnect the actuator wire harness (Item 1) [Figure the control valve.
20-41-13].
Use a punch to remove the actuator pin (Item 2) [Figure
20-41-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-150-4.)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-41-16
1
2
P-54568

Inspect the O-ring (Item 1) [Figure 20-41-16] on the face
of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-16] and

replace as needed.

(CONT’D)
Actuator Removal And Installation (Out Of Loader)
Figure 20-41-17
1
1
P101625
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-19] from the actuator
and the spool.
P101623 Remove the actuator and linkage pin from the valve.

Figure 20-41-20
Remove the two mount bolts (Item 1) [Figure 20-41-17]
from the actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-18
P-54340

1 of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-20] and

P101624 replace as needed.
Slide the actuator retainer (Item 1) [Figure 20-41-18]

away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-18].

(CONT’D)

(Cont’d)
Figure 20-41-21
1
1
P-54343
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-23] from the actuator
and the spool.
P101626
Remove the actuator and linkage pin from the valve.

Remove the two mount bolts (Item 1) [Figure 20-41-21] Figure 20-41-24
from the actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-22
P-54340
1
of the actuator, and replace as needed.
P101627 Inspect the linkage pin (Item 2) [Figure 20-41-24] and

replace as needed.
Slide the actuator retainer (Item 1) [Figure 20-41-22]

away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-22].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)

(Cont’d)
Figure 20-41-25
1
3 P101629

NOTE: The two long bolts (Item 1) are used to install
the lift actuator and retainer (Item 2). The two
short bolts (Item 3) are used to install the tilt
actuator and the retainer (Item 4) [Figure 20-
41-25].
Installation: Tighten the bolts (Item 1 & 3) [Figure 20-

41-25] to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (CONT’D)
Identification Chart
Figure 20-41-26
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1
F1 MR C1

H1
J3
J1
NA5825
ITEM DESCRIPTION ITEM DESCRIPTION

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulic Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(2756 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – 24132 kPa (241 bar)
(276 bar) (4000 psi) (3500 psi)
Tilt (Rod End)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-27 IMPORTANT

damage the system.
I-2003-0888
1 Figure 20-41-29
P-90280
Support the mounting bracket (Item 1) [Figure 20-41-27].

Figure 20-41-28 1
1
P107848
Remove the charge tubeline (Item 1) [Figure 20-41-29]

from the BICS™ valve fitting on the top of the lift load
check valve.
P110095
Remove the two control valve mount bolts (Item 1)

[Figure 20-41-28].
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-32

(Cont’d)
Figure 20-41-30
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
32].

Remove the lift load check valve (Item 1) [Figure 20-41-
30] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-41-32].
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are
Figure 20-41-31 interchangeable.
Figure 20-41-33
1
5
1
2
2
3 4 4
P107716
3
P107624
[Figure 20-41-31].
Inspect the spring (Item 3) and the free movement in the 20-41-33].
load check valve (Item 4) [Figure 20-41-31].
Inspect the orifice (Item 3) [Figure 20-41-33] in the
Inspect the orifice (Item 5) [Figure 20-41-31] to make poppet to make sure it is not plugged.
sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-41-
33] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-36

Rod End)
Figure 20-41-34
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-36].

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-34]. Figure 20-41-37
Figure 20-41-35
1
2
2
4 1
P107952
3
P107624
20-41-35]. Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-41-35] in the needed.
Installation: Tighten the port relief / anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
35] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-40

Installation (Tilt, Base End)
Figure 20-41-38
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-40]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-41-38] from the base end of the tilt section. Figure 20-41-41
Figure 20-41-39
1
1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief / anti-cavitation relief

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-41-42
P107628

P107628

Figure 20-41-43
1
1
2
P107629


(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-46
P107628

P107628

Figure 20-41-47
1
1
2
P107629


(CONT’D)
Plug Removal And Installation
Figure 20-41-50
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-52].
P107631
Figure 20-41-53
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-50].

Figure 20-41-51
1
P107633

plug.
P107633

plug.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
(CONT’D)
The tool listed will be needed to do the following
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-5.) Remove the end cap block from the control valve [Figure
20-41-54].
Figure 20-41-54
Figure 20-41-56

2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-54] from

the end cap block. Remove the O-ring (Item 1) [Figure 20-41-56].
Remove the two end cap block mount screws (Item 2) Installation: Replace the O-ring, and lubricate lightly
[Figure 20-41-54]. with oil before installation of the end cap block.
Installation: Lubricate the screws and tighten to 10,4 - Figure 20-41-57

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-55
1
P107753
1
P107852 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-41-57] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-55]

from the control valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-58
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-60] from the control valve.
P107854
Figure 20-41-61
Remove the four screws (Item 1) [Figure 20-41-58] from


11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-59
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-41-61]

from the actuator end of the valve.
P107855
Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-41-59] from the control valve.

59] and lubricate lightly with oil before installation of the
spool centering block.

(CONT’D)
Lift Spool Disassembly And Assembly
Figure 20-41-62
1
P107647

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-

41-62]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-65
Figure 20-41-63
3
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-41-65].
centering spring.

(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Figure 20-41-66 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-68].
2 Figure 20-41-69
P107856

20-41-66] from the tilt spool.
Figure 20-41-67
P107770
Remove the spool seal (Item 1) [Figure 20-41-69].
P107769
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the spool centering block.

(CONT’D)
Tilt Spool Disassembly And Assembly

2 1
Figure 20-41-70
3
N-18944B
3), and washer (Item 4) [Figure 20-41-72].
P107646
Put the actuator end of the spool in the vise [Figure 20-

41-70].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-41-71
P107647


in-lb) torque.
Remove the spring tool from the spring assembly.

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-73
2
1
2 P107760

1 (Item 2) [Figure 20-41-75] from the auxiliary spool.
P107758
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.
(Item 2) [Figure 20-41-73] from the auxiliary spool.

Figure 20-41-76
retainer on the opposite end also.
Figure 20-41-74
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
(CONT’D)
Figure 20-41-78
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-77
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-41-78] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-41-77]. Remove the solenoids (Item 2) [Figure 20-41-78].

Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -
23.9 in-lb) torque.
Figure 20-41-79
P107798

[Figure 20-41-79] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-41-79].

(CONT’D)
Figure 20-41-80 1
P107857
Remove the solenoid stem (Item 1) [Figure 20-41-82].
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-80] from the Figure 20-41-83

solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-80]. 3

2
Figure 20-41-81
N-18694

[Figure 20-41-83] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-81] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-83] may be
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-84
1 2 P107937

P107858
Figure 20-41-87
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-

84]. 1 3
Figure 20-41-85 2
1
P107767

P107859 valve (Item 3) [Figure 20-41-87].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-41-85] from the back of the control valve.


(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-88
1 P107937

P107860
Figure 20-41-90
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-41-88] from the front of the control valve.
1 3
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque. 2
P107767

valve (Item 3) [Figure 20-41-90].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-93
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-91
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-41-93].
Figure 20-41-94
Remove the fitting (Item 1) [Figure 20-41-91] from the

valve.
1
Figure 20-41-92
1 2
P107745A
Remove the O-ring (Item 1) and back-up rings (Item 2)

P-51437 [Figure 20-41-94] from the main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-41-
92].
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-41-95
1 P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-97].
P107848
Remove the tubeline (Item 1) [Figure 20-41-95]. Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.
Figure 20-41-96
P107864
Remove the check valve fitting (Item 1) [Figure 20-41-

96] from the hydraulic control valve.


LIFT ARM BYPASS CONTROL VALVE Testing
Description Figure 20-50-1
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by 1

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90° clockwise. Then pull up and hold the lift arm
bypass control knob until the lift arms slowly lower. The
valve releases the hydraulic fluid from the base end of the
lift cylinder(s) which allows the lift arm to slowly come
down to the transport position.
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly

lower.
The knob must return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the knob (Item 1). Remove the nut (Item 2)
unless supported by an approved lift arm [Figure 20-50-2] from the valve shaft.

D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING 3

W-2059-0598
2
Lower the lift arms.

1
P-85671
IMPORTANT Disconnect the hydraulic tubeline (Item 1) and hose (Item

2) [Figure 20-50-3].
When repairing hydrostatic and hydraulic systems, Remove the two bolts and nuts (Item 3) [Figure 20-50-3].
parts clean. Always use caps and plugs on hoses, Installation: Tighten the bolts to 21 - 23 N•m (180 - 200
tubelines and ports to keep dirt out. Dirt can quickly in-lb) torque.
damage the system.
I-2003-0888 Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] and damage and replace if necessary.
remove the bypass valve bracket.

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
lb) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on

the valve block for damage and replace if necessary.


HYDRAULIC PUMP
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (CONT'D) Figure 20-60-1
Pump Test At Quick Couplers

2
IMPORTANT
I-2024-0284
WARNING P106632
W-2006-1209

loader.
WARNING
W-2017-0286

procedure:
MEL10003 or MEL1744 - Hydraulic Tester


1.)

hoses must be at least 19 mm (0.75 in)
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

Pump Test At Quick Couplers (Cont’d)
Figure 20-60-2
1
2 1
P-16903 P106632
Warm the fluid to 60°C (140°F) by turning the restrictor

NA3267 control (Item 1) [Figure 20-60-4] clockwise on the tester
so it reads 6895 kPa (69 bar) (1000 psi).
Start the engine and run at low idle. Press the Auxiliary
hydraulics button (Item 1) once to activate the auxiliary NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
hydraulics. The light (Item 2) [Figure 20-60-2] will be on. psi).

Figure 20-60-3 Turn the restrictor control (Item 1) [Figure 20-60-4]
Check the free flow specification. (See Hydraulic System

on Page SPEC-10-4.)
NOTE: If free flow is below specification perform the

direct pump test.

1 restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
1
P106677
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-60-3]
20-60-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
female coupler (female coupler is pressurized).
main relief valve needs to be adjusted. (See Adjusting on
front auxiliary hydraulic switch (Item 1) [Figure 20-60-3]
Page 20-30-4.)
a second time.
If flow does not match specifications go to the Direct
NOTE: When the operator is seated and raises the
Pump Testing. (See Direct Pump Test (Standard Section)
seat bar, the Auxiliary Hydraulic System
on Page 20-60-4.)
(Front and Rear) will deactivate.
If no flow is indicated on the tester, the hoses are

connected wrong. With the hoses connected correctly,
increase the engine speed to full rpm.

Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool

MEL10006 - Fitting Kit
WARNING
P106709
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-6
1.)

support device. (See Installing on Page 10-20-2.)
WARNING 2 1

P106631
W-2059-0598
Raise the operator cab. Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-5]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-60-6] from the tester to the control valve fitting on the
REMOTE START TOOL (SERVICE TOOL) KIT - control valve.
7217666 on Page 10-61-1.)

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
IMPORTANT
position before you start the engine.
I-2024-0284
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6895 kPa (69 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.

On the Remote Start Tool engage the auxiliary
hydraulics, the light will come ON. Pull the trigger on the
right joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (U.S. gpm). The high pressure
flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
FREE FLOW (U.S. gpm)
A low percentage may indicate a failed pump.
*For system relief pressure and full rpm. (See Hydraulic

System on Page SPEC-10-4.)

Direct Pump Test (Charge Section) EARLIER MODELS
The tools listed will be needed to do the following 1

procedure:

WARNING P106710
LATER MODELS
1
W-2017-0286

1.)

P116327
WARNING Disconnect the inlet line (Item 1) [Figure 20-60-7].
Figure 20-60-8
W-2059-0598
2 1
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

P106631
Connect the Remote Start Tool. (See REMOTE START Connect the INLET hose (Item 1) [Figure 20-60-8] from
TOOL KIT - MEL1563 on Page 10-60-1.) or (See the tester to the OUTLET hose (Item 1) [Figure 20-60-7]
REMOTE START TOOL (SERVICE TOOL) KIT - of the pump. Connect the OUTLET hose (Item 2) [Figure
7217666 on Page 10-61-1.) 20-60-8] from the tester to the inlet fitting on the fan.

Direct Pump Test (Charge Section) (Cont’d)
IMPORTANT
I-2024-0284
rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.

Turn the restrictor down to system operating pressure
approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=


HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Fluid on Page 10-130-1.)
Figure 20-60-9
WARNING
support device can allow the lift arms or attachment 1
W-2059-0598
1
1
1
DANGER
P-90180
Disconnect the four hoses (Item 1) [Figure 20-60-9] from

the hydraulic pump.

Remove the Power Bob-Tach block (if equipped). (See
P-90328
Figure 20-60-10
AVOID DEATH
D-1009-0409
IMPORTANT
When repairing hydrostatic and hydraulic systems, P-90509
Disconnect the outlet hoses (Item 1) [Figure 20-60-10]
from the hydraulic pump.
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


Figure 20-60-11
1
2
P-43940
1
Remove and replace the O-ring (Item 1) [Figure 20-60-

P106593 13] from the hydraulic pump.
Reverse the removal procedure to install the hydraulic

Remove the bracket mounting bolt / nut (Item 1) [Figure pump.
20-60-11].

Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28
ft-lb) torque.
Figure 20-60-12
P106594
Remove the two mounting bolts (Item 2) [Figure 20-60-

11] and [Figure 20-60-12].

lb) torque.
Remove the hydraulic pump.

HYDRAULIC PUMP (CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Fluid on Page 10-130-1.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-14 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
1 of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.

P100685
Figure 20-60-15
P106712
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-14] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-15].

Figure 20-60-16
1. Bolt 13.Auxiliary Pump Center Section

2. Charge Pump End Section 14. Auxiliary Pump End Section
3. Section Seal 15. Shaft Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
7
8
9

3
10
3 2
4
6 5
8
4
11
7
8
3 12
4
6 13
4 8
10
11
15 3
14
P-66540

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-60-11.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 1)

[Figure 20-60-16] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plates (Item 4) [Figure 20-

60-16] as shown with the bronze side toward
the gears.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.

HYDRAULIC PUMP (HIGH FLOW)
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
The high flow hydraulic pump has an additional pump

section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched
from a button on the panel in the cab.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Figure 20-61-1
Pump Test At Quick Couplers
IMPORTANT
I-2024-0284
WARNING P106632
W-2006-1209

loader.
WARNING
W-2017-0286

procedure:


1.)

hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) If no flow is indicated on the tester, the hoses are
connected wrong. With the hoses connected correctly,
Pump Test At Quick Couplers (Cont’d) increase the engine speed to full rpm.
2 1
NA3267 P106632
P-16903
Start the engine and run at low idle. Press the Auxiliary Warm the fluid to 60°C (140°F) by turning the restrictor
hydraulics button (Item 1) once to activate the auxiliary control (Item 1) [Figure 20-61-4] clockwise on the tester

hydraulics. The light (Item 2) [Figure 20-61-2] will be on. so it reads 6895 kPa (69 bar) (1000 psi).
Figure 20-61-3 NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
Turn the restrictor control (Item 1) [Figure 20-61-4]

Check the free flow specification. (See Hydraulic System

on Page SPEC-10-4.)
NOTE: If free flow is below specification perform the

1 direct pump test.

restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
1 kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
P106677 (213,7 bar) (3100 psi) the flow should start decreasing
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-61-3]
female coupler (female coupler is pressurized).
20-61-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
front auxiliary hydraulic switch (Item 1) [Figure 20-61-3]
a second time.
main relief valve needs to be adjusted. (See Adjusting on
Page 20-30-4.)
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System If flow does not match specifications go to the Direct
(Front and Rear) will deactivate. Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-61-4.)

Direct Pump Test (Standard Section)

procedure:

1
WARNING
P106709
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-6
1.)

WARNING 2 1

P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-6] from
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-61-6] from the tester to the fitting on the control valve.
7217666 on Page 10-61-1.).
NOTE: The control panel is shown removed for photo

clarity. IMPORTANT
I-2024-0284

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses MEL10003 or MEL1744 - Hydraulic Tester
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

control on the tester to 6895 kPa (69 bar) (1000 psi). DO
NOT exceed system relief pressure. Open the restrictor
WARNING
control and record the free flow (U.S. gpm) at full rpm*.
On the Remote Start Tool engage the auxiliary of the frame before running the engine for service.
hydraulics, the light will come ON. Pull the trigger on the Failure to use jackstands can allow the machine to
right joystick for fluid flow to the quick coupler (fluid fall or move and cause injury or death.
pressure will go over main relief). Record the highest W-2017-0286
pressure (psi) and flow (U.S. gpm). The high pressure
flow must be at least 80% of free flow. Lift and block the loader. (See Procedure on Page 10-10-
1.)
%=
FREE FLOW (U.S. gpm) Raise the lift arms and install an approved lift arm


WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.
Connect the Remote Start Tool. (See REMOTE START

TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT’D)
Direct Pump Test (Charge Section) (Cont’d)

IMPORTANT
Figure 20-61-7
EARLIER MODELS position before you start the engine.
I-2024-0284
1
rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
P106710 psi).
LATER MODELS NOTE: DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
1
gpm) at full rpm*.

Turn the restrictor down to system operating pressure
approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
P116327

Disconnect the inlet line (Item 1) [Figure 20-61-7].
*For pump flow and rpm. (See Hydraulic System on Page
Figure 20-61-8 SPEC-10-4.)
2 1
P106631
Connect the INLET hose (Item 1) [Figure 20-61-8] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-8] from the tester to the inlet fitting on the fan.

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-9] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

7217666 on Page 10-61-1.).

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 6895 kPa (69 bar) (1000
Direct Pump Test (High Flow Section) (Cont'd) psi).
Figure 20-61-10 NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
2 gpm) at full rpm. Increase the restriction and the flow
should drop to 0 L/min (0 U.S. gpm) between 24132 kPa
(241 bar) (3500 psi) and 25510 kPa (255 bar) (3700 psi).
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-11.)
1
Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.
P101694 HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
Disconnect the high flow pump OUTLET hose (Item 1) A low percentage may indicate a failed pump.
from the high flow check valve INLET fitting (Item 2)

[Figure 20-61-10]. *For system relief pressure and full rpm. (See Hydraulic
Figure 20-61-11
2 1
P106631
Connect the INLET hose (Item 1) [Figure 20-61-11] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-10]. Connect the OUTLET hose (Item 2)
[Figure 20-61-11] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-10].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
[Figure 20-61-15] will need to be turned clockwise 1/4
turn and retested with the procedure above. (1/4 turn
equals approximately 1379 kPa (13,8 bar) (200 psi).) 1
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-11.) If relief
valve has been tested and is OK, go to the P110094
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-17.) Figure 20-61-14
Remove right rear wheel. (See Wheel Nuts on Page 10-

160-1.)
Figure 20-61-12 1

1
2
1
P110096
1
Locate the high flow relief valve (Item 1) [Figure 20-61-
13] and [Figure 20-61-14] along the right side of the
P110093
engine.
Remove the plug (Item 2) [Figure 20-61-14] located on

Remove the bolts (Item 1) [Figure 20-61-12] from the the bottom of the high flow relief valve.
cover and remove the cover from the loader.

High Flow Relief Valve Adjustment (Cont’d)
Figure 20-61-15
P101697
If the pump reaches 25511 kPa (255,1 bar) (3700 psi)

and there is flow stop the engine. The relief screw (Item

1) [Figure 20-61-15] must be turned 1/4 turn and
retested with the procedure above.
NOTE: The relief valve is shown removed from the

loader for photo clarity.

High Flow Relief Valve Removal And Installation

1
WARNING 4

of the frame before running the engine for service. 2
Failure to use jackstands can allow the machine to 3
W-2017-0286
Figure 20-61-16 P101698
1
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-18].
1
If the relief valve is bad, it must be replaced as a
complete unit.

Remove the plug (Item 3) and O-ring (Item 4) [Figure 20-
61-18].
P110093
Remove the bolts (Item 1) [Figure 20-61-16] from the

access cover and remove the cover from the loader.
Figure 20-61-17
P110096
Remove the relief valve (Item 1) [Figure 20-61-17] from

the pump.
Installation: Tighten the relief valve to 41 - 47 N•m (30 -

35 ft-lb) torque.

Solenoid Removal And Installation 1
Figure 20-61-19
P-45461
Remove the solenoid valve (Item 1) [Figure 20-61-21].

P-43958
Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Disconnect the electrical connector (Item 1) [Figure 20-
61-19] from the high flow pump solenoid. Figure 20-61-22

Figure 20-61-20
2
1
2
P-45462
P-45460
[Figure 20-61-22].
Remove the solenoid nut (Item 1) [Figure 20-61-20].
Remove the solenoid (Item 2) [Figure 20-61-20].
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -

72 in-lb)

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Drain the hydraulic fluid from the reservoir. (See
Removal And Installation 120-2.) OR (See Removing And Replacing Hydraulic
Fluid on Page 10-121-2.).
Remove the Power Bob-Tach block (if equipped). (See

WARNING Removal And Installation on Page 20-130-2.)

Figure 20-61-23
to fall and cause injury or death. 1
W-2059-0598
1
DANGER

1
P-90184
P-90328 Disconnect the inlet hoses (Item 1) [Figure 20-61-23]

from the front of the hydraulic pump.
AVOID DEATH
Figure 20-61-24
D-1009-0409
IMPORTANT 1

parts clean. Always use caps and plugs on hoses, P-90185
damage the system.
I-2003-0888 Disconnect the hoses (Item 1) [Figure 20-61-24] from
the back of the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)


Figure 20-61-25
1
P106594

P-90509A 26] and [Figure 20-61-27].

Disconnect the outlet hoses (Item 1) [Figure 20-61-25] lb) torque.
from the hydraulic pump.

Remove the hydraulic pump.
Figure 20-61-26
Figure 20-61-28
P106593
P-43940
Remove the bracket mounting bolt / nut (Item 1) [Figure

20-61-26]. Remove the O-ring (Item 1) [Figure 20-61-28].
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28 Reverse the removal procedure to install the hydraulic
ft-lb) torque. pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) OR (See After operating the engine at low idle, remove the lift arm
Removing And Replacing Hydraulic Fluid on Page 10- support device and fully raise and lower the loader lift
121-2.). arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
Figure 20-61-29 of cylinder stroke.


P-100685
Figure 20-61-30
P106712
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-61-29] to the starter terminal S (Item 1) and

Figure 20-61-31
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal
13
17. Center Housing

4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-16.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 7)

[Figure 20-61-31] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plate (Item 4) [Figure 20-61-

31] inlet as shown with the bronze side toward
the gears on all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.


HYDRAULIC / HYDROSTATIC FILTERS
Description
The hydraulic / hydrostatic filters help to remove

IMPORTANT
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating. When repairing hydrostatic and hydraulic systems,
The hydraulic / hydrostatic filter system consists of one parts clean. Always use caps and plugs on hoses,
main filter and one charge flow filter. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The main filter removes contaminants before entering
gear pumps including fluid returning from the main valve.
The charge flow filter removes contaminants after the support device. (See Installing on Page 10-20-2.)
charge pump.
Housing Removal And Installation
Drain the fluid from the reservoir. (See Removing And
DANGER 121-2.).
Figure 20-70-1

P-90328 2
AVOID DEATH
can cause lift arms to drop. 2
P-90010
D-1009-0409
from the hydraulic / hydrostatic filter sender.
Disconnect the three hoses (Item 2) [Figure 20-70-1]

WARNING from the hydraulic / hydrostatic filter housing.

W-2059-0598

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
P106711
Remove the two hoses (Item 1) [Figure 20-70-2] from

the bottom of the hydraulic / hydrostatic filter housing.

Figure 20-70-3
P106683
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
1
The hydraulic fluid reservoir is located behind the
operator’s cab under the rear grille on the right side of the
loader.

P110098
Remove the clamps and the hoses (Item 1) [Figure 20-
Drain the fluid from the reservoir. (See Removing And 80-2].
Removing And Replacing Hydraulic Fluid on Page 10- Figure 20-80-3
121-2.)

Remove the Hydraulic / Hydrostatic Filter Housing. (See
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-1
1
1
2
P110099
Remove the hydraulic fluid reservoir from the loader.

1
Installation: Tighten the bolts and nuts to 21,7 - 24,4
1 N•m (16 - 18 ft-lb) torque.
P110097
Remove the bolts (Item 1) and grille (Item 2) [Figure 20-

80-1].

HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-4
P-90506

Remove the hydraulic fluid reservoir breather cap from
the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-4] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER (EARLIER MODELS) Figure 20-90-2
Description
The oil cooler is used to cool the loaders hydraulic fluid.

Oil passages are coiled into a heat exchanger. Air is
forced, with the cooling fan, around the passages cooling
the fluid.
The oil cooler is located underneath the rear grille

between the A/C condenser and the radiator.
Removal And Installation 1
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.) P106796
Remove the pin (Item 1) [Figure 20-90-2] from the

IMPORTANT support bar.
Figure 20-90-3

tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system. 2
I-2003-0888
Remove the rear grille from the loader. (See Removing

on Page 50-60-1.)
Remove the condenser. (See Removal And Installation 1

on Page 80-60-1.)
Figure 20-90-1
P106797
Remove the hose (Item 1) and pins (Item 2) [Figure 20-

90-3]
1 Lift up the oil cooler and remove the cooler from the
2
loader.
P106795
Remove the hose (Item 1) [Figure 20-90-1].
Unhook the rubber straps (Item 2) [Figure 20-90-1].


OIL COOLER (LATER MODEL)
The oil cooler and radiator are removed from the loader
as a unit. (See Radiator / Oil Cooler Removal And


BUCKET POSITION VALVE Figure 20-100-1
Description
The Bucket Position Valve is an option that allows the 3

operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower 1

right rear side of the loader frame.
See the Hydraulic Schematic for more circuit information.

2 P106714
DANGER Remove the two bolts (Item 1), move the hose clamp
inlet assembly (Item 3) [Figure 20-100-1] off to the side.
Figure 20-100-2

3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 2
D-1009-0409
1 P-90197

IMPORTANT from the bucket position shut-off solenoid.
Disconnect the two tubelines (Item 2) [Figure 20-100-2].

clean the work area before disassembly and keep all Remove the solenoid nut, coil, and stem (Item 3) from the
parts clean. Always use caps and plugs on hoses, bucket positioning valve [Figure 20-100-2].
damage the system. Installation: Tighten the solenoid stem to 40,7 - 50,2
I-2003-0888 N•m (30 - 40 ft-lb) torque. Tighten the solenoid nut to 8
N•m (6 ft-lb) torque. Overtightening may cause valve
Drain the hydraulic reservoir. (See Removing And failure.
NOTE: The engine is shown removed for photo
clarity.
121-2.).

BUCKET POSITION VALVE (CONT’D) Solenoid Testing
Description (Cont'd) Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
Figure 20-100-3 information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
1
2
N-18191
Remove the O-rings (Item 1) and the back-up ring (Item

2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT’D) Figure 20-100-5
DANGER
1 P-90197
P-90328
AVOID DEATH Disconnect the wire harness (Item 1) [Figure 20-100-5].

tubeline, hose, fitting, component or a part failure NOTE: The engine is shown removed for photo
can cause lift arms to drop. clarity.
unless supported by an approved lift arm Figure 20-100-6

D-1009-0409

Replacing Hydraulic Fluid on Page 10-120-2.) OR (See 1
121-2.).
Figure 20-100-4
3 3
4
P-90188
1 Disconnect the tilt base inlet hose (Item 1), the tilt rod
inlet hose (Item 2), the lift rod inlet hose (Item 3), and the
lift base inlet hose (Item 4) [Figure 20-100-6].
2 P106714
Remove the two bolts (Item 1), move the hose clamp
inlet assembly (Item 3) [Figure 20-100-4] off to the side.

Figure 20-100-7
2 P-90190A
1
Remove the bolts (Item 1) [Figure 20-100-9].

P-90189A
Remove the bucket position valve from the loader.
Disconnect the tilt cylinder rod end hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]

from the valve block.
Figure 20-100-8
2
2
1
P-90197A
Disconnect the lift base outlet hose and tubeline (Item 1)

and the lift rod outlet hose and tubeline (Item 2) [Figure
20-100-8] that route from the lift cylinders.

Figure 20-100-10
3
1
2
1 3
2 4
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2) and plug (Item 3) [Figure 20-100-12].

Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-10]. Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

ft-lb) torque.
Assembly: Tighten the nut to of 8 N•m (6 ft-lb) torque.
Overtightening may cause valve failure. Tighten the Figure 20-100-13
solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb) torque.
Figure 20-100-11
1
2 3
2 P-90193
P-90195 Remove the plug (Item 1), spring (Item 2) and unloading
spool (Item 3) [Figure 20-100-13].
Remove the flow adjustment valve (Item 1). Remove the Remove the O-ring (Item 4) [Figure 20-100-13].
O-ring (Item 2) [Figure 20-100-11].
Assembly: Tighten the flow adjustment valve to 36,6 - Inspect all parts for wear and damage. Replace all worn
48,8 N•m (27 - 36 ft-lb) torque. and damaged parts.


REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts fluid from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located on each side of the rear

frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.
Figure 20-110-3

P9137

resistance is 8.6 - 9.5 ohm.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
resistance for the solenoid coil with a molded connector
is 8.1 - 9.9 ohm.

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-4
DANGER
P-90583
P-90328
AVOID DEATH Disconnect the tubelines (Item 1) [Figure 20-110-4].

tubeline, hose, fitting, component or a part failure Figure 20-110-5

D-1009-0409
1 1
IMPORTANT
parts clean. Always use caps and plugs on hoses, P-93303
damage the system.
I-2003-0888 Disconnect the tubelines (Item 1) [Figure 20-110-5].

1.)


121-2.).

REAR AUXILIARY DIVERTER VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-6 assembly.
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent and dry with compressed air. Install
1 new O-rings and back-up rings.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent and dry with compressed air.
Figure 20-110-8
P100810
Disconnect the accessory wiring harness (Item 1)

[Figure 20-110-6] from the main harness.

Figure 20-110-7
1
1
2
P-48751
1 Remove the plugs (Item 1) [Figure 20-110-8].
Figure 20-110-9
P-90581
1
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7].
P-48752

plug.

Disassembly And Assembly (Cont'd)
Figure 20-110-10
P-48755
Remove the differential sensing valve (Item 1) [Figure

P-48755 20-110-12].
Installation: Tighten the sensing valve to 68 - 75 N•m

Remove the shuttle valve (Item 1) [Figure 20-110-10]. (50 - 55 ft-lb) torque.

Installation: Tighten the shuttle valve to 14 - 16 N•m (10 Figure 20-110-13
- 12 ft-lb) torque.
Figure 20-110-11
1
2
1 1 1
1 1
2 2 P-48757
P-48756 Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-110-13].

[Figure 20-110-11].

Figure 20-110-14
P-48759
1
Remove the nut (Item 1) [Figure 20-110-16] from the

P-48753 solenoid valve stem.
Installation: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

Remove the relief valve (Item 1) [Figure 20-110-14]. torque.

Installation: Tighten the relief valve to 27 - 34 N•m (20 - NOTE: Before removing the solenoid coils mark the
25 ft-lb) torque. coils for proper alignment.
Figure 20-110-15 Figure 20-110-17
P-48754 1
P-48760
Remove the O-rings (Item 1) and back-up ring (Item 2) Remove the spacer (Item 1) and solenoid valve coils
[Figure 20-110-15] for damage. (Item 2) [Figure 20-110-17].

Figure 20-110-18
1
1
P-48763
2
Remove the O-rings (Item 1) [Figure 20-110-20] and
P-48761 back-up rings.
Figure 20-110-21
Remove the nuts (Item 1) [Figure 20-110-18] from the
solenoid valve stems.

torque.
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the coils (Item 2) [Figure 20-110-18].
Figure 20-110-19
P-48763A
Remove the solenoid valve stem (Item 1) [Figure 20-

110-21].
1
Installation: Tighten the solenoid valve stem to 41 - 47
P-48762
Remove the solenoid valve stem (Item 1) [Figure 20-

110-19].
Installation: Tighten the solenoid valve stem to 27 - 34


Figure 20-110-22
1
1
P-48766
Remove and inspect the orifice (Item 1) [Figure 20-110-

P-48764 24] for dirt and debris.
Installation: Tighten the orifice to 29,8 N•m (22 ft-lb)

Remove the O-rings (Item 1) [Figure 20-110-22] and torque.
back-up rings.

Figure 20-110-25
Figure 20-110-23
1 1
P-48765
P-48765
Remove the plug (Item 1) [Figure 20-110-25].

Installation: Tighten the plug to 13,6 N•m (10 ft-lb)
Installation: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
torque.

REAR AUXILIARY DIVERTER VALVE (CONT’D)
Figure 20-110-26
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].

Installation: Tighten the orifice to 4,5 N•m (3.3 ft-lb)
torque.
Figure 20-110-27
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].
Installation: Tighten the plugs to 19 N•m (14 ft-lb)

torque.

BOB-TACH (POWER) BLOCK (S/N A3NL11001 - Removal And Installation
A3NL12242)
Description
The Power Bob-Tach is an option that allows the operator

WARNING
to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments. Never work on a machine with the lift arms up unless
The Power Bob-Tach is operated by a switch on the right support device. Failure to use an approved lift arm
switch panel. support device can allow the lift arms or attachment
The Power Bob-Tach block is mounted on the right side W-2059-0598
of the machine in front of the engine on the back side of
the hydraulic pump.
DANGER

P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (S/N A3NL11001 - Figure 20-120-2
A3NL12242) (CONT'D)
1
2 4
IMPORTANT
clean the work area before disassembly and keep all 3
parts clean. Always use caps and plugs on hoses, 3
damage the system.
I-2003-0888
3
P-90969
Figure 20-120-1 Mark the hydraulic hoses for proper installation.
Disconnect the outlet hose (Item 1) [Figure 20-120-2]

from block.
1 Remove the hydraulic muffler (if equipped) (Item 2)

[Figure 20-120-2] from block.
Disconnect the hoses (Item 3) [Figure 20-120-2] from

block.
Remove the four bolts (Item 4) [Figure 20-120-2] from

block.

P-90968 lb) torque.
Remove the Power Bob-Tach block.

1.)


121-2.)
Disconnect the two electrical solenoid connectors (Item

1) [Figure 20-120-1] from the loader electrical harness.

A3NL12242) (CONT'D)

2
Figure 20-120-3
1
1
3
P100770
Remove the spring (Item 1) and spool (Item 2) [Figure

20-120-5].
P100820
Remove the O-ring (Item 3) [Figure 20-120-5] on the
plug and replace as needed.
Do not remove the plugs (Item 1) [Figure 20-120-3].

Figure 20-120-6
NOTE: Do not remove the two plugs located next to
the outlet port. A new Power Bob-Tach valve
will be required if tampered with. All other
plugs can be removed.
Figure 20-120-4
1
P100823

P100769 torque.
Clean the block (Item 1) [Figure 20-120-4] to remove dirt

before disassembly. Block ports are labeled for correct
assembly.

torque.

A3NL12242) (CONT'D)
Figure 20-120-7
1
3
1 P100821
2
Remove the orifice (Item 1) [Figure 20-120-9].
P107069 Installation: Tighten the orifice to 8,1 - 10,8 N•m (6 - 8 ft-

lb) torque.
Remove the spool (Item 1), the spring (Item 2) and the Figure 20-120-10
orifice (Item 3) [Figure 20-120-7].

Installation: Clean threads on the orifice and apply
Loctite® 603 before installing the orifice.
Figure 20-120-8
P100774
Remove the solenoid coil nut (Item 1) [Figure 20-120-

10].
P100826 Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-120-8]. NOTE: Mark the solenoid coil orientation for ease of
assembly.
torque.

A3NL12242) (CONT'D)

2 2 2
Figure 20-120-11
1 1 1 1 1
P100776
Remove the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-13].
P100773
Figure 20-120-14
Remove the solenoid coils (Item 1) [Figure 20-120-11].

Figure 20-120-12
P100828
Remove the fitting (Item 1) [Figure 20-120-14].

P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

12].
Installation: Tighten the solenoid coil stem to 27,14 N•m

(20 ft-lb) torque.

A3NL12242) (CONT'D)
Figure 20-120-15
P100841
1 Remove the filter assembly (Item 1) [Figure 20-120-17].
P100829 Figure 20-120-18

Figure 20-120-16
1
P100842
P100840 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.

torque.

A3NL12242) (CONT'D)
Figure 20-120-19
2
1
P100839
P100843 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.
Remove the shuttle seat (Item 1) and check ball (Item 2) Figure 20-120-22

[Figure 20-120-19].
Figure 20-120-20
1
2
1
P100835
P100845 Remove the spring (Item 1) and the check ball (Item 2)
[Figure 20-120-22].
Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

A3NL12242) (CONT'D)
Figure 20-120-23
1
P100846
P100837 Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
Figure 20-120-26

torque.
Figure 20-120-24
2
P100847
1
Remove pilot piston (Item 1) [Figure 20-120-26].
P100838
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-24].

A3NL12242) (CONT'D)
Figure 20-120-27
1 1
1
2
P100849
2
Remove the annular orifice shaft (Item 1) and the annular
orifice shaft guide (Item 2) [Figure 20-120-29].
P100834
Figure 20-120-30
Remove the back-up rings (Item 1) and the O-ring (Item

2) [Figure 20-120-27].

1
Figure 20-120-28
P100850
P100852 Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

torque.

BOB-TACH (POWER) BLOCK (S/N A3NL11001 -
A3NL12242) (CONT'D)
Figure 20-120-31
P100851

torque.
Figure 20-120-32
P100854

BOB-TACH (POWER) BLOCK (S/N A3NL12243 &
ABOVE)
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right

switch panel.
The Power Bob-Tach block is mounted on the right side

of the machine in front of the engine on the back side of
the hydraulic pump.

BOB-TACH (POWER) BLOCK  Figure 20-121-2
(S/N A3NL12243 & ABOVE) (CONT'D)
Testing Relief Valve
1
WARNING
not use your bare hand. Wear safety goggles. If fluid P106674
W-2072-0807 Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
Figure 20-121-3
WARNING

explosion or fire. 1
W-2103-0508
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-121-1 P122238
Install the gauge (Item 1) [Figure 20-121-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH “WEDGES DOWN” Switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

121-1].
Push and hold BOB-TACH “WEDGES UP” switch until

levers are in the unlocked position (Wedges fully raised).

BOB-TACH (POWER) BLOCK 
Testing Relief Valve (Cont’d)
Figure 20-121-4
P122229
NOTE: Relief valve removed from block for photo

clarity.
If adjustment is required loosen the jam nut (Item 1) and

turn the adjusting screw (Item 2) [Figure 20-121-4]
clockwise to increase pressure or counterclockwise to
decrease pressure.
Test the relief valve setting after adjustment has been

made.

BOB-TACH (POWER) BLOCK  NOTE: After repairing a machine that required the
(S/N A3NL12243 & ABOVE) (CONT'D) Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
Removal And Installation make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
WARNING Maintenance Manual, the electrical

connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
Never work on a machine with the lift arms up unless inspection to verify the wedges function
the lift arms are secured by an approved lift arm correctly.
support device can allow the lift arms or attachment Lift and block the loader. (See LIFTING AND BLOCKING
to fall and cause injury or death. THE LOADER on Page 10-10-1.)
W-2059-0598

DANGER
Replacing Hydraulic Fluid on Page 10-120-2.) or (See
121-2.)

Remove the fan duct. (See Fan Duct Removal And
Installation on Page 70-50-3.) or (See Fan Duct Removal
And Installation on Page 70-51-4.)
P-90328
Figure 20-121-5
AVOID DEATH
unless supported by an approved lift arm 1
D-1009-0409
IMPORTANT
P122161
parts clean. Always use caps and plugs on hoses, Disconnect the two wire connectors (Item 1) [Figure 20-
tubelines and ports to keep dirt out. Dirt can quickly 121-5] from the solenoid coils.
damage the system.
I-2003-0888

Figure 20-121-6
2 2
P122162
Disconnect and cap the hose (Item 1) [Figure 20-121-6]

from block.
Disconnect and cap the hoses (Item 2) [Figure 20-121-6]

from block.
Figure 20-121-7
1 1
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-121-

7].
Installation: Tighten the mounting bolts to 48 - 54 N•m

Remove the Power Bob-Tach block.

IMPORTANT 3

1
damage the system. 2
I-2003-0888
4 P122197
Figure 20-121-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.

torque.

Replace the O-ring (Item 4) [Figure 20-121-9] on the
1
plug.
Figure 20-121-10
1
P122196
Do not remove these plugs (Item 1) [Figure 20-121-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
1
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-121-10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.


2
Figure 20-121-11
P122201
3
Replace the O-rings (Item 1) and the back-up rings (Item

1 2) [Figure 20-121-13].
P122199
Figure 20-121-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-121-

11].
Figure 20-121-12
2
1
P122202
Remove the fitting (Item 2) [Figure 20-121-12] and

1 replace the O-ring (Item 1) [Figure 20-121-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-121-

12].
Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-121-15
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-17]. Inspect and replace
P122203 as needed.
Figure 20-121-18
Remove the plug (Item 1) [Figure 20-121-15] and

replace the O-ring.

torque. 1
Figure 20-121-16
P122205

1
torque.
P122205

torque.

Figure 20-121-19
2
3 1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert

1 (Item 2) [Figure 20-121-21]. Inspect and replace as
P122207 needed.
Figure 20-121-22
Remove the O-ring (Item 1), the spring (Item 2) and the
check ball (Item 3) [Figure 20-121-19]. Inspect and

replace as needed.
Figure 20-121-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
P122208 Installation: Tighten the relief valve to 20 N•m (15 ft-lb)

torque.

torque.

Figure 20-121-23
2
2
P122212
Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-121-23].

Figure 20-121-24
P122213
Replace the O-ring (Item 1) [Figure 20-121-24].
NOTE: After repairing a machine that required the

Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535

If unable to identify the supplier part number on the male
coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONT’D)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONT’D)
Disassembly And Assembly (FFI/FI) (Cont’d)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7].

1
Remove the O-rings (Item 2) [Figure 20-130-7] from the
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and inspect the seal

(Item 1) [Figure 20-130-8] for damage and replace as
needed.

(CONT’D)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].

Installation: Tighten the coupler fittings (Item 1) [Figure
20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

(CONT’D)
Disassembly And Assembly (FFH/FH) (Cont’d)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].

Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assembly if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.


AUTOMATIC RIDE CONTROL
Description
The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

AUTOMATIC RIDE CONTROL (CONT'D)

WARNING
Open the rear door.
Remove the rear grille and engine cover. (See Removing
on Page 50-60-1.)
explosion or fire.
WARNING W-2103-0508

support device. Failure to use an approved lift arm WARNING
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.

See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Drain the hydraulic fluid reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-140-1
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P114272
When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

AUTOMATIC RIDE CONTROL (CONT'D) Figure 20-140-4
Figure 20-140-2
1
3
P128096
1
Remove the hose (Item 1) [Figure 20-140-4].
P114645
Figure 20-140-5
Reposition clamp (Item 1), remove nut / bolt (Item 2),

remove the fuel tank vent hose (Item 3) and remove the
two mounting bracket nuts (Item 4) [Figure 20-140-2].

Remove the filler neck assembly and plug the fuel tank
inlet.
Figure 20-140-3
P128339
1
the manifold.
1
P128342
Disconnect the three connectors (Item 1) [Figure 20-

140-3] from the manifold.

Figure 20-140-6
P128335
Remove the two nuts (Item 1) and the accumulator /

manifold assembly (Item 2) [Figure 20-140-6].

Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
reduced ride control performance, or loss of damage the system.
I-2003-0888
ride control function.
Remove the automatic ride control assembly. (See

The tools listed will be needed to do the following WARNING

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

support device can allow the lift arms or attachment WARNING
W-2059-0598 RIDE CONTROL ACCUMULATOR INSTALLED
DANGER control for 5 seconds to release pressure from lift
circuit before servicing.
W-3015-0816
Figure 20-140-7
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
D-1009-0409
P128321

accumulator.

Checking The Pressure In The Accumulator (Cont’d)
Figure 20-140-8 1
2
1
P128489
Turn the T-handle (Item 1) [Figure 20-140-10]

P128322 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Loosen the Allen plug (Item 1) [Figure 20-140-8]
approximately 1/4 turn. Pressure in the accumulator should be 915 psi [63 bar].

Figure 20-140-9 Close the valve by turning the T-handle (Item 1) [Figure
20-140-10] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-10].
2 Remove the tool / gauge from the accumulator.
Tighten the Allen plug (Item 1) [Figure 20-140-8] to 20

N•m (15 ft-lb) torque.
1
P128488
Make sure the manual bleed valve (Item 1) is closed.

Install the tool / gauge (Item 2) [Figure 20-140-9] onto
the accumulator.

Adding Nitrogen To The Accumulator

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
P128322
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present. Loosen the Allen plug (Item 1) [Figure 20-140-12]
• Engine is running. approximately 1/4 turn.
W-2505-0604
Figure 20-140-13

WARNING 1
RIDE CONTROL ACCUMULATOR INSTALLED

control for 5 seconds to release pressure from lift
circuit before servicing.
W-3015-0816
2 P128488
Figure 20-140-11 Install the tool / gauge (Item 1) [Figure 20-140-13] onto
the accumulator.
Make sure the manual bleed valve (Item 2) [Figure 20-

140-13] is closed.
P128321

accumulator.

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-14
2
1
P128491
Turn the T-handle (Item 1) [Figure 20-140-16]

P128490 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Install the hose (Item 1) [Figure 20-140-14] to the tool on
the accumulator. Pressure in the accumulator should be 915 psi [63 bar].

Figure 20-140-15 Slowly open the valve on the nitrogen tank. Close the
valve by turning the T-handle (Item 1) [Figure 20-140-16]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1
Close the valve by turning the T-handle (Item 1) [Figure
20-140-16] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-16].
Remove the hose from the tank and the accumulator.
Tighten the Allen plug (Item 1) [Figure 20-140-12] to 20

N•m (15 ft-lb) torque.
P128327
Install the other end of the hose / fitting (Item 1) [Figure

20-140-15] to the nitrogen tank.

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removal And Installation (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Removal And Installation (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-22
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-9
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-9
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-14

HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
HYDROSTATIC PUMP (SJC) (S/N A3NL13651 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . 30-52-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-1
Port Locations And Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-2
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-9
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-10

Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-25
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
TWO-SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost do to internal leakage in the components
of the hydrostatic system.

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-80-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
DANGER
There are two hydrostatic motors mounted to motor
carriers. The motor carriers are mounted to the
transmission which houses the drive chains.
The hydrostatic motors do not have an internal brake.
Inside the end cap of the hydrostatic motor, there is a

shuttle valve. The shuttle valve helps to keep the motor P-90328
cool by mixing case drain fluid with cooled low pressure
fluid from the charge circuit. The shuttle valve is shifted AVOID DEATH
by the high pressure fluid coming from the hydrostatic • Disconnecting or loosening any hydraulic
pumps. If the shuttle valve sticks, a delay or lack of drive tubeline, hose, fitting, component or a part failure
may or may not be felt in the controls and / or an can cause lift arms to drop.
overheated hydrostatic motor will result. • Keep out of this area when lift arms are raised
D-1009-0409

WARNING
W-2059-0598
WARNING
explosion or fire.
W-2103-0508


HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-2
Figure 30-20-1
P106945
Loosen the bolts (Item 1) [Figure 30-20-2] holding the

P106956 lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
below the motor.
Remove the four motor cover bolts (Item 1) [Figure 30-
20-1]. Figure 30-20-3

Installation: Tighten bolts to 20 - 27 N•m (15 - 20 ft-lb)
torque.
IMPORTANT
damage the system.
I-2003-0888
P106946
Remove the lower bolt (Item 1) [Figure 30-20-3] from the

motor.
Installation: Tighten the bolt to 136 N•m (100 ft-lb)

torque.

Figure 30-20-4
1
3 1
P129382
Remove the bolt (Item 1 [Figure 30-20-6].

P106968
Installation: Tighten the bolts to 122 - 136 N•m (90 - 100
ft-lb) torque.
the hydrostatic motor. Remove the hydrostatic motor.

Remove the case drain hose (Item 2) [Figure 30-20-4] Figure 30-20-7
from the hydrostatic motor.
NOTE: The hydraulic fittings (Item 3) [Figure 30-20-4] 1

must be tightened to 156 - 170 N•m (115 - 125
ft-lb) torque.
2
Figure 30-20-5
P129384
1
Remove the O-ring (Item 1) and shaft seal (Item 2)
[Figure 30-20-7].
P106965
Installation: Tighten the bolts to 136 N•m (100 ft-lb)

torque.
Remove the motor from the loader.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Ref. Description
1. Shaft
2. Seal
3. O-ring
4. Flange
5. Seal 16
6. Back-up Ring 14
20 3
7. Spring
15
8. Outer Balance Plate 14
19 14
9. Inner Balance Plate 16
10. Ball 3 18
13
11. Geroler® 18
19
12. Valve Plate
13. End Cap 17 3 5
14. Poppet
12
15. Spring
16. Plug
17. Bolt 5
18. Sleeve
11

19. Spring
20. Shuttle Valve
10
5
9
8
7 10
6 3
3
5
4
2
1
PE2620T


1
IMPORTANT
damage the system.
I-2003-0888
P-68211
Drain the fluid from the motor.
Seal all open ports and clean the motor with solvent. Remove the bolts (Item 1) [Figure 30-20-9] from the
motor.
Figure 30-20-8
Figure 30-20-10
3
8

6
5
9
2
1
7
4
P-64267
P-68211
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-8]. Assembly: Initially tighten the bolts to 61 - 75 N•m (45 -
55 ft-lb) torque in the order shown [Figure 30-20-10].
Final tighten the bolts to 75 - 88 N•m (55 - 65 ft-lb) torque

in the order shown [Figure 30-20-10].

Disassembly And Assembly (Cont’d)
Figure 30-20-11
3
1
2
4
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet

P-64267 (Item 3) that make up the relief valve assembly. Remove
the O-ring (Item 4) [Figure 30-20-13].
Once the bolts have been removed and the motor begins Installation: Tighten the plug to 41 N•m (30 ft-lb) torque.
to separate, the drive shaft (Item 1) [Figure 30-20-11]

can be removed. Figure 30-20-14
Assembly: Install drive shaft before tightening the bolts.
Figure 30-20-12
1
2
1
3
P-68213
Remove the plug (Item 1) and shuttle valve assembly

P-68212 (Item 2). Remove the O-ring (Item 3) [Figure 30-20-14].
Installation: Tighten the plug to 41 N•m (30 ft-lb) torque.

Remove the end cap (Item 1) [Figure 30-20-12] from the
motor.

Figure 30-20-15
2
P-64274

P-39897
Remove the Geroler® section as an assembly (Item 2)
[Figure 30-20-17].
Remove the remaining pieces to the shuttle valve
assembly (Item 1) [Figure 30-20-15] from the inside of NOTE: There are two check balls on the backside of

the end cap. the Geroler® section. Do not lose these check
balls. See [Figure 30-20-18].
Figure 30-20-16
Figure 30-20-18
1
2
1 1
P-39898
P-39901
Remove the O-rings (Item 1) [Figure 30-20-16].

Remove the two check balls (Item 1) [Figure 30-20-18]
Remove the valve plate (Item 2) [Figure 30-20-16]. from the Geroler®.
NOTE: Care should be taken to keep the Geroler®

assembly together. If rollers are removed,
install the rollers in the original bores.

Figure 30-20-19
2 1
3
1
P-64271
Remove the O-rings (Item 1) [Figure 30-20-21].

P-64268
Figure 30-20-22
Remove the inner balance plate (Item 1) [Figure 30-20-

19]. 1

Remove the outer balance plate (Item 3) [Figure 30-20-

19].
Figure 30-20-20
P-64272
Remove the Belleville spring (Item 1) [Figure 30-20-22].
Assembly: If the Belleville spring is no longer cone

1 shaped, replace with new.
P-64270
Remove the back-up ring (Item 1) [Figure 30-20-20].
NOTE: One side of the back-up ring is grooved to fit

against the O-ring underneath.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-23
P-64273
Turn the mounting flange over and remove the seal (Item
1) [Figure 30-20-23].


HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing drive
loop return fluid with cooled low pressure fluid from the
charge circuit. The shuttle valve is shifted by the high
pressure fluid coming from the hydrostatic pumps. If the
shuttle valve sticks, a delay or lack of drive may or may
not be felt in the controls and / or an overheated
hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Remove the front and rear wheel / tire assemblies. (See
(CONT’D) Wheel Nuts on Page 10-160-1.)
Removal And Installation (Left Side) Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.).
DANGER Remove the linkage on foot control loaders. (See Linkage
121-2.).
Mark all hoses and tubelines before removing for correct
installation.
P-90328 Figure 30-21-1
AVOID DEATH

1
D-1009-0409
WARNING 2
P106956
support device. Failure to use an approved lift arm Remove the motor cover bolts (Item 1) and remove the
support device can allow the lift arms or attachment motor cover (Item 2) [Figure 30-21-1] from the loader.
W-2059-0598 Figure 30-21-2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P106945
1.)
Raise the lift arms and install an approved lift arm Loosen the bolts (Item 1) [Figure 30-21-2] and swing the
support device. (See Installing on Page 10-20-2.) panel open. The panel is located under the loader frame
directly below the drive motor.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-5
(CONT’D)
Removal And Installation (Left Side) (Cont'd)

1
Figure 30-21-3
P-73664
1
Remove the lower bolt (Item 1) [Figure 30-21-5] from the

motor.
P106959
torque.
Remove the case drain hose (Item 1) [Figure 30-21-3].

Figure 30-21-6
Figure 30-21-4
2
1
P106958
P106957
Remove two bolts (Item 1) [Figure 30-21-6] from the

Remove the hose (Item 1) [Figure 30-21-4] from the motor.
motor.
Remove the shift pressure tubeline (Item 2) [Figure 30- torque.
21-4] from the motor.

(CONT’D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
P-82716

Figure 30-21-8
CORRECT WRONG
P-73542
Installation: Install the seal (Item 1) [Figure 30-21-8] in

the flange of the motor with the convex surface facing
outward.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Drain the hydraulic reservoir. (See Removing And
(CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.) OR (See
Removal And Installation (Right Side) 121-2.)
Mark all hoses and tubelines before removing for correct

installation.
DANGER Figure 30-21-9
1
P-90328
AVOID DEATH 1
2
unless supported by an approved lift arm P106956

D-1009-0409
Remove the motor cover bolts (Item 1) and remove the
motor cover (Item 2) [Figure 30-21-9].
Installation: Tighten bolts to 20 - 27 N•m (15 - 20 ft-lb)

WARNING torque.
Never work on a machine with the lift arms up unless Figure 30-21-10
W-2059-0598
IMPORTANT
1
P-73665
damage the system.
I-2003-0888
Loosen the bolts (Item 1) [Figure 30-21-10] and swing
the panel open. The panel is located under the loader
Raise the lift arms and install an approved lift arm frame directly below the drive motor.

(CONT’D)
Removal And Installation (Right Side) (Cont'd)
Figure 30-21-11
1 1
P106971
Disconnect the case drain tubeline (Item 1) [Figure 30-

P106970
Figure 30-21-14
Remove the shift pressure tubeline (Item 1) [Figure 30-

1
Figure 30-21-12
P-73664
Remove the lower bolt (Item 1) [Figure 30-21-14] from

the motor.
P106969
torque.
Remove the hoses (Item 1) [Figure 30-21-12] from the
motor.

(CONT’D)
Removal And Installation (Right Side) (Cont'd)

1
Figure 30-21-15
CORRECT WRONG
P-73542
Installation: Install the seal (Item 1) [Figure 30-21-17] in

the flange of the motor with the convex surface facing
P-76145 outward.
Remove two bolts (Item 1) [Figure 30-21-15] from the

motor.

torque.
Figure 30-21-16
P-82716

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT’D)
Ref. Description
1. O-ring
2. Spool Housing 3
3. Plug 7
7 4
4. Bolt
5. Plug 6 5
6. Spool 2
7. Spring
8. Gasket
9. Selector Plate
10. Valve Drive 3
11. Geroler® 8 1
12. Main Drive
13. Mounting Flange
14. Shaft Seal 9
15. Bolt
16. Shuttle Valve Assembly
17. Ball Seat
18. Ball 1
19. Valve Housing
20. Poppet 11
21. Dowel

22. Back-up Ring
23. Inner Balance Ring
24. Outer Balance Ring
25. Valve 1
10
3 13
15
12 3
19
14 3
16 16
3
7
21
22 18
17
23 3
22 7
20
22 1
24 7
3
25
1
MS2315SA

(CONT’D)
Disassembly
Drain the fluid from the motor casing.
Figure 30-21-18
P106490
Figure 30-21-21
P106488

Mark the side of the motor for ease of assembly [Figure 1
30-21-18].
Figure 30-21-19
P106491
1 2
Remove the dowel pin (Item 1) [Figure 30-21-21].
P106489
Remove the bolts (Item 1) and valve housing (Item 2)

[Figure 30-21-19].

(CONT’D)
Disassembly (Cont'd) 1
Figure 30-21-22
1 P106494
Remove the outer balance ring (Item 1) [Figure 30-21-

24] from the valve housing.
P106492
Figure 30-21-25
Remove the inner balance ring (Item 1) [Figure 30-21-

22] from the valve housing.
Figure 30-21-23
1
1 1
P106496
Remove the O-ring and two back-up rings (Item 1)

[Figure 30-21-25] from the outer balance ring.
P106493
Remove four springs (Item 1) [Figure 30-21-23].

(CONT’D)
Disassembly (Cont'd)
Figure 30-21-26
1
1
1
P106498

valve housing.
1 P106497
Figure 30-21-29

Figure 30-21-27
1 P106500

P106495 valve housing.
Remove the back-up ring (Item 1) [Figure 30-21-27] from

the valve housing.

(CONT’D)
Figure 30-21-30
P106499
1
valve housing.
P-76394A
Figure 30-21-33

Figure 30-21-31
2
3 P-76394A
1
P106502
Remove the orifice (Item 1). Remove the O-ring (Item 2)

and the ball (Item 3) [Figure 30-21-31].
NOTE: The orifice is threaded into the valve housing.

(CONT’D)
Figure 30-21-34
1
4
3
2 P-76394A
1
P106501 Figure 30-21-37
Remove the spring seat (Item 1), spring (Item 2), spring
seat (Item 3) and shuttle valve (Item 4) [Figure 30-21-

34].
Figure 30-21-35
3
2
1
P106505
1 Remove spring seat (Item 1), spring (Item 2) and spring

seat (Item 3) [Figure 30-21-37].
P106504

(CONT’D)
Figure 30-21-38
P106506
1
P106503 Figure 30-21-41

Figure 30-21-39
P-76394A
1
P-76394A

(CONT’D)
Figure 30-21-42 1
P106509
1
2
Remove the selector plate (Item 1) [Figure 30-21-44].
P106507 Figure 30-21-45

30-21-42].
1
Figure 30-21-43
P106510
Remove the valve drive (Item 1) [Figure 30-21-45].
P106508
Remove the valve (Item 1) [Figure 30-21-43].

(CONT’D)
1
Figure 30-21-46
P106618
2 Remove the plate (Item 1) [Figure 30-21-48].
P106511 Figure 30-21-49

Remove the Geroler® (Item 2) [Figure 30-21-46].
2
Figure 30-21-47
1 1
P106620
Remove the O-ring (Item 1) and back-up ring (Item 2)

[Figure 30-21-49].
P106512
Remove the main drive (Item 1) [Figure 30-21-47].

(CONT’D)
Figure 30-21-50
1
P106622

groove in the seal.
P106621
Figure 30-21-53
Remove the spring washer (Item 1) [Figure 30-21-50].

Figure 30-21-51
P106513
Remove the shaft seal (Item 1) [Figure 30-21-53].

P106619
Remove the seal / O-ring assembly (Item 1) [Figure 30-

21-51].

(CONT’D)
1 1
Figure 30-21-54
1 1
1 P106515
Remove the screws (Item 1) [Figure 30-21-56] from the

selector spool housing.
P106514
Figure 30-21-57

Figure 30-21-55
P106516
1
Remove the gasket (Item 1) [Figure 30-21-57].

P-76394A

plug.

(CONT’D)
Figure 30-21-58
1
P106519
Remove the springs (Item 1) [Figure 30-21-60] from the

spool housing.
P106517
Figure 30-21-61

NOTE: The plug is under spring pressure.
Figure 30-21-59
P-73523
1 Remove the inner spring (Item 1) from the outer spring

(Item 2) [Figure 30-21-61].
P106518

(CONT’D)
Figure 30-21-62
P-76389
P106520 Figure 30-21-65
Remove the spool (Item 1) [Figure 30-21-62] from the

spool housing.
1
Figure 30-21-63
P106523
1
spool housing.
P106522

spool housing.

(CONT’D)
Figure 30-21-66
P-76389

(CONT’D)
Assembly
Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
1
Figure 30-21-67
P-76389
Install the O-ring (Item 1) [Figure 30-21-69] on the plug.
Figure 30-21-70

1
P-76389
1
Figure 30-21-68
P-73550A
1 Install the plug (Item 1) [Figure 30-21-70] in the spool

housing.
Tighten the plug to 19 - 24 N•m (14 - 18 ft-lb) torque.
P-76438
Install the plug (Item 1) [Figure 30-21-68] in the spool

housing.

(CONT’D)
Assembly (Cont’d)
Figure 30-21-71
P106518
P106520 Figure 30-21-74
Install the spool (Item 1) [Figure 30-21-71] into the spool

housing.
1
Figure 30-21-72
P106517
Install the plug (Item 1) [Figure 30-21-74] with a light

coat of oil.
P106519 Tighten the plug to 45 - 56 N•m (33 - 42 ft-lb) torque.
Install the inner and outer springs (Item 1) [Figure 30-21-

72] on the spool shaft.

(CONT’D)
Assembly (Cont'd)
Figure 30-21-75
Apply Loctite® 262 Here

1 1
1
1
P106516
1 1 1 Install the gasket (Item 1) [Figure 30-21-76] on the

selector plate.
P-73775
Figure 30-21-77
Use the correct size tap to clean any remaining thread 1 1

lock from the threaded holes (Item 1) [Figure 30-21-75].

Put a VERY SMALL amount of Loctite® 262 into each of
the threaded holes of the selector plate. DO NOT put
Loctite® on the screw threads.
NOTE: If too much Loctite® is applied and any

trapped air is not removed, it can pool in the
bottom of the threaded holes. This can 1
1
prevent the screws from reaching full thread
contact and the correct torque may not be
reached.
P106515
Wipe any excess Loctite® from the selector plate surface.
NOTE: Installing the screws can force some of the Install the screws (Item 1) [Figure 30-21-77].
Loctite® out of the holes and onto the selector
plate surface. If any Loctite® gets between the
new gasket and the selector plate it will create
a poor seal. Be sure to wipe excess Loctite®
from the surface.

(CONT’D)
Assembly (Cont'd)
Figure 30-21-78
10 4 1 6 7
1
1
P106514
9 5 2 3 8
Install the plug (Item 1) [Figure 30-21-80].
MS2316S Figure 30-21-81
Tighten the screws to 8 - 9 N•m (70 - 80 in-lb) torque

using the sequence shown [Figure 30-21-78].

Allow the Loctite® to cure for six hours after assembly.
1
Figure 30-21-79
P106622
Install the O-ring (Item 1) [Figure 30-21-81] in the seal

1 groove.
P-76394A

(CONT’D)
Assembly (Cont'd)
Figure 30-21-82
2
P106620
Install the O-ring (Item 1) and back-up ring (Item 2)

[Figure 30-21-84].
P106619
Figure 30-21-85
Install the seal / O-ring assembly (Item 1) [Figure 30-21-

82].
Figure 30-21-83
P106618
Install the plate (Item 1) [Figure 30-21-85].
P106621
Install the spring washer (Item 1) [Figure 30-21-83].

(CONT’D)
Assembly (Cont'd)
Figure 30-21-86 1
1 2
P106510
Install the valve drive (Item 1) and O-ring (Item 2) [Figure

30-21-88].
P106512
Install the main drive (Item 1) [Figure 30-21-86].

Figure 30-21-87
2 1
P106540
Install the Geroler® assembly (Item 1) with the groove

(Item 2) in the ring and star facing up. Align the holes
(Item 3) [Figure 30-21-87].

(CONT’D)
Assembly (Cont'd)
1
Motor Timing
Figure 30-21-89
3 2
P-73545
Install the valve (Item 1) [Figure 30-21-91] on the valve

1 2 drive. The round holes and four grooves must be facing
up.
P-73544 Align any one of the four grooves (Item 2) in the valve
with the marked tooth on the valve drive (Item 3) [Figure

Locate a tooth (Item 1) [Figure 30-21-89] that lines up 30-21-91].
with a star tip.
Rotate the valve clockwise until the spline teeth engage
Mark the spline (Item 2) in the Geroler® star that is 11.25 in the valve.
degrees counterclockwise. Mark the corresponding tooth
(Item 3) on the small end of the valve drive that aligns
with the spline mark (Item 2) [Figure 30-21-89].
Figure 30-21-90
P-73527
Install the selector plate (Item 1) with the slotted holes

facing up. Align the case drain holes (Item 2) [Figure 30-
21-90].

(CONT’D)
Assembly (Cont’d)
Figure 30-21-92
P-76394A
1
P-76389 Figure 30-21-95

Figure 30-21-93
P106507
1
Install the poppet (Item 1) and spring (Item 2) [Figure 30-
21-95].
P106503

(CONT’D)
Assembly (Cont’d)
Figure 30-21-96
P-76394A
1
P106506 Figure 30-21-99

Figure 30-21-97
P106504
1
2
3
P106505
Install the spring seat (Item 1), spring (Item 2) and spring
seat (Item 3) [Figure 30-21-97].

(CONT’D)
Assembly (Cont’d)
Figure 30-21-100
1 1
2
3 P106499
4
P106501 Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
Figure 30-21-103
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and spring seat (Item 4) [Figure 30-21-100].

Figure 30-21-101
2 1
P106502
1
Install the O-ring (Item 1) on the orifice. Install the ball

P-76394A (Item 2) and orifice (Item 3) [Figure 30-21-103].

(CONT’D)
Assembly (Cont’d)
Figure 30-21-104
1 1
P106495
Install the back-up ring (Item 1) [Figure 30-21-106] on

the valve housing.
P106500
Figure 30-21-107

Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque. 1
Figure 30-21-105
1
P106497
1 Install the compression springs (Item 1) [Figure 30-21-

107].
P106498
Install the O-ring (Item 1) [Figure 30-21-105] on the

valve housing.

(CONT’D)
Assembly (Cont’d)
Figure 30-21-108
1 1
P106493
1
Install the compression springs (Item 1) [Figure 30-21-

110].
P106496
Figure 30-21-111
Install the O-ring and two back-up rings (Item 1) [Figure

30-21-108] on the outer balance ring.
Figure 30-21-109
P106492
Install the inner balance ring (Item 1) [Figure 30-21-111]

in the valve housing.
P106494
Install the outer balance ring (Item 1) [Figure 30-21-109]

in the valve housing.

(CONT’D)
Assembly (Cont’d) 1
2
Figure 30-21-112
P106489
Install the valve housing (Item 1) [Figure 30-21-114],

taking care to maintain correct alignment.
P106491
NOTE: When installing the valve housing the balance
rings and springs must remain in position.
Install the dowel pin (Item 1) [Figure 30-21-112].

Install the bolts (Item 2) [Figure 30-21-114].
Figure 30-21-113
Figure 30-21-115
5 8
1 2 3
7 6
4 9
P106490
1 MS2317S

Initially tighten the bolts to 68 - 95 N•m (50 - 70 ft-lb)
torque in the sequence shown [Figure 30-21-115].
Final tighten the bolts to 149 N•m (110 ft-lb) torque in the
sequence shown [Figure 30-21-115].

(CONT’D)
Assembly (Cont'd)
Figure 30-21-116
P106544
Turn the motor over and install the shaft seal (Item 1)

[Figure 30-21-116].
Figure 30-21-117
2 3
1
P106545
Lay the motor flat. Pour clean hydraulic fluid in the ports.
Rotate the shaft (Item 1) clockwise. There must be
suction at the B port (Item 2) and pressure at the A port
(Item 3) [Figure 30-21-117].


HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
A brake disk is installed on each hydrostatic motor

carrier. The brake disk is mounted to the shaft in the
motor carrier.
The hydrostatic motor carriers are made to fit on both the

right or left hand side of the loader. There are two sets of
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
side and another set for the right hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-2
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

DRIVE MOTOR on Page 30-20-1.) or (See
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) on Page
30-21-1.)
WARNING P-82715
AVOID INJURY OR DEATH Use a slide hammer to remove the seal from the motor
Wear safety glasses to prevent eye injury when any carrier shaft [Figure 30-30-2].
• When fluids are under pressure. Figure 30-30-3

W-2019-0907
1
Figure 30-30-1
P-82713
Install a new seal (Item 1) [Figure 30-30-3] over the

shaft.
P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-30-1].

HYDROSTATIC MOTOR CARRIER (CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-4
P-82714
Install MEL1420 Carrier Seal Tool (Item 1) [Figure 30-

30-4] over the carrier seal.

Hit the tool with a hammer until the seal is fully seated on
the carrier shaft.
Figure 30-30-5
1 2
P-82716
NOTE: Before installing the hydrostatic motor,

inspect the plug (Item 2) [Figure 30-30-5]
located in the center of the carrier shaft. If the
plug is loose, case drain fluid from the
hydrostatic motor can leak into the chaincase.

WARNING
1
W-2059-0598
P-54227
Raise the loader lift arms and install an approved lift arm
Remove the parking brake disc (Item 1) [Figure 30-30-
Lift and block the loader. (See Procedure on Page 10-10- 6]. (See Disc Removal And Installation on Page 40-10-1.)
1.)
Raise the loader operator cab. (See Raising on Page 10- inside of the chaincase.
30-2.)

Installation: Tighten the bolts to 170 - 190 N•m (125 -
Drain the fluid from the chaincase. (See Removing And 140 ft-lb) torque.
Replacing Fluid on Page 10-130-1.)
Figure 30-30-7
Remove the engine speed control. (See Removal And
1
on Page 50-100-2.) or (See Removal And Installation on
Page 50-101-1.)
2
Remove the lift arm bypass control valve. (See Removal
Remove the traction lock assembly. (See TRACTION

LOCK on Page 60-110-1.)
Remove the center chaincase cover. (See Center Cover

Removal And Installation on Page 40-30-2.) P-54226
Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-1.) Fasten the front drive chain to the chaincase as shown
(Item 1) [Figure 30-30-7].
Remove the front axle and sprocket. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-20- Tip the end of the sprocket toward the rear of the loader
4.) and remove the rear drive chain (Item 2) [Figure 30-30-
7] from the sprocket.
DRIVE MOTOR on Page 30-20-1.)

Figure 30-30-8
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

30-8].

Installation: Clean and dry the motor carrier sealing
surface and transmission sealing face. Apply
polyurethane sealant to both surfaces.
Figure 30-30-9
P-39813
Fasten a chain hoist to the motor carrier and remove the

carrier from the loader [Figure 30-30-9].

Ref. Description
1. Shaft
2. Plug
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
2 3

4 5
6
7
NA6549S

Disassembly
Figure 30-30-10
76,2 mm O.D. Diameter

(3.00 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
(7.000 in) P-39816
Put the motor carrier in the hydraulic press as shown and

MC-2102 press the sprocket shaft out of the motor carrier housing
[Figure 30-30-12].
It is necessary to fabricate a press tool for this procedure. Figure 30-30-13

Refer to [Figure 30-30-10] for the correct dimensions of

the tool needed.
Remove the shaft seal. (See Shaft Seal Removal And

Figure 30-30-11 2
1
P-4365
Remove the housing from the press and install a bearing

1 puller (Item 1) [Figure 30-30-13] on the sprocket shaft.
Put the assembly in the hydraulic press and remove the

P-82709 bearing (Item 2) [Figure 30-30-13] from the shaft.
Remove the snap ring (Item 1) [Figure 30-30-11] from

the motor carrier shaft.

Disassembly
Figure 30-30-14
P-39817
Remove the inner bearing race (Item 1) from the carrier

housing (Item 2) [Figure 30-30-14].

Figure 30-30-15
P-39818
Put the motor carrier housing in the hydraulic press as

shown [Figure 30-30-15].
Press the outer bearing race from the housing.

Assembly

Inspect all part for wear or damage. Replace all worn or
damaged parts.
Figure 30-30-16
P-39819
Turn the motor carrier housing over as shown [Figure 30-

30-17].
Press the outer bearing race into the motor carrier

housing [Figure 30-30-17].
P-39820

Press the bearing race in until it is fully seated in the
carrier housing.
Put the motor carrier housing in the press as shown
[Figure 30-30-16].
Press the inner bearing race into the motor carrier


carrier housing.

Assembly (Cont’d)
Figure 30-30-18
2 2

P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-30-19]
over the shaft as shown.
Use the fabricated press tool (Item 1) and a plate (Item 2)
to install the new inner bearing (Item 3) [Figure 30-30- Put the outer bearing over the end of the shaft and press
18] on the shaft as shown. the bearing on with the press tool (Item 2) [Figure 30-30-
19].

Assembly (Cont’d)
Figure 30-30-20
P-4375
1
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-30-
P-82708 22] and install the shaft seal.
Figure 30-30-23
Install the snap ring (Item 1) [Figure 30-30-20].

Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-30-21
P-39821
1 Use a rubber mallet [Figure 30-30-23], tap down on the

shaft.
P-82707
Install the seal (Item 1) [Figure 30-30-21] on the

sprocket shaft.

Assembly (Cont’d)
Figure 30-30-24

N-15087
Install a dial indicator as shown [Figure 30-30-24].
Use a pry bar (Item 1) [Figure 30-30-24] to lift the shaft

and measure the end play on the dial indicator.
The shaft must turn freely with end play not to exceed
0,17 mm (0.007 in).

HYDROSTATIC MOTOR CARRIER (TWO-SPEED) Figure 30-31-1
Description
Single Speed Two-Speed

The hydrostatic motor carrier is the mating connection
from the hydrostatic drive motor to the transmission case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
1 1
A brake disk is installed on each hydrostatic motor P-73920
P-68214
carrier. The brake disk is mounted to the shaft in the
motor carrier.
Figure 30-31-2
The hydrostatic motor carriers are made to fit on both the
right or left hand side of the loader. There are two sets of Single / Two-Speed
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
side and another set for the right hand side of the loader.

2
1
P-82710
The motor carrier hydrostatic motor mounting holes (Item

1) [Figure 30-31-1] and [Figure 30-31-2] are the only
difference between the single, two-speed and single /
two-speed motor carriers with SJC controls. The
disassembly and assembly procedures are the same.
The single / two-speed motor carrier has a notch (Item 2)

[Figure 30-31-2] removed from one side of the carrier.

(CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool

30-21-1.).
WARNING P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-31-4].
Figure 30-31-5

W-2019-0907
Figure 30-31-3
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-31-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-31-3] is

located on the outside of the motor carrier shaft.

(CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-31-6
2 1
P-82716
P-82713 NOTE: Before installing the hydrostatic motor,

inspect the plug (Item 2) [Figure 30-31-8]
located in the center of the carrier shaft for
Installation: Install a new seal over the motor carrier correct torque. If the plug becomes loosen,
shaft [Figure 30-31-6].

case drain lubrication fluid from the
hydrostatic motor can leak into the chaincase.
Figure 30-31-7
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-31-7].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-31-7].

(CONT’D)
WARNING 2

W-2059-0598
P-39781
support device. (See Installing on Page 10-20-2.) Remove the parking brake disc (Item 1) [Figure 30-31-
9]. (See BRAKE on Page 40-10-1.)
1.) Remove the six motor carrier mounting bolts (Item 2)
[Figure 30-31-9] from the inside of the chaincase.
Raise the loader operator cab. (See Raising on Page 10-

30-2.) Installation: Tighten the motor carrier mounting bolts to
170 - 190 N•m (125 - 140 ft-lb) torque.
Drain the fluid from the chaincase. (See Removing And
Replacing Fluid on Page 10-130-1.) Figure 30-31-10
Remove the engine speed control. (See Removal And

Installation on Page 70-20-1.) 1

on Page 50-100-2.)
2
Remove the lift arm bypass control valve. (See Removal
Remove the traction lock assembly. (See TRACTION


Removal And Installation on Page 40-30-2.) P-54226

Removal And Installation on Page 40-30-1.) For ease of removal, fasten the front drive chain
(previously removed) to the chaincase as shown (Item 1)
Remove the front axle and sprocket. (See Axle, Sprocket [Figure 30-31-10].
And Bearings Removal And Installation on Page 40-20-
4.) Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-31-
Remove the hydrostatic motor. (See HYDROSTATIC 10] from the sprocket.
30-21-1.).

HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-11
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

31-11].
Installation: The motor carrier sealing surface and

transmission sealing surface must be clean and dry.
Apply polyurethane sealant to both surfaces.
Figure 30-31-12
P-39813
Fasten a chain hoist to the bolt (Item 1) on the motor

carrier and remove the carrier from the loader [Figure
30-31-12].

HYDROSTATIC MOTOR CARRIER (TWO-SPEED) (CONT’D)
Ref. Description
1. Shaft
2. Plug
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
2 3
5

4
6
7
NA6550S

(CONT’D)
Disassembly
Figure 30-31-13
76,2 mm O.D. Diameter

(3.000 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
P-39816
(7.000 in)
Put the motor carrier in the hydraulic press as shown

[Figure 30-31-15].
MC-2102
Use 57,2 mm (2-1/4 in) driver tool and press the shaft out
of the housing [Figure 30-31-15].
It is necessary to locate or fabricate a press tool for this
procedure [Figure 30-31-13].

NOTE: The outer bearing will now be free from the
shaft.
Figure 30-31-14
Figure 30-31-16
2
1
P-82709
P-4365
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-31-16] on the shaft.
Remove the motor carrier shaft seal. (See Shaft Seal
Removal And Installation on Page 30-31-2.). Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-31-14] from 31-16] from the shaft.
the motor carrier shaft using the snap ring pliers.
NOTE: The sensor disc has been removed on late
model machines and can be eliminated on
older machines that have been upgraded to
allow the removal of the speed sensors.

(CONT’D)
Figure 30-31-17
P-39817
Fasten the housing to the work surface with the inner

bearing race (Item 1) [Figure 30-31-17] facing up.

Install the slide hammer with puller end (Item 2) [Figure
30-31-17] on the bottom side of the bearing race.
Remove the bearing race from the carrier housing

[Figure 30-31-17].
Figure 30-31-18
P-39818
Put the housing in the hydraulic press as shown [Figure

30-31-18].
Use a 98,4 mm (3-7/8 in) driver tool and press the outer
bearing race from the housing.

(CONT’D)
Assembly

Inspect all parts for wear and damage. Replace any worn
or damaged parts.
Figure 30-31-19
P-39819
Turn the motor carrier housing over as shown [Figure 30-

31-20].
Use 109,5 mm (4-5/16 in) driver tool and press the new
outer bearing race into the motor carrier housing [Figure
30-31-20].

P-39820
carrier housing.
Put the motor carrier housing in the press as shown
[Figure 30-31-19].
Use 109,5 mm (4-5/16 in) driver tool and press the new
inner bearing race into the motor carrier housing [Figure
30-31-19].

carrier housing.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-21

P-4371
Put the motor carrier housing (Item 1) [Figure 30-31-22]

over the shaft as shown.
Put the outer bearing over the end of the shaft and press
the bearing on with the press tool and driver tool [Figure
30-31-22].
P-4366
Remove the press and driver tools from the sprocket

shaft.
Use the fabricated press tool (Item 1) and 76,2 mm (3.0
in) driver tool to install the inner bearing (Item 2) [Figure
30-31-21] on the shaft as shown.
Remove the press and drive tools from the shaft.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-23
P-82708
Put the snap ring (Item 1) [Figure 30-31-23] over the end P-4375

of the sprocket shaft.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-31-
NOTE: Use the snap ring pliers to spread the snap 25] and install the shaft seal.
ring so it will fit over the sprocket shaft.
Figure 30-31-26
Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-23] over the shaft.
Press the snap ring on until it snaps into the groove on

the shaft.
Figure 30-31-24
P-76463
1 Use a rubber mallet [Figure 30-31-26], tap down on the

shaft.
P-82707
Put the shaft seal (Item 1) [Figure 30-31-24] on the

shaft.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-27
P-76467
Install a dial indicator as shown [Figure 30-31-27].

Use a pry bar (Item 1) [Figure 30-31-27] to lift the shaft
and measure the end play on the dial indicator.
The shaft must turn freely with end play not to exceed
0,17 mm (0.007 in).

CHARGE PRESSURE
Description
Charge pressure is a supply of fluid to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

CHARGE PRESSURE (CONT’D)
Testing
WARNING
WARNING Hydraulic fluid escaping under pressure can have
Never work on a machine with the lift arms up unless and possible death if proper medical treatment by a
the lift arms are secured by an approved lift arm physician familiar with this injury is not received
support device. Failure to use an approved lift arm immediately.
support device can allow the lift arms or attachment W-2145-0290
W-2059-0598 Figure 30-40-2

procedure: 1
MEL1355-2 - Pressure gauge 6895 kPa (68,9 bar) (1000

psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler

Hydraulic hose, approximately 1,5 m (5.0 ft), purchased 3
locally. Must be rated for pressures above 6895 kPa (68,9 2 3
bar) (1000 psi).
Figure 30-40-1 P-43196D
Assemble the gauge (Item 1), hose (Item 2) and the

correct test coupler (Item 3) [Figure 30-40-2]. Tighten all
1 3 fittings.
WARNING
2
4 Never work on a machine with the lift arms up unless
P121789 to fall and cause injury or death.
W-2059-0598
Test ports have changed on the Main valve. If your test

port looks like (Item 2) use test coupler (Item 1). If your Raise the loader lift arms and install an approved lift arm
test port looks like (Item 4) Use test coupler (Item 3) support device. (See Installing on Page 10-20-2.)
[Figure 30-40-1].

CHARGE PRESSURE (CONT’D) Connect the Remote Start Tool. (See REMOTE START
Testing (Cont’d) REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.).
Figure 30-40-3
Start the loader and warm the hydraulic fluid to 60°C
(140°F).
1
Record the pressure on the gauge (Item 1) [Figure 30-
40-2].
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2620 - 3310 kPa (26,2 - 33,1 bar) (380 - 480 psi) with the
pump in neutral.
On SJC equipped loaders the charge pressure at high

idle, with the fluid temperature of 60°C (140°F) is 2516 -
3206 kPa (25,1 - 32,1 bar) (365 - 465 psi) with the pump
P109149B in neutral.
Figure 30-40-4

1
P107933
Connect the test coupler (Item 1) [Figure 30-40-4] to the

test port (Item 1) [Figure 30-40-3].

CHARGE PRESSURE (CONT’D) Figure 30-40-6
Adjusting
Non SJC Machines
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
N-19568
I-2003-0888
Figure 30-40-5 There are several different thickness of the shims (Item 1)
[Figure 30-40-6] used to adjust the charge pressure.
1 NOTE: 0,254 mm (0.010 in) shim is approximately
55.1 kPa (0,6 bar) (8 psi) increase in pressure.
Adding shims increases charge pressure.

Removing shims decreases charge pressure.
The charge pressure is 2620 - 3310 kPa (26,2 - 33,1 bar)

(380 - 480 psi).
P-43856
If the charge pressure is not correct remove the charge

relief valve plug (Item 1) [Figure 30-40-5].
NOTE: The pump is shown removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Installation: Tighten the plug to 41 - 68 N•m (30 - 50 ft-

lb) torque.
Inspect the poppet, spring and poppet seat for wear or

damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.

CHARGE PRESSURE (CONT’D) Inspect the poppet and spring for wear or damage.
Adjusting (Cont’d) Inspect the seat inside the hydrostatic pump case for
wear or damage.
SJC Machines
Figure 30-40-8
IMPORTANT
damage the system.
I-2003-0888 1
Figure 30-40-7
P-64435
There are several different thickness of shims (Item 1)

[Figure 30-40-8] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim is approximately 20,7 kPa (3,0

bar) (43.5 psi) increase in pressure. Adding
shims increases charge pressure. Removing
shims decreases charge pressure.
The charge pressure is 2516 - 3206 kPa (25,1 - 32,1 bar)

(365 - 465 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-7].
NOTE: The pump is shown removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Installation: Tighten the plug to 41 - 68 N•m (30 - 50 ft-

lb) torque.

CHARGE PRESSURE (CONT’D) Figure 30-40-10
Sender Removal And Installation EARLIER MODELS
Remove the fan duct. (See Fan Duct Removal And

Figure 30-40-9
EARLIER MODELS
P106780
LATER MODELS
1
P106779
1
LATER MODELS

1
P115649A
Remove the sender (Item 1) [Figure 30-40-10] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

P116327 10,9 N•m (7.4 - 8.1 ft-lb) torque.

from the sender.

HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-50-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-50-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-50-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two bolts (Item 1) [Figure 30-50-3] and nuts.
ft-lb) torque
Installation: Tighten the bolts and nuts to 88 - 95 N•m

HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-10.)
Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-50-3.)

Replenishing / High Pressure Relief Valve Removal

And Installation 1
Figure 30-50-4
1
2
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-50-4] and [Figure 30-50-5] from the pump.
P-43857
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
torque.
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-50-4] in the hydrostatic pump Inspect for damage and replace as needed.
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function. Remove the O-ring (Item 2) [Figure 30-50-5].
NOTE: The two top valves are for the reverse drive If the high pressure relief valve must be replaced, it must
loop and the two bottom valves are for the be replaced as a complete unit.
forward drive loop.
The pressure setting for a new high pressure relief valve
is 34500 kPa (345 bar) (5000 psi).

HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Thrust Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
8
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Thrust Plate
16. Swash Plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

Disassembly
NOTE: The disassembly procedure is shown on the

left half of the hydrostatic pump. The 3
procedure is the same for the right half of the
hydrostatic pump.
Figure 30-50-6
2 3
1
N-19571
1
Remove the pump coupler (Item 1) [Figure 30-50-8].
Remove the two O-rings (Item 3) [Figure 30-50-8].

1

P-43858 Figure 30-50-9
Remove the four bolts (Item 1) [Figure 30-50-6]. 1 1
Figure 30-50-7
N-19550
Remove the four bolts (Item 1) [Figure 30-50-9] from the

pump housing end cap.
N-19570
Separate the two hydrostatic pumps [Figure 30-50-7].

2
1
Figure 30-50-10
N-17194
2
Remove the valve plate locating pin (Item 1) [Figure 30-
N-19551 50-12].
Remove the needle bearing (Item 2) [Figure 30-50-12].

Remove the end cap (Item 1) [Figure 30-50-10].
Figure 30-50-13

Remove the gasket (Item 2) [Figure 30-50-10].
Figure 30-50-11
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-50-13]

from the pump.
Remove the valve plate (Item 1) [Figure 30-50-11].

2 2
Figure 30-50-14
1
2 1
2
2
N-17200
Remove the washer (Item 1) [Figure 30-50-16].

N-17198
Remove the four pins (Item 2) [Figure 30-50-16] from the
cylinder block.
Remove the piston retainer (Item 1) and pistons [Figure
30-50-14] from the cylinder block. Figure 30-50-17

Remove the pistons (Item 2) [Figure 30-50-14] from the
retainer.
Figure 30-50-15
1 1
N-17201
Remove the thrust plate (Item 1) [Figure 30-50-17] from

the pump housing.
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-50-

15] from the cylinder block.

Figure 30-50-18
1
1
2
N-17240
3
N-17481 the pump housing. Remove the drive shaft and bearing
from the housing.
Turn the pump over and remove the drive shaft key (Item Figure 30-50-21
1), snap ring (Item 2) and the washer (Item 3) [Figure 30-

50-18].
Figure 30-50-19
N-17241

N-17239 the drive shaft. Remove the bearing.
Remove the seal (Item 1) [Figure 30-50-19] from the

pump housing.

Figure 30-50-22
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-50-24] from the pump housing.
Figure 30-50-25
Remove the snap ring (Item 1) [Figure 30-50-22].

Figure 30-50-23
1
1
1 1 N-17246
N-17243 Remove the bolts (Item 1) from the pump housing.

Remove the linkage bracket (Item 2) [Figure 30-50-25].

trunnion cover. Remove the cover.

Figure 30-50-26
1 N-17248
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17247 [Figure 30-50-28] from the pump housing.
Figure 30-50-29
Remove the trunnion cover (Item 1) [Figure 30-50-26].

Figure 30-50-27
1
N-17251
N-17250 Remove the bearing (Item 1) [Figure 30-50-29].
Remove the seal (Item 1) [Figure 30-50-27].

Figure 30-50-30
N-17252
Tilt the swash plate (Item 1) [Figure 30-50-30] and

remove the swash plate and bearing from the pump

housing.
Figure 30-50-31
N-17253
Remove the bearing (Item 1) [Figure 30-50-31] from the

swash plate.

Assembly

Inspect all parts for wear or damage. Replace any worn
or damaged parts.
Figure 30-50-32 1
N-17249
Install the bearing (Item 1) [Figure 30-50-34] on the

swash plate shaft.
Figure 30-50-35
N-17253

Install the bearing (Item 1) [Figure 30-50-32] on the
swash plate.
Figure 30-50-33
2
N-17248
Install the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-35].
N-17252
Install the swash plate and bearing into the pump


Assembly (Cont’d)
Figure 30-50-36
1 N-17246
Install the linkage bracket (Item 1) [Figure 30-50-38] and

N-17250 the bolts. Tighten to 24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-50-39
Install the seal (Item 1) [Figure 30-50-36] in the trunnion
cover.

Figure 30-50-37
1 N-17244
Install the bearing race (Item 1) and O-ring (Item 2)

N-17247 [Figure 30-50-39].
Install the trunnion cover (Item 1) [Figure 30-50-37].

Assembly (Cont’d)
Figure 30-50-40
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-50-

N-17243 42] on the shaft.
Figure 30-50-43
Align the marks on the trunnion cover and pump housing.
Install the bolts (Item 1) [Figure 30-50-40] and tighten to

24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-50-41
1
1
N-17240
Install the shaft into the pump housing. Install the snap
ring (Item 1) [Figure 30-50-43].
N-17242
Install the snap ring (Item 1) [Figure 30-50-41] on the

shaft.

Assembly (Cont’d)
1
1
Figure 30-50-44
1
1 3
1 2
N-17200
Install the four pins (Item 1) [Figure 30-50-46] into the

N-17239 cylinder block.
Install the washer (Item 2) into the retainer (Item 3)

Install the seal (Item 1) [Figure 30-50-44] into the pump [Figure 30-50-46].
housing.

Figure 30-50-47
Figure 30-50-45
1
3
2
1
N-17199
N-17481
Install the ball guide and washer (Item 1) [Figure 30-50-

Install the washer (Item 1), snap ring (Item 2) and the 47] onto the pins.
drive shaft key (Item 3) [Figure 30-50-45].

Assembly (Cont’d)
1
2
Figure 30-50-48
N-17194
1 Install the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-50].
Figure 30-50-51
Install the pistons (Item 1) into the piston retainer. Install
the piston / piston retainer (Item 2) [Figure 30-50-48] into

the cylinder bores.
Figure 30-50-49
2
1
N-17196
The bearing cage (Item 1) [Figure 30-50-51] must

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
N-17197 surface of the end cap.
The valve plate locating spring pin (Item 2) [Figure 30-

Install the cylinder block (Item 1) [Figure 30-50-49] and 50-51] must protrude from 4,19 - 4,70 mm (0.165 - 0.185
piston assembly over the shaft and into the housing. in) from the surface of the end cap.

Assembly (Cont’d)
1 1
Figure 30-50-52
1
2
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-54] to 47 - 61
Coat the backside of the valve plate with assembly lube. Figure 30-50-55
Install the valve plate (Item 1) [Figure 30-50-52] onto the

end cap.
The notch (Item 2) [Figure 30-50-52] on the valve plate

must engage the locating pin.
Figure 30-50-53 1
1
1
N-19571
1
Install the O-rings (Item 1) [Figure 30-50-55].
Install the pump coupler (Item 2) [Figure 30-50-55].
N-19551
Install the gasket (Item 1) [Figure 30-50-53] on the end

cap.

Assembly (Cont’d)
Figure 30-50-56
N-19570
Align the pump coupler (Item 1) with the shaft (Item 2)

[Figure 30-50-56] and install the left pump on the right

pump.
Figure 30-50-57
1
P-43858
Install the four bolts (Item 1) [Figure 30-50-57]. Tighten

to 47 - 61 N•m (35 - 45 ft-lb) torque.

HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The end caps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1

P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
WARNING

of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-51-2 I-2003-0888
Figure 30-51-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-7
Hydraulic Controller Removal And Installation

(Cont'd)
1
Figure 30-51-5
1 2
3 P-90210
2
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4
N•m (7.7 ft-lb) torque. Ensure bolts are tightened to
P-90210 specifications.
Remove the controller (Item 1) [Figure 30-51-5] from the NOTE: When a hydraulic controller is replaced, the
pump. hydrostatic pumps must be calibrated. (See

Hydraulic Controller Neutral Adjustment on
Remove the controller gaskets (Item 2) [Figure 30-51-5] Page 30-51-26.)
from the pump.
Figure 30-51-8
Installation:
Figure 30-51-6
2 2
P-64978
1
With the engine running and the loader on jack stands:
P-90209
Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
NOTE: Do NOT remove the three screens (Item 2)
2 turns. Leave the screw loose until fluid comes dripping
[Figure 30-51-6] they will be damaged during
out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
removal and must be replaced.
torque.
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in
Repeat the bleed procedure for all the solenoids.
the center of the servo piston groove (Item 1) [Figure 30-
51-6].
Use a small amount of grease on a new gasket and

install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].

HYDROSTATIC PUMP (SJC) (CONT’D) Figure 30-51-10

Page 70-10-7.)

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-51-10] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-51-9 Remove the pump pulley from the pump drive shaft.
Figure 30-51-11
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-9] on the
hydrostatic pump drive shaft.
Remove the two mounting bolts and nuts (Item 1) [Figure
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 30-51-11].
ft-lb) torque
Installation: Tighten the mounting bolts and nuts to 88 -

HYDROSTATIC PUMP (SJC) (CONT’D)
Figure 30-51-12
P-90224

12] at the hydraulic pump mounting bracket.

Installation: Tighten mounting bolt to 125 - 135 N•m (90
- 100 ft-lb).

BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-51-6.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-51-13

1
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-51-13].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic fluid until the hydraulic fluid flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

1. O-ring
2. Bolt 3 1
3. End Housing 4 1
4. Right Rotating Assembly
5. Timing Pin 6
6. Bearing 5
7. Spacer/Coupler 7
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover
13. Hydraulic Controller 9
14. High Pressure Relief 1 8 2
15. Case Housing 1
16. Plug 10
17. Dowel Pin 11
18. Charge Pressure Relief
19. Left Servo 2
20. Right Servo 12
21. Left Rotating Assembly 16 2
22. End Housing 2 14
17

16
15 13
13
18 20
14
22 19
5
2 6
21
8 1
1
9
10 1
11
12 2
2 P-90240

High Pressure Relief And Bypass Valve
Figure 30-51-14
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-16]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-16] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-14] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-14].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 35000 kPa (350 bar)
Figure 30-51-15 (5075 psi).
4
3
2 1
P-64436
Inspect the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-15], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-15]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-51-15] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-51-17 1 4 5
3 6
2
1 P-64435
Inspect the O-ring (Item 1) [Figure 30-51-18].

P-64431
Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-51-18] for damage or foreign material. Ensure
The charge relief valve (Item 1) [Figure 30-51-17] is the poppet moves freely in it’s bore.
located on the back of the hydrostatic pump.

Inspect the sealing ring (Item 4) [Figure 30-51-18] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Assembly: Tighten charge relief valve to 70 N•m (52 ft-
lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-51-18].
NOTE: 1,0 mm shim (Item 6) [Figure 30-51-18] = 299,9

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.

HYDROSTATIC PUMP (SJC) (CONT’D) Note the connectors facing each other.
Disassembly And Assembly Figure 30-51-21

Page 70-10-7.)
1
Remove the hydrostatic pump. (See Removal And
Figure 30-51-19
2
P-90228
1 1 Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-51-21].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-51-

19]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-20
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-20].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-20] from both sides.
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT’D) Right End Housing
Disassembly And Assembly (Cont'd) Figure 30-51-24
Figure 30-51-22
3
1
1
1
P-64445
P-90217
Left End Housing
Assembly: Note the slotted portion (Item 1) of the Figure 30-51-25

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-51- 3 1
22].
Figure 30-51-23
1
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-51-24] and [Figure 30-51-25].
Assembly: Alternately, tighten mount bolts to 130 N•m

Inspect and replace the O-ring (Item 1) [Figure 30-51- (96 ft-lb) torque.
23].

Figure 30-51-26
P-64466
Ensure servo follower (Item 2) [Figure 30-51-27] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-28].
Pull the end housings from the case housing [Figure 30- Figure 30-51-29
51-26].

Figure 30-51-27
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-51-29] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-27].

Figure 30-51-30
RIGHT SIDE
P-64454
Figure 30-51-31

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-30] and

[Figure 30-51-31] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-30] and [Figure 30-51-31] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-51-32
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-51-35
P-64455
LEFT SIDE
Figure 30-51-33 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64502 32] and [Figure 30-51-33] in the case housing with the
notch (Item 1) [Figure 30-51-34] and [Figure 30-51-35]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-51-32] and [Figure 30-51-33] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-34] and [Figure
30-51-35].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

Figure 30-51-36
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-38].

B25012
Figure 30-51-39
Right Side Rotating Group [Figure 30-51-36].

Figure 30-51-37
1
P-64475

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-37].


1
Figure 30-51-40
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 42].
Figure 30-51-43
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-51-40] in the slippers, are not
1

plugged.
Figure 30-51-41
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-43]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-41].


3
Figure 30-51-44
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-51-46].
Remove the swash plate from the end cap housing (Item
Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-46].
1) [Figure 30-51-44].

Remove the slide ring (Item 3) [Figure 30-51-46], ensure
Figure 30-51-45 it pivots freely.
Figure 30-51-47
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-45] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in end cap housing (Item 2) [Figure 30-51-47].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-51-45] are not bent or damaged.

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-48
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 50].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-50] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-48]. the outside of the end cap housing

Figure 30-51-49 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-51-50].

2
Figure 30-51-51
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-49].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-51-49] on swash plate.
Replace O-ring (Item 1) [Figure 30-51-51].
Inspect wear surfaces (Item 2) [Figure 30-51-51] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-51-52
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-51-54] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-51-55
Figure 30-51-53
RIGHT SIDE

1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-52] and a rubber mallet.
[Figure 30-51-53] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-55] and remove
bearing.

Figure 30-51-56
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

51-58].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-51-59

B25013
Servo Piston Assembly [Figure 30-51-56].

1
The Servo Piston Assembly [Figure 30-51-56] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-57
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-59].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-57].

Figure 30-51-60
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-51-62] is parallel to the drive shaft
centerline. Measure with a straight-edge [Figure 30-51-
61].
Slide the servo piston assembly out of the bore. [Figure
30-51-60]. Figure 30-51-63

Figure 30-51-61
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-51-63] from the pump housing.

Figure 30-51-64 1
1
2
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-51-66] from

P-64494 the servo piston.

Each servo has a pair of bushings (Item 1), O-rings (Item cover.
2), and square-cut seals (Item 3) [Figure 30-51-64].

Figure 30-51-67
Figure 30-51-65
1
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-51-67] from the

Remove the locknut (Item 1) [Figure 30-51-65] from the servo piston.
servo piston.
Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT’D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-68 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
WARNING
P-64498
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-68] from the servo piston. Raise the lift arms, and install an approved lift arm

Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-51-68]
Figure 30-51-69 TOOL KIT - MEL1563 on Page 10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
2 find an accessible connector to disconnect.
1 If equipped disconnect the speed sensors located on the

top of the drive motors. This prevents uncommanded
wheel movement error codes from occurring during
adjustments.
P-64502
WARNING
Bearings (Item 1) [Figure 30-51-69] in case housing are
replaced by using a press and bearing driver. Hydraulic fluid escaping under pressure can have
Inspect center coupler (Item 2) [Figure 30-51-69]. penetrating the skin. This can cause serious injury
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-70
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-72] from the

P-64973 MA ports on the bottom of the pump, and install 51711
kPa (517,1 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-70] Figure 30-51-73

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-51-71
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-73]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51711 kPa (517,1
bar) (7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-51-71] from the pump mechanical neutral setting.
MB ports on the front side of the pump, and install 51711
kPa (517,1 bar) (7500 psi) pressure gauges.

Figure 30-51-74
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-76]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment locknut (Item 1)
[Figure 30-51-74]. Figure 30-51-77

Start the loader using the Remote Start Tool and run at
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-75
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT’D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-78 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
2 NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the locknut (Item 2) [Figure 30-51-78] to 30 N•m

(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-2.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-51- Connect the Remote Start Tool. (See REMOTE START
26.) TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)

1
Figure 30-51-79
P-64975
1 Install 3447 kPa (34,5 bar) (500 psi) pressure gauges

P-90239 (Item 1) [Figure 30-51-81] in the X1 and X2 ports
pertaining to the side of the hydrostatic pump you are
adjusting.
Disconnect the hydraulic controller connectors (Item 1)
[Figure 30-51-79] from the loader wiring harness for the Figure 30-51-82

hydraulic controller you are adjusting.
Figure 30-51-80
1 1
P-90236
P-90226 Loosen the locking screw (Item 1) [Figure 30-51-82].
Start the loader using the Remote Start Tool and run at
Remove the X1 plug (Item 1) and X2 plug (Item 2) an idle.
[Figure 30-51-80] pertaining to the side of the
hydrostatic pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Figure 30-51-83
P-90236

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-86

in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-84
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-51-86] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-84] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-150-1.)

HYDROSTATIC PUMP (SJC) (S/N A3NL13651 &
ABOVE)
Description
The tandem closed circuit piston pumps convert input

torque to hydraulic power. The tandem design powers
two independent drive trains for dual-path propel
applications. The two-piece input shaft transmits
rotational force to the cylinder block. A splined coupling
connects the front and rear shafts. Bearings at the front,
rear, and center of the pump support the shaft. Splines
connect each shaft to a cylinder block. A lip-seal at the
front end of the pump prevents leakage where the shaft
exits the pump housing. The spinning cylinder block
contains nine reciprocating pistons. Each piston has a
brass slipper connected at one end by a ball joint. The
block spring, ball guide, and slipper retainer hold the
slippers to the swashplate. The reciprocating movement
of the pistons occurs as the slippers slide against the
inclined swashplates during rotation. Via the valve plates,
one half of each cylinder block is connected to port A or
C and the other half to port B or D (See Port Locations
And Gauge Installation on Page 30-52-2.)

Front and rear sections have independent porting in the
center section. As each piston cycles in and out of its
bore, fluid is drawn from one port and displaced to the
other thereby imparting hydraulic power into the system.
A small amount of fluid is allowed to flow from the
cylinder block/valve plate and slipper/swashplate
interfaces for lubrication and cooling. Case drain ports
return this fluid to the reservoir. An external charge pump
(not shown) provides clean, cool fluid to makeup this
lubricating flow and to maintain minimum loop pressure.
The angle of each swashplate controls the volume and

direction of fluid displaced into the system. The servo
pistons control the angle of the swashplates. Each pump
control, by varying the pressure at the servo pistons,
controls each piston’s position. An electric signal to the
control coils transmits the command from the operator to
the pump. Mechanical feedback of the swashplate
position to the control through the feedback pins allows
for very precise displacement control and increases
overall system stability. Non-feedback control options do
not use the mechanical feedback link.

HYDROSTATIC PUMP (SJC) (S/N A3NL13651 & ABOVE) (CONT’D)
Port Locations And Gauge Installation
Figure 30-52-1

NA13920
PORT GAUGE SIZE,

PORT SIZE READING
IDENTIFIER BAR (PSI)
L1, L2, L3 1 1/16 - 12 Case Drain 10 BAR (100 PSI)
MA, MB, MC, MD 9/16 - 18 System 600 BAR (10,000 PSI)

Pressure
M3 9/16 - 18 Charge 50 BAR (1000 PSI)

Pressure
M4, M5 716 - 20 Servo Pressure 50 BAR (1000 PSI)
AM3 9/16 - 18 Alternate 50 BAR (1000 PSI)

Charge PSI
A, B, C, D 1 5/16 - 12 System Ports -
E 7/8 - 14 Charge Filtration -
M14 7/16 - 20 Case Gauge 10 BAR (100 PSI)

Port

HYDROSTATIC PUMP (SJC)  Figure 30-52-3

Page 70-10-7.)

1
Remove the Drive Belt. (See Belt Replacement on Page
30-60-2.)
P-90222
IMPORTANT Use a puller (Item 1) [Figure 30-52-3] to loosen the

pulley from the pump drive shaft.
clean the work area before disassembly and keep all NOTE: DO NOT strike puller or pump shaft with a
parts clean. Always use caps and plugs on hoses, hammer. Internal pump damage may result.

damage the system. Remove the nut and washer from the pump drive shaft.
I-2003-0888
Remove the pump pulley from the pump drive shaft.

Figure 30-52-2
Figure 30-52-4
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-52-2] on the

hydrostatic pump drive shaft. Remove the two mounting bolts and nuts (Item 1) [Figure
30-52-4].
ft-lb) torque Installation: Tighten the mounting bolts and nuts to 88 -

HYDROSTATIC PUMP (SJC) 
Figure 30-52-5
P114386
Remove the mounting bolt (Item 1) [Figure 30-52-5] at

the hydraulic pump mounting bracket.

Installation: BEFORE STARTUP: Fill the hydrostatic

pump with hydraulic fluid. This will remove trapped air in
the hydrostatic pumps before startup. (See Hydrostatic
Pump Startup on Page 30-52-5.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydraulic fluid.
1
This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
P-100685
Filling the hydrostatic pump is best done by removing a
plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the Figure 30-52-8
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-52-6
1

2
P114478
1 Attach a push button starter switch (MEL1712) (Item 1)

P133853 [Figure 30-52-7] to the starter terminal S (Item 1) and
NOTE: This procedure is necessary to prevent a dry Crank the engine for 15 seconds, then stop for at least 30
startup of the hydraulic or hydrostatic pump. seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
BEFORE STARTUP: Fill the housing by adding hydraulic
fluid to the upper case drain port (Item 1). If the controls Start the loader from the operator’s cab and run the
are installed on top, open the plugs (Item 2) [Figure 30- engine at low idle for 1 - 2 minutes without operating the
52-6] in the top of the housing to assist in air bleed. hydraulics.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque. After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Fill the system with hydraulic fluid. (See Removing And arms several times or until air is purged from the system.
Replacing Hydraulic Fluid on Page 10-120-2.) Avoid running over the relief valve setting at the end
of cylinder stroke.


HYDROSTATIC PUMP (SJC) (S/N A3NL13651 & ABOVE) (CONT'D)
9 3
14 15 4
5 7 6
16
10 8
12 1
17
3 11
18 13 1 2
3 5
16
19 16
20 15
11 16 14
3
13
22
21
14
24 11

28 27
16 25
23
29
16
29
26
11
16
26 12
21
24
9 16
23
22
14 15 10
7 30
16 10 16 6
17 20
13 21
3 3
13 18
5
15 18 3
14 14
12 19
3
NA14930S

Parts Identification (Cont’d)
Ref. Description
1. Retainer Ring
2. Seal
3. O-ring
4. Shaft Seal
5. Bearing Race
6. Bearing
7. Washer
8. Shaft
9. Controller
10. Feedback Link
11. Dowel Pin
12. Housing
13. Servo Cylinder
14. Bolt
15. Lock Plate
16. Plug

17. Slider Block
18. Piston Ring
19. Servo Piston
20. Cylinder Piston
21. Swash Plate Bearing
22. Swash Plate
23. Gasket
24. Valve Plate
25. Coupling
26. Journal Bearing
27. Lifting Bracket
28. Charge Relief Valve
29. SCR Valve Assembly
30. Shaft

Parts Identification (Cont’d)
1. Screw 1
2. Cover
3. Bolt 8 2
4. Plug 10
5. Cap 11 5
6. Nut
6
7. Housing 3
8. Coil Nut
9
9. O-ring
10. Solenoid
4
11. Solenoid Valve 1 9
1 9
12. Gasket
2
7
9 8

3 12 11
8 5
1
10
10 6
1
9
11
4
12 11
1
10 8
NA14941S

High Pressure Relief And Bypass Valve

2
Figure 30-52-9
1 1
P133823

[Figure 30-52-11].
P133892
Inspect the valve (Item 2) [Figure 30-52-10] for damage.
There are four system check relief valves (Item 1) Inspect seats inside case housing.

[Figure 30-52-9] on the engine side of the hydrostatic
pump. Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.
Remove the valve seat plug (Item 1) [Figure 30-52-9].
Factory setting on the relief valve is 35000 kPa (350 bar)
Assembly: Tighten plug to 80 N•m (59 ft-lb) torque. (5076 psi).
Figure 30-52-10
P133824
Inspect the valve seat plug (Item 1) [Figure 30-52-10].
Remove relief valve assembly (Item 2) [Figure 30-52-10]

and ensure valve moves freely in its bore.
Inspect the conical spring (Item 3) [Figure 30-52-10] to

ensure it is not broken or flattened.

Charge Pressure Relief Valve 1

2 3
Figure 30-52-12 4
1
5
P133826
P133890 Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-52-13] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge pressure relief valve (Item 1) [Figure 30-52-

12] is located on the engine side of the hydrostatic pump. Inspect the spring (Item 4) [Figure 30-52-13].
Remove the charge pressure relief valve. NOTE: Replace the charge pressure relief valve as a
complete unit. Do not attempt to repair the
Assembly: Tighten charge pressure relief valve to 52 internal components of the valve.
N•m (38 ft-lb) torque and locking nut to 40 N•m (30 ft-lb)
torque. Factory setting on the charge pressure relief valve is
2400 kPa (24 bar) (348 psi) with fluid temperature at
50°C (120°F).
NOTE: Pressure change per turn of the adjusting

screw (Item 5) [Figure 30-52-13] is dependent
on charge flow entering pump. Clockwise
rotation increases charge pressure,
counterclockwise rotation decreases charge
pressure.

IMPORTANT 1

damage the system.
I-2003-0888
P133818
Drain the fluid from the pump.

Remove the solenoid retaining nut (Item 1) [Figure 30-
Seal all open ports and clean the pump with solvent. 52-15].
Remove the hydrostatic pump / engine assembly from Assembly: Tighten retaining nut to 5 N•m (3.7 ft-lb)
the loader. (See Engine Removal And Installation on torque.
Page 70-10-7.)

Figure 30-52-16
Remove the hydrostatic pump. (See Removal And
Figure 30-52-14
1
1
2
P133817
1
P133891
Remove the six bolts (Item 1) and remove the hydraulic

controller (Item 2) [Figure 30-52-14].
Assembly: Tighten bolts to 13,5 N•m (10 ft-lb) torque.

Figure 30-52-17
1 1
P133813
2
Remove the bolts (Item 1) and the sensor switch guard

(Item 2) [Figure 30-52-19].
P133816
Assembly: Tighten bolts to 13,5 N•m (10 ft-lb) torque.
Remove the three bolts (Item 1) and solenoid valve (Item Figure 30-52-20
2) [Figure 30-52-17].

Figure 30-52-18
2
1
1
P133801
Remove the screws (Item 1) and the sensor (Item 2)

[Figure 30-52-20].
P133815

Figure 30-52-21
2 1
3
P133849
Lightly tap on adjusting screw (Item 1) [Figure 30-52-23].
P133812 Figure 30-52-24
Remove the screws (Item 1), spacer (Item 2) and plug

(Item 3) [Figure 30-52-21].

Figure 30-52-22
1
3 2
1
P133848
Remove actuator assembly (Item 1) [Figure 30-52-24].
Figure 30-52-25
P133810
Remove the sensor magnet (Item 1),gasket (Item 2) and

adjusting screw locknut (Item 3) [Figure 30-52-22].
Assembly: Tighten locknut to 10 N•m (7 ft-lb) torque.
P133847
Remove the spool (Item 1) [Figure 30-52-25].

Figure 30-52-26
2 3
P133843
Remove the right side (Item 1) from the center block

(Item 2) [Figure 30-52-28].
P133808
NOTE: Mark the orientation and keep the valve plates
(Item 3) [Figure 30-52-28] on the same side
Inspect actuator assembly and spool [Figure 30-52-26]. that they came off. The valve plates are not

interchangeable.
Figure 30-52-27
Figure 30-52-29
1
2 1
P133844
P133842
Remove the six bolts (Item 1) [Figure 30-52-27]. (Two

bolts are not visible in the photo). Remove the housing gasket (Item 1) and swash plate
feedback pin (Item 2) [Figure 30-52-29].
Assembly: Tighten swash plate feedback pin to 25 N•m
(18 ft-lb) torque.

Figure 30-52-30
P-64476
1
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-52-32] in the slippers, are not
P133840 plugged.
Figure 30-52-33
Remove the piston assembly (Item 1) [Figure 30-52-30].

Figure 30-52-31
1
1
P-64477
P-64475 Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-52-33].

rotating block.

Figure 30-52-34
P-64474
Inspect the spherical washer for scoring and wear (Item

1) [Figure 30-52-36].
P-64471
Figure 30-52-37
Remove the spherical washer (Item 1) [Figure 30-52-

34].
1
Figure 30-52-35
2
1
3
1
P-64478
Inspect the back surface of the rotating block (Item 1)

[Figure 30-52-37] where the valve plate seals. Ensure
P-64472 there is no scratches or scoring.
Visually ensure spring (Item 2) and c-clip (Item 3)

Inspect the pins (Item 1) [Figure 30-52-35]. They should [Figure 30-52-37] are not bent or damaged.
be the same length. Do not remove.

Figure 30-52-38
2 2
1 1
1
P133837
Remove the seals (Item 1) and inspect the bronze slider

block (Item 2) [Figure 30-52-40].
P133839
Figure 30-52-41
Remove the locking plate bolts (Item 1) and lock plate.

Mark servo adjusters (Item 2) [Figure 30-52-38] and

remove from housing.
Assembly: Tighten the bolts to 14,5 N•m (11 ft-lb)

torque.
Figure 30-52-39
1
1
P133836
Remove the swash plate (Item 1) [Figure 30-52-41] from

the pump housing.
P133838
Remove the servo piston (Item 1) [Figure 30-52-39] from

housing.

Figure 30-52-42
2
1
2 P133833
1
The drive shaft (Item 1) [Figure 30-52-44] can be tapped

out of the end housing with a rubber mallet.
P133835
for excessive wear.
Inspect the swash plate (Item 1) and bearings (Item 2)

[Figure 30-52-42] for wear or damage. Inspect bearing (Item 2) [Figure 30-52-44] for wear or
damage.
Figure 30-52-43
Figure 30-52-45
P133834
P133832
Remove the drive shaft and bearing assembly (Item 1)

[Figure 30-52-43]. Inspect the bearing seats (Item 1) [Figure 30-52-45] in
the housing.

Figure 30-52-46
1
1
P133829
Remove the bushing (Item 1) and fitting (Item 2) [Figure

30-52-48] from the housing (Both sides).
P133831
Figure 30-52-49
Remove the valve plate (Item 1) [Figure 30-52-46] from

the center housing.
Figure 30-52-47 3 1
1 P133828
Remove the three plugs (Item 1), bolt (Item 2) and lifting
bracket (Item 3) [Figure 30-52-49].
P133830
Assembly: Tighten the plugs to 45 N•m (33 ft-lb) torque.
Remove the coupler (Item 1) [Figure 30-52-47] from the

housing.

for excessive wear.

Figure 30-52-50
1
1
P133822
P133827 Assembly: Tighten the plug to 48 N•m (35 ft-lb) torque.
Left side swash plate assembly is identical to right side

Remove the charge pressure relief valve (Item 1) [Figure except the input shaft and bearing procedure.

30-52-50].
NOTE: There is a earlier and later seal assembly for
Assembly: Tighten charge pressure relief valve to 52 the input shaft on the H1 hydrostatic pump.
N•m (38 ft-lb) torque and locking nut to 40 N•m (30 ft-lb) The procedure for both seals are shown.
torque.
Earlier Models
Figure 30-52-51
Figure 30-52-53
1 1
1
P133825
P133820
Remove the four HPRV valves (Item 1) [Figure 30-52-

51]. Remove snap ring (Item 1) and input shaft assembly
(Item 2) [Figure 30-52-53].
Assembly: Tighten the HPRV valves to 80 N•m (60 ft-lb)
torque.

Figure 30-52-54
P134179
Remove the seal (Item 1) [Figure 30-52-56].
P133819 Figure 30-52-57

and bearing for excessive wear [Figure 30-52-54].

Later Models
Figure 30-52-55
P134180
1
Remove the snap ring (Item 1) [Figure 30-52-54].
Figure 30-52-58
P134178
Remove snap ring (Item 1) [Figure 30-52-53].
P134181
Remove the input shaft and bearing assembly (Item 1)

[Figure 30-52-58].

(S/N A3NL13651 AND ABOVE) (CONT'D)

3
Figure 30-52-59 2 4
P134177
2
The input shaft assembly [Figure 30-52-61] consists of
the following components:
P134182
1. Input Shaft
Remove the snap ring (Item 1) and bearing (Item 2) 2. Bearing

[Figure 30-52-59].
3. Snap Rings
Figure 30-52-60
4. Seal
1 2
P134183
Inspect surfaces for scratches and input shaft splines

(Item 1). Inspect bearing (Item 2) [Figure 30-52-60] for
wear or damage.

HYDROSTATIC PUMP (SJC)  Mechanical neutral is set with the pump running at 1800
(S/N A3NL13651 & ABOVE) (CONT'D) (rpm). To set neutral, you must stroke the pump in each
direction. You can do this with a small movement of the
Mechanical Neutral Adjustment eccentric screw on EDC controls. If you perform this
adjustment with the pump installed in a machine, safely
The mechanical neutral adjustment sets the position of elevate the wheels or disconnect the mechanism to allow
the servo piston and pump swash plate relative to the safe operation during adjustment.
hydraulic controller. This procedure should be followed if
the hydrostatic pump has been disassembled for This procedure details setting neutral for the entire pump,
servicing the servo piston and the setting has been one side at a time. The procedure is the same for each
disrupted. side of each pump so you will need to repeat it four times
to set mechanical neutral for both the front and rear
Place the loader on jackstands. (See Procedure on Page sections. Alternate M4/M5 and MA/MB to zero out
10-10-1.) forward and reverse directions of the front unit, then
move the gauges to M4/M5 of the rear unit and MC/MD
(system gauge ports for the rear unit). Refer to the
WARNING drawing to identify all ports (See Port Locations And

Gauge Installation on Page 30-52-2.). The front and rear
sections are basically mirror images of each other. The
Put jackstands under the front axles and rear corners control solenoids C1 and C2 are marked on each control.
of the frame before running the engine for service. While performing this adjustment, you monitor the
Failure to use jackstands can allow the machine to following pressures:
W-2017-0286 1. Servo pressure at M4 and M5.

2. System pressure at MA and MB or MC and MD.
Raise the lift arms, and install an approved lift arm
Pump setup
1. Attach a 50 bar [1000 psi] gauge to each servo
pressure port M4 and M5.
Connect the remote start tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 2. Attach a 600 bar [10 000 psi] gauge to each system
REMOTE START TOOL (SERVICE TOOL) KIT - pressure port (MA and MB for front pump, MC and MD
7217666 on Page 10-61-1.) for rear pump).
Disconnect the swash plate sensors in the electrical 3. Remove servo cylinder locking screws (E350) and
harness. This prevents unwanted swash plate movement plates (E300) from both sides of the pump.
error codes from occurring during adjustments.
Disconnecting the sensors does not have to be done
4. Disconnect the control solenoids from the vehicle
directly at the sensor, follow the harness back to find an
wiring harness.
accessible connector to disconnect.
5. If using a PWM signal to set mechanical neutral,
connect the control solenoids C1 and C2 to the signal
source. Ensure the source supplies no current to the
WARNING solenoids until required in the following procedure.

immediately.
W-2145-0290

Servo Adjustment
1. Run engine at 1800 (rpm).
2. If using a PWM signal, ensure the signal is off. Check

the servo pressure gauges. Ensure the differential
between M4 and M5 is less than 2.5 bar [36 psi].
3. Using a 3/4 in deep socket, loosen both servo

cylinders 2 - 3 turns. This step ensures the servo
cylinders have no contact with the servo piston.
4. Stroke the pump by turning the control eccentric

screw (or supplying current to solenoid C1) until the
servo pressure at port M4 is 1 - 2 bar [14 – 29 psi]
greater than at port M5 and the system pressure
gauges indicate displacement. Pressure should be
greater at port MA for clockwise rotation, or MB for
counterclockwise rotation. This also indicates the

servo piston is in contact with the servo cylinder
onside M5.
5. Maintain servo pressure differential between 1 - 2 bar

[14 - 29 psi] during this step. Slowly thread the servo
cylinder on the M5 side in until the system pressure
differential starts to decrease. Continue turning the
servo cylinder in until the system delta pressure
results in no machine movement. System delta
pressure (ports MA to MB or MC to MD) between 3 -
4 bar typically does not cause machine movement. If
service of a pump is not performed on the machine,
validation of machine movement must be checked
upon machine startup.
6. To complete setting neutral, repeat steps 1 - 5 but

stroke the pump in the opposite direction by turning
the eccentric screw in the opposite direction, or by
supplying current to solenoid C2. Reverse gauge
locations (M4 for M5, MB for MA etc.) from those
stated above since the pump is now stroking the other
direction.
7. Set neutral for the rear pump by repeating steps 1 - 6

on the rear pump. Remember that the rear pump is a
mirror image of the front pump and therefore the
locations of the servo gauge ports (M4/M5) and the
control solenoids (C1/C2) are opposite.
8. Remove all gauges and replace gauge port plugs.

Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment aligns the

pump swash plate and the control spool so that a zero
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are 2 1
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.

P133892
10-10-1.)
Install a 50 bar [1000 psi] gauge in each of the two servo

gauge ports (M4 (Item 1) and M5 Item 2) [Figure 30-52-
WARNING 62]. For the port locations (See Port Locations And
Gauge Installation on Page 30-52-2.) Disconnect the
external control input (electrical connections) from the
control.

Start the loader using the remote start tool and run at
W-2017-0286
idle.
Figure 30-52-63
procedure:
MEL1355-2 - Pressure gauge 6895 kPa (68,9 bar) 

(1000 psi)
MEL1563 or 7217666 Remote Start Tool. 2
Raise the lift arms, and install an approved lift arm

1
Connect the remote start tool. (See REMOTE START

REMOTE START TOOL (SERVICE TOOL) KIT - P133813
7217666 on Page 10-61-1.)
Hold the neutral adjusting screw (Item 1) stationary while

loosening the locknut (Item 2) [Figure 30-52-63].
WARNING Observe pressure gauges. If necessary, turn adjusting

screw to reduce any pressure differential. Adjustment of
Hydraulic fluid escaping under pressure can have the EDC is very sensitive. Be sure to hold the hex wrench
sufficient force to enter a person’s body by steady while loosening the locknut. Total adjustment is
penetrating the skin. This can cause serious injury less than 120 degrees.
immediately.
W-2145-0290

Rotate the neutral adjusting screw clockwise until the

pressure increases on the gauge. Note the angular
position of the wrench. Then rotate the neutral adjusting
screw counterclockwise until the pressure increases by
an equal amount on the other gauge. Again note the
angular position of the wrench.
Rotate the neutral adjusting screw clockwise half the

distance between the wrench positions noted above. The
gauges should read the same pressure, indicating that
the control is in its neutral position.
Figure 30-52-64

1
P133813
Hold the neutral adjusting screw (Item 1) stationary and

tighten the locknut (Item 2) [Figure 30-52-64] to 10 N•m
(7 ft-lb) torque. Do not over torque the nut.
When the neutral position is set, stop the engine, remove

the gauges, and install the gauge port plugs. Reconnect
the external control input. A small pressure differential of
2.5 bar (36 psi) or less is acceptable. Zero differential is
usually not possible.

DRIVE BELT Adjustment
Belt Adjustment Figure 30-60-3
See the SERVICE SCHEDULE for the correct service 1


2
Figure 30-60-1
P107973
Loosen the spring loaded drive idler mounting bolt (Item

1) [Figure 30-60-3].
Push the spring loaded drive idler against the belt using a

P107971A
pry bar (Item 2). The pointer will be at the 90 degree
position (Item 3) [Figure 30-60-3] when the idler is
against the stop.
The spring loaded drive idler is located below the air
cleaner [Figure 30-60-1]. Allow the spring loaded drive idler to raise slightly so that
the idler is operating on spring tension and not against
Inspection the stop.
Figure 30-60-2 NOTE: Do not set the spring loaded drive idler
against the travel stop.
Minimum Maximum
Tighten the spring loaded drive idler mounting bolt (Item
1) [Figure 30-60-3] to 48 - 54 N•m (35 - 40 ft-lb) torque.
1 1
NA3224 NA3225
The pointer (Item 1) [Figure 30-60-2] on the spring

loaded drive idler must be maintained between the two
positions shown for correct belt tension.

DRIVE BELT (CONT’D) Figure 30-60-6
Belt Replacement
Stop the engine and open the rear door. 1
Figure 30-60-4
P107972
1 Loosen the spring loaded drive idler mounting bolt (Item

1) and allow the idler (Item 2) [Figure 30-60-6] to move
up. Remove the mounting bolt, washer, and idler
P107974
assembly.
Remove the drive belt from the hydrostatic pump pulley

Remove the drive belt shield bolt (Item 1) [Figure 30-60- and flywheel pulley. Inspect the pulleys for wear.
4].
Install new drive belt.
Figure 30-60-5
Apply Loctite® 242 to the mounting bolt. Install the spring
loaded drive idler, washer, and mounting bolt [Figure 30-
60-6].
1
Figure 30-60-7
2
2
P107970 3
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
[Figure 30-60-5] toward the back of the loader to unseat
P107973
the shield from the top and bottom drive belt shield
mounting bolts.
Push the spring loaded drive idler against the belt using a
Remove the drive belt shield (Item 2) [Figure 30-60-5]. pry bar (Item 2). The pointer will be at the 90 degree
position (Item 3) [Figure 30-60-7] when the idler is
against the stop.

DRIVE BELT (CONT’D) Figure 30-60-9
Belt Replacement (Cont’d)
Allow the spring loaded drive idler to raise slightly so that

the idler is operating on spring tension and not against
the stop.
NOTE: Do not set the spring loaded drive idler

against the travel stop.
Tighten the spring loaded drive idler mounting bolt (Item

1) [Figure 30-60-7] to 48 - 54 N•m (35 - 40 ft-lb) torque. 1
Figure 30-60-8
P107974
Top Mounting Bolt
Install the drive belt shield bolt (Item 1) [Figure 30-60-9].

1

P107207
Bottom Mounting Bolt
P107206
Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
of the loader to fully seat the shield onto the top and
bottom mounting bolts (Item 1 and 2) [Figure 30-60-8].


TWO-SPEED Figure 30-70-1
Valve Block Removal And Installation
DANGER
1
P-90328 P106954
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the four hydraulic lines (Item 1) [Figure 30-70-1]
tubeline, hose, fitting, component or a part failure from the two-speed valve block.
• Keep out of this area when lift arms are raised Figure 30-70-2
D-1009-0409

2
WARNING
1
W-2059-0598
P106955
Disconnect the wire harness connector (Item 1) [Figure

WARNING 30-70-2] from the two-speed solenoid.
Remove the two bolts (Item 2) [Figure 30-70-2] from the

Put jackstands under the front axles and rear corners valve block and remove the valve block.
W-2017-0286
Mark all hydraulic hoses for proper installation.

TWO-SPEED (CONT’D)
Valve Block Disassembly And Assembly
Figure 30-70-3
P106951
Remove the two bolts (Item 1) [Figure 30-70-3] from the

valve.

Figure 30-70-4
2 1
P106952
Use a test meter and test the solenoid (Item 1) [Figure

30-70-4] for resistance.
The resistance value for the solenoid coil can be found on

the electrical schematic.
Assembly: Always install new O-rings (Item 2) [Figure

30-70-4].

DRAIN MANIFOLD Drain Manifold Removal And Installation
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic fluid to the reservoir. IMPORTANT
damage the system.
I-2003-0888

121-2.)
Figure 30-80-1

1
2
2
2
P106953
Disconnect the wiring harness from the fluid temperature

switch (Item 1) [Figure 30-80-1].
Remove the hoses and tubelines (Item 2) [Figure 30-80-

1].


DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3


BRAKE Disc Removal And Installation
Description Raise the loader lift arms and install an approved lift arm
Figure 40-10-1
WARNING
1 W-2059-0598

30-2.)
P-85491
Disconnect and remove the engine speed control. (See
The brake is used to hold the machine in place. The
brake is operated by a switch (Item 1) [Figure 40-10-1] Remove the control panel from the loader. (See Removal

located on the front accessory panel. And Installation on Page 50-100-2.)
The brake is applied by a spring-loaded wedge that drops Remove the center chaincase cover. (See Center Cover
into two notched brake discs attached to the motor carrier Removal And Installation on Page 40-30-2.)
shafts. An electric solenoid is sent power from a relay to
pull the wedge away from the discs. A signal from the Remove the traction lock assembly.
main Bobcat controller holds the wedge away from the
discs. Figure 40-10-2
The hold signal will be interrupted and the wedge will

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid. 1
For more information on the brake. (See TRACTION

N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.

BRAKE (CONT’D) Figure 40-10-4
Disc Removal And Installation (Cont’d)
Figure 40-10-3
N-19082A
1 Figure 40-10-5
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-10-3]

and the brake disc for damage or wear and replace as

necessary. (See Inspecting on Page 60-110-3.)
N-19083A
Remove the snap ring (Item 1) [Figure 40-10-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

DRIVE COMPONENTS
Description
NA6546S Dealer Copy -- Not for Resale
The drive components consist of the chaincase, drive chains, sprockets, axle shafts, hubs, drive motor carrier and a brake.
The chaincase is partially filled with hydraulic fluid to lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT’D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

MEL1714 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)

1.)
NOTE: If the axle and bearings are being replaced,

also loosen the sprocket mounting bolt inside 1
the chaincase before lifting and blocking the P-4159
loader. (See Axle, Sprocket And Bearings
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.
Remove the tire / wheel assembly. (See Mounting on
Page 10-160-2.)

WARNING

NEVER STAND IN-LINE OF THE HUB WHEN
Remove the fluid from the chaincase. (See Removing
REMOVING A HUB FROM AN AXLE. The hub has a
And Replacing Fluid on Page 10-130-1.)
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
Figure 40-20-1
W-2186-0395
2 Remove the hub from the axle.
Figure 40-20-3
1
2
P-4157
1
Remove the bolt (Item 1) [Figure 40-20-1] and plate.
Remove two wheel studs (Item 2) [Figure 40-20-1] P-4161

across from each other.
Remove the key (Item 1) [Figure 40-20-3] from the axle.

Axle Seal Removal And Installation
Figure 40-20-4
P-4157
1
Installation: Install hub. Torque hub bolt (Item 1) [Figure

P-4181
40-20-6] to 1050 - 1119 N•m (775 - 825 ft-lb).
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end into the axle seal.

NOTE: Use care not to damage axle housing.
Remove the axle seal.
Figure 40-20-5
P-4160
Clean the seal area and inspect the shaft for wear.
Installation: Place the seal with the lip facing in [Figure

40-20-5].
Installation: Use a hammer, install the new axle seal

until the tool (MEL1714) is flush with the edge of the axle
tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT’D) Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the fluid from the chaincase. (See Removing
MEL1242 - Port-a-Power
MEL1202 - Axle Bearing Service Set Figure 40-20-7
NOTE: The procedure shown for removal and

installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the 2
same for the rear axle.
DANGER 1

P-68196
Remove the axle sprocket bolt (Item 1) and backing

P-90328 washer (Item 2) [Figure 40-20-7].
AVOID DEATH Installation: Tighten the axle sprocket bolt to 699 - 726
• Disconnecting or loosening any hydraulic N•m (515 - 535 ft-lb) torque.
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
• Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
support. Replace if damaged. Figure 40-20-8
D-1009-0409
WARNING
W-2059-0598
Raise the lift arms and install an approved lift arm P-4158A
Lift and block the loader. (See Procedure on Page 10-10- Install a Port-a-Power ram between the two sprockets
1.) [Figure 40-20-8].

DRIVE COMPONENTS (CONT’D) NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
Axle, Sprocket And Bearings Removal And the mounting surface.
Installation (Cont'd)
Figure 40-20-11
Figure 40-20-9
P-4171
P5406A
Press the splined end of the axle free from the bearing
Push the axle out until the ram is at the end of the stroke. [Figure 40-20-11].

Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)

[Figure 40-20-9].
Installation: Pack the inner and outer bearing with

grease before installing them.
Figure 40-20-10
P-4170
A bearing puller (Item 1) [Figure 40-20-10] is needed to

do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-10].


Figure 40-20-12
P4812
Use the tools provided in the MEL1202 Axle Bearing

Service Set. A slide hammer is also needed.
P-4175
Use the long driver handle (Item 1) [Figure 40-20-13]
and the bearing cup removal tool to remove the inner
Installation: Put the spline end of the axle shaft into the bearing cup.

bearing and press the bearing onto the axle.
Figure 40-20-14
NOTE: Hold the axle during installation because it
will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-12] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-12].
P5637
To remove the outer bearing, install a bearing cup

removal tool on the slide hammer.
Install the slide hammer / tool assembly behind the

bearing cup [Figure 40-20-14].


Figure 40-20-15
2
P4811
Install the installation tool (Item 1) [Figure 40-20-17] on

the threaded rod. Install the nut.
P4816
Hold the inside nut (Item 3) [Figure 40-20-16] with a
wrench and tighten the outside nut [Figure 40-20-17].
Use the slide hammer to remove the bearing cup from

the axle tube [Figure 40-20-15]. Tighten the nut until the bearing cup is seated.
Figure 40-20-16 Remove the installation tool and threaded rod.
2
1
P5468A
Use the bearing cup installation tool (Item 1) [Figure 40-

20-16] and (Item 1) [Figure 40-20-17].
Put the inner cup (Item 2) [Figure 40-20-16] in the axle

tube.
Install the long threaded rod (Item 2) [Figure 40-20-17]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-16].

DRIVE COMPONENTS (CONT’D)

Figure 40-20-18
P4813
To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-18].

DRIVE COMPONENTS (CONT’D) Remove the brake disc. (See Disc Removal And
Chain Removal And Installation
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
DANGER Figure 40-20-19
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic Front Drive
Chain
tubeline, hose, fitting, component or a part failure Rear Drive
Chain
unless supported by an approved lift arm P-68194

D-1009-0409
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
removed.
WARNING
W-2059-0598


1.)

on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)

Remove the fluid from the chaincase. (See Removing


DRIVE COMPONENTS (CONT’D)
Chain Removal And Installation (Cont’d)
The tools listed are needed for the following procedure:
MEL1269 - Chain Breaker

MEL1246 - Chain Link Press Tool
MEL1364 - Chain Link Installation Tool
Figure 40-20-20

B-13504A
Use the chain breaker MEL1269 to separate the chain.
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use the chain link installation tool MEL1364 to hold both

ends of the chain.
Secure the tool MEL1246 and place the connector link in

the tool as shown [Figure 40-20-20].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-20]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Installing on Page 10-20-2.) 2

30-2.) 3
3

on Page 50-100-2.) P-34255
Remove the front chaincase cover mounting screws

DANGER (Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are tabs (Item 3) [Figure 40-30-1] on the
side of the cover to help pry the covers off.
Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Disconnect the electrical connector (Item 3) [Figure 40-
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-2.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH

Figure 40-30-3
3
D-1009-0409
2

on Page 50-100-2.)
Figure 40-30-2 1
P-90048
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
3 30-3] from the loader.
NOTE: There are tabs (Item 3) [Figure 40-30-3] on the

P-90047 Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
screw threads to stop fluid leakage. Tighten the mounting
If loader is equipped with SJC, skip to [Figure 40-30-3]. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
1 3
30-2.) 2
DANGER 1
3
P-90056
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
P-90328 Remove chain case cover (Item 2) [Figure 40-30-4].
AVOID DEATH NOTE: There are tabs (Item 3) [Figure 40-30-4] on the

can cause lift arms to drop. Installation: Apply polyurethane sealer to mating
• Keep out of this area when lift arms are raised surfaces. Polyurethane sealant should be applied to the
unless supported by an approved lift arm screw threads to stop fluid leakage. Tighten the mounting
support. Replace if damaged. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Block Removal And Installation
on Page 30-70-1.)
Remove the drain manifold. (See Drain Manifold Removal

Disconnect the front steering linkage bars from the rear

linkage bars. (See Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.


MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1


Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-16
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-20
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-2

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
Lower the operator cab. (See Lowering on Page 10-30-
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P-90021

Remove the seat bar (Item 1) [Figure 50-10-3] from the
1
operator cab.
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Disconnect the seat bar sensor (Item 1) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P106764
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023

4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.


OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without

the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
1
Figure 50-20-1
P106764
Remove the retaining pin (Item 1), pin (Item 2), and the
gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D)
Gas Spring Bracket Disassembly And Assembly
Figure 50-20-4
1
1
P-85661
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-

20-4].
Installation: Apply thread-locker on the threads of the

gas spring rod before installing the clevis.
WARNING
AVOID INJURY
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987

OPERATOR CAB (CONT’D) Figure 50-20-7

1
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 50-20-5
2 1
P106767
1
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].
Cap and plug the hoses and expansion valve fittings with
proper A/C caps and plugs.
P100756 Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)

torque.
Unhook the four fasteners (Item 1) and remove the cover

(Item 2) [Figure 50-20-5].
Figure 50-20-6
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
1 2
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Remove the engine speed control cable from the cab.

(See Cable Removal And Installation on Page 70-20-2.)
Remove the operator cab gas spring(s). (See Gas Spring

1 Removal And Installation on Page 50-20-1.)
P106766
NOTE: Use the hoist connected to the operator cab
grab handles to lower or (raise) the operator
Disconnect the expansion / heater unit wiring harness cab when the gas spring(s) are disconnected.
(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve to

prevent coolant loss from the system.

OPERATOR CAB (CONT’D) Figure 50-20-10
Figure 50-20-8
P-85662
1
Using a strap and a hoist remove the cab from the loader
P106768 [Figure 50-20-10].
Disconnect the cab wire harness (Item 1) [Figure 50-20-

8].

Figure 50-20-9
P106769

both sides of the cab.
Installation: Tighten the bolts and nuts to 24,4 - 29,8


OPERATOR SEAT Seat Belt Removal And Installation (Retractable)
Removal And Installation Figure 50-30-2
Figure 50-30-1
P-90355
P-85776
Remove the mounting nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the seat belt.

Remove the four seat mounting nuts (Item 1) [Figure 50- Installation: Tighten the mounting nut to 73 N•m (54 ft-
30-1] and washers from the operator seat mounting lb) torque.
studs.

3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.

OPERATOR SEAT (CONT’D) Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation Figure 50-30-4

(Standard)
Figure 50-30-3
3 1
P101250
P101249 Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the bracket mounting bolts (Item 1) [Figure 50-

Remove the lower mounting bolt, washer and nut (Item 30-4].

1). Remove the upper mounting bolt and nut (Item 2)
[Figure 50-30-3]. Remove the bracket (Item 3) [Figure 50-30-3].
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting bolts to 73 N•m (54 ft-

lb) torque.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure

Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3

3.)
Remove the seat. 2
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-31-6
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.

Figure 50-31-5
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-31-9
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
31-7]. the seat back to the upright position.

Figure 50-31-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-31-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) Remove the mounting nut (Item 1) [Figure 50-31-11].

Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-31-10]. Figure 50-31-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-31-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-31-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-31-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
13].

Figure 50-31-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-31-14].


BOB-TACH (HAND LEVER) Figure 50-40-3
Description
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.

1
Figure 50-40-1
P-31402

1 both sides of the Bob-Tach pivot pin grease plug.
Figure 50-40-4

P-85554
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm [3 in]) under each side of the
Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

1
the rod end pivot pin. P-31404
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque. Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
Figure 50-40-2 [Figure 50-40-4].
P-85649

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-7
Figure 50-40-5
P-31406
1
Remove the bolt (Item 1) [Figure 50-40-7] from the Bob-
P-31405 Tach pin.
Installation: Tighten the bolt and nut to 260 N•m (192 ft-
Remove the O-ring (Item 1) [Figure 50-40-5]. lb) torque.

P-31403 P-31407
Remove the nut (Item 1) [Figure 50-40-6] from both of With a punch (Item 1) [Figure 50-40-8] and a hammer,
the Bob-Tach pivot pin bolts. drive the pivot pin out of the lift arm and Bob-Tach.

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-11
Lever And Wedge Disassembly And Assembly
Figure 50-40-9
1
2
P-85665
Remove the washer, spring (Item 1) and the lever

P-85664 assembly (Item 2) [Figure 50-40-11].
Figure 50-40-12

Figure 50-40-10
35,3 mm
(1.39 in)
P-85666
P127544 Remove the roll pin (Item 1) [Figure 50-40-12] from the
Bob-Tach wedge and spring clevis.
Installation: Tighten the lever mounting nut until the Remove the spring clevis assembly (Item 2) [Figure 50-
spring is compressed to 35,3 mm (1.39 in) [Figure 50- 40-12].
40-10].

BOB-TACH (HAND LEVER) (CONT’D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-40-14

(Cont'd)
Figure 50-40-13 4
2
1
P19287
P-85667 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Remove the bolt (Item 1) [Figure 50-40-14] and
Remove the wedge (Item 1) [Figure 50-40-13] out the replace the damaged parts as needed.

bottom of the Bob-Tach.
Assembly: Clean the threads and apply Loctite® 242 to
Always replace bent or broken wedges. the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135
Later Design
Figure 50-40-15
2
P121303
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
replace the damaged parts as needed.

the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54

BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-16
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Bob-Tach.
Remove the bushing (Item 2) [Figure 50-40-16] from the

Bob-Tach.
Figure 50-40-17
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-40-17].


BOB-TACH (POWER) Removal And Installation
Description Figure 50-41-1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm [3 in]) under each side of the
Bob-Tach [Figure 50-41-1].
IMPORTANT

Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct
installation.
Remove the hoses from the cylinder.
damage the system.
I-2003-0888
Remove the bolts (Item 2) [Figure 50-41-1], washers and
nuts.

lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402

P-85554 both sides of the Bob-Tach pivot pin grease plug.
Figure 50-41-5
Remove the bolt (Item 1) [Figure 50-41-2] and nut from

Installation: Tighten the bolt to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5].
P-85649

Figure 50-41-6
P-31406
1
Remove the bolt (Item 1) [Figure 50-41-8] from both of
P-31405 the Bob-Tach pivot pin.

Remove the O-ring (Item 1) [Figure 50-41-6]. torque.

1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22 mm (0.875 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin bolts. and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.

Lever And Wedge Disassembly And Assembly 35,3 mm

(1.39 in)
Figure 50-41-10
1 1
P127544
Installation: Tighten the lever mounting nut until the

P-85570 spring is compressed to 35,3 mm (1.39 in) [Figure 50-
41-12].
Remove the bolts (Item 1) [Figure 50-41-10], washers Figure 50-41-13

and nuts.

lb) torque.
Remove the cylinder from the lever pivots.
Figure 50-41-11
1
2
P-85665
1
Remove the washer, spring (Item 1) and the lever
assembly (Item 2) [Figure 50-41-13].
P-85664

BOB-TACH (POWER) (CONT’D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Remove the roll pin (Item 1) [Figure 50-41-14] from the replace the damaged parts as needed.

Bob-Tach wedge and spring clevis.
Remove the spring clevis assembly (Item 2) [Figure 50- the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
41-14]. N•m (90 - 100 ft-lb) torque.
Figure 50-41-15 Later Design
Figure 50-41-17
1
1
P-85667
3
2
P121303
Remove the wedge (Item 1) [Figure 50-41-15] out the
bottom of the Bob-Tach.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Always replace bent or broken wedges. or clevis (Item 4) are damaged, put the assembly in a
replace the damaged parts as needed.

the bolt (Item 1) [Figure 50-41-17], tighten to 48 - 54

BOB-TACH (POWER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Remove the Power Bob-Tach. (See Removal And

Figure 50-41-18
2 1
P-85669

Bob-Tach.
Remove the bushing (Item 2) [Figure 50-41-18] from the

Bob-Tach.
Figure 50-41-19
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0,050 in) (Item
3) [Figure 50-41-19].

LIFT ARMS Figure 50-50-3

121-2.)
1
Remove the air cleaner. (See Housing Removal And
Figure 50-50-1
P106773
2
Disconnect the electrical control harness (Item 1) [Figure

50-50-3].
Figure 50-50-4

2
1
2
P106772
Remove the bolt (Item 1) and washer. Remove the

tubelines (Item 2) [Figure 50-50-1].
1
Figure 50-50-2
P106659
2
1 Remove the bolt and nut (Item 1) [Figure 50-50-4] from

the pin on the rod end of the lift cylinder (both sides).

2 40 ft-lb) torque.
2
end of the lift cylinder (both sides).
P106771
Remove the bolt (Item 1) and washer. Remove the

tubelines (Item 2) [Figure 50-50-2].

LIFT ARMS (CONT’D) Figure 50-50-7

1
Figure 50-50-5
P106770
Remove the bolt (Item 1) and nut. Remove the pin (Item
P-85687 2) [Figure 50-50-7] from both sides.

Install a floor jack (Item 1) [Figure 50-50-5] under the 40 ft-lb) torque.
front of the lift arms, and raise the lift arms 50 - 76 mm (2

- 3 in). Remove the lift arms from the loader.
Figure 50-50-6
P-85686
Install two lift straps (Item 1) [Figure 50-50-6] on the lift

arms as shown.
NOTE: Position the lift straps as shown in [Figure 50-

50-6] to balance the lift arms for removal and
installation.

REAR GRILLE Installing
Removing Figure 50-60-2
Figure 50-60-1 1
P107953A P107279
Align the edge of the rear grille under the shield (Item 1),
P107251
insert the tabs into the slots (Right side shown) (Inset)
[Figure 50-60-2], and lower.

Lift and pull the rear grille backward to remove from the Close the rear door.
loader [Figure 50-60-1].


REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
2 2
1
P-85695
Remove the top and bottom door hinge bolts and nuts
P101519 (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the main frame harness. hinge as shown.

Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the bolts and nuts to 34 - 38 N•m
the door. (See Rear Removal And Installation on Page (25 - 28 ft-lb) torque.
60-60-2.)
Remove the door from the loader frame.
Figure 50-70-2
2
1 1
P-90584
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker Disassembly And Assembly
Striker Removal And Installation Figure 50-70-5
Figure 50-70-4
5
1
3 4
2 1
P106584
1
P-85698B
Remove the locknut (Item 1) [Figure 50-70-5].
Remove the two striker bolts (Item 1) [Figure 50-70-4]. Remove the bolt (Item 2), spacer (Item 3), and roller
(Item 4) from the bracket (Item 5) [Figure 50-70-5].

Remove the striker assembly from the loader.

REAR DOOR (TAILGATE) (CONT’D) Latch Removal And Installation
Striker Adjusting Figure 50-70-7
WARNING
AVOID INJURY OR DEATH 2
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
1
Figure 50-70-6
1 P-85699
Disconnect the spring (Item 1) [Figure 50-70-7].

the latch.

Figure 50-70-8
1
P-85698B
3
Loosen the striker assembly bolts (Item 1) [Figure 50-70-
6].
Align the striker assembly in the center of the mounting

holes. 2
1
NOTE: Tighten the top striker assembly bolt only,
until it will hold the striker assembly in the
center of the mounting slots. P-85700
Close the rear door. (This will align the striker assembly
to the correct position.) Remove the spring (Item 1) [Figure 50-70-8] from the
door handle.
Open the door.
Remove the spring (Item 2) [Figure 50-70-8] from the
Tighten both bolts (Item 1) [Figure 50-70-6] to 125 - 135 door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the
Close the rear door. door handle.

REAR DOOR (TAILGATE) (CONT’D)
Latch Removal And Installation (Cont’d)
Figure 50-70-9
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

the rear door.

FUEL TANK Later Models
Remove the engine / hydrostatic pump assembly from

1
Page 70-10-7.)
Earlier Models
Figure 50-80-1
1 1
P116356
Remove the hose (Item 1) [Figure 50-80-3] from the fuel

pump and place into a suitable container.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

50-80-3] to start the fuel siphoning from the tank.
P106962
Drain the fuel into the container.
Remove the bolts (Item 1) [Figure 50-80-1] from the Reuse, recycle, or dispose of fuel in an environmentally
access cover at the rear of the loader frame. safe manner.
Remove the access cover.
Figure 50-80-2
WARNING
explosion or fire.
1 W-2103-0508
P106964
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.

FUEL TANK (CONT’D) Figure 50-80-6
All Models 2
Figure 50-80-4
1
1
1
3
P106868
Remove the bolts (Item 1) and the bracket (Item 2)

2 [Figure 50-80-6].
P106867 Figure 50-80-7

Remove the fuel vent hose (Item 1), fuel fill hose (Item 2)
and remove the two bolts (Item 3) [Figure 50-80-4].
1
Figure 50-80-5
P106870
1 2
At the right side of the loader, remove the two main frame
bolts and nuts (Item 1) [Figure 50-80-7].
P106871 Installation: Tighten the bolts to 122 - 135 N•m (90 - 100
ft-lb) torque.
Remove the hose (Item 1) and fitting (Item 2) [Figure 50-

80-5].

FUEL TANK (CONT’D) Figure 50-80-10
All Models (Cont’d)
Figure 50-80-8
P106875
1
Remove the tank [Figure 50-80-10].
1
P106869

At the left side of the loader, remove the two main frame
bolts and nuts (Item 1) [Figure 50-80-8].
Installation: Tighten the bolts to 122 - 135 N•m (90 - 100

ft-lb) torque.
Figure 50-80-9
P106874
Remove the bolt (Item 1) [Figure 50-80-9] and tubeline

clamp.

FUEL TANK (CONT’D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-13
Figure 50-80-11
1
1
2
2
P106820
P106961
Remove the two bolts (Item 1) and remove the fuel fill
hose (Item 2) [Figure 50-80-13].
from the fuel level sender. Figure 50-80-14

NOTE: Loosen and reposition the hoses (Item 2)
[Figure 50-80-11] as needed to access the
sender.
Figure 50-80-12
1
P-85715
Remove the fuel fill screen (Item 1) [Figure 50-80-14].
P106963
Remove the fuel level sender (Item 1) [Figure 50-80-12].
Inspect the fuel level sender and replace if worn or

damaged.

CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING P-85675
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598

Figure 50-90-2
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar (Item 2) [Figure 50-90-5] from the

Remove the bolt and nut (Item 1) [Figure 50-90-3] to pivot.
disconnect the lift pedal linkage from the crossbar.

Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-7 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2
Figure 50-90-9
P-85675
Remove the bolt (Item 1) [Figure 50-90-7] and nut from

the pedal linkage.

Remove the linkage (Item 2) [Figure 50-90-7].
P-85676
Figure 50-90-8 Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
1 Figure 50-90-10
2
1
P-85675A
Remove the bolt (Item 1) [Figure 50-90-8] and nut from P-85675
the pedal linkage.
Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
Remove the linkage (Item 2) [Figure 50-90-8]. the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-90-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11

1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.

to fall and cause injury or death. Figure 50-91-2
W-2059-0598

DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.

Figure 50-91-4 P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]

from the pedal mounting bracket.
Figure 50-91-6
1
1
P-90981 2
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot.
P-85675
Repeat for other side.
Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7

1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].


CONTROL PANEL
Description
Figure 50-100-1

NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings [Figure 50-100-1].
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT’D) Figure 50-100-2
DANGER
1
P106720
P-90328
AVOID DEATH Figure 50-100-3


D-1009-0409
1
WARNING
P106718
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598 the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Two Piece Shaft
Figure 50-100-4 Remove Control Panel. (See Removal And Installation on

Page 50-100-2.)
Figure 50-100-6
2
1 1
2 2
2
P106716
Scribe a mark across the top of the steering linkage bars 1 1

P-85864
(Item 1) [Figure 50-100-4] which are connected to the

steering shaft on the control panel.
Remove the nuts (Item 1) and the steering stabilizers
Remove the four steering linkage bolts, nuts and rubber (Item 2) [Figure 50-100-6].
isolators (Item 2) [Figure 50-100-4].
Inspect and replace any damaged parts.
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage bolts to 47,5 - 54,2
Figure 50-100-5
3
3
1
2
1
4
3 3
P106717
Remove the two bolts (Item 1) and the knob (Item 2)

[Figure 50-100-5] from the lift arm bypass valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Two Piece Shaft (Cont’d) 2
Figure 50-100-7
2
2
P-85867
1
3 1 3 3
3 Remove the four bolts (Item 1) [Figure 50-100-9] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-9].

Figure 50-100-8 Figure 50-100-10
4
3
1
1
P-85861 P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2), Remove the tie straps (Item 1), the four nuts (Item 2), and
and washers (Item 3) [Figure 50-100-7] and [Figure 50- the plate (Item 3) [Figure 50-100-10].
100-8].
Remove the control handle (Item 4) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8].

CONTROL PANEL (CONT’D) One Piece Shaft
Disassembly And Assembly (Cont’d) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Two Piece Shaft (Cont’d)
Figure 50-100-13
Figure 50-100-11
1 1
2
2
1 2 1
1 1
P-85864
P-85872
Remove the nuts (Item 1) and the steering stabilizers

Remove the two bolts (Item 1) from the bellcrank (Item 2) (Item 2) [Figure 50-100-13].
[Figure 50-100-11].
Remove the bellcrank from the bracket [Figure 50-100-

11].
Figure 50-100-12
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-12] for wear and
replace as needed.
Repeat the procedure for the other control handle

assembly.


1 2
One Piece Shaft (Cont’d) 2
Figure 50-100-14
1 1
2 2
1
1
P-85867
1
3 1 3 3
3 Remove the eight bolts (Item 1) [Figure 50-100-16] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-16].

Figure 50-100-15 Figure 50-100-17
4
3
1 1
P-85861 P-85868
Remove the bolts and nuts (Item 1), steering link, (Item Remove the tie straps (Item 1), the four nuts (Item 2), and
2), and washers (Item 3) [Figure 50-100-14] and [Figure the plate (Item 3) [Figure 50-100-17] on both sides.
50-100-15].
Remove the control handles (Item 4) [Figure 50-100-17].
Installation: Verify correct orientation of components


4
One Piece Shaft (Cont’d)
Figure 50-100-18
1
1 1 P126303
2
Inspect the shaft (Item 1), bellcrank (Item 2), four
bushings (Item 3) and the two torsion bushings (Item 4)
[Figure 50-100-20] for wear and replace as needed.
P126302

Figure 50-100-19
2
2
1
1
P126301
P126310
Remove the two bolts (Item 1) from the bellcrank (Item 2)

Remove the bellcrank assembly (Item 2) [Figure 50-100-

18] and [Figure 50-100-19] from the bracket.

CONTROL PANEL (CONT’D) Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage bolts to 47,5 - 54,2
Linkage Removal And Installation N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
WARNING be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-12.)
Figure 50-100-22
W-2059-0598
WARNING

2
W-2017-0286 P-48631
Lift and block the loader. (See Procedure on Page 10-10- Remove the nut (Item 1) from the end of the centering
1.) spring shoulder bolt (Item 2) [Figure 50-100-22].
Raise the lift arms and install an approved lift arm Remove the bolt / spring assembly.
Installation: Tighten the centering spring bolt and a
Raise the operator cab. (See Raising on Page 10-30-2.) NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-100-21 Figure 50-100-23
1
2
P106716 P-48632
Scribe a mark across the top of the steering linkage bars Slide the centering plate (Item 1) [Figure 50-100-23] as
(Item 1) [Figure 50-100-21] which are connected to the shown to remove it from the hydrostatic pumps.
steering shaft on the control panel.
Remove the four steering linkage bolts and nuts (Item 2)

[Figure 50-100-21].

CONTROL PANEL (CONT’D) NOTE: The washers go between the bolts and the
centering plate.
Linkage Removal And Installation (Cont’d)
Figure 50-100-26
Figure 50-100-24
7
6 8 1
3 1 4
3
2
5
2
P-54617
P-48630
Remove the bolts and washers (Item 1) [Figure 50-100-

The centering plate assembly consists of the following 26] from the pintle.
parts: bolt (Item 1), bushing (Item 2), washer (Item 3),

spacer (Item 4), spring (Item 5), locknut (Item 6), Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
centering plate (Item 7), and guide bushings (Item 8) ft-lb) torque.
[Figure 50-100-24].
Remove the pintle arm (Item 2) from the pintle base (Item
Figure 50-100-25 3) [Figure 50-100-26].
Figure 50-100-27
2 1
2
1
1 4
3
2
2
P-48629
1
P-48624
Inspect for wear on the centering blocks (Item 1) [Figure
50-100-25].
Remove the bolt and nut (Item 1) [Figure 50-100-27].
If the centering blocks are worn, remove the bolts (Item
2) [Figure 50-100-25]. Remove the centering blocks. Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control lever (Item 4) [Figure 50-100-27] for
NOTE: If the centering blocks are worn, the blocks damage and replace as needed.
can be removed and rotated 180 degrees and
reinstalled. NOTE: The washers (Item 2) [Figure 50-100-27] are
hardened, and must be replaced with Bobcat
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 Parts.
ft-lb) torque.

CONTROL PANEL (CONT’D)
Linkage Removal And Installation (Cont’d)
Figure 50-100-28
1
P-54615
Loosen the bolt (Item 1) [Figure 50-100-28].

Remove the pintle base (Item 2) [Figure 50-100-28].
Figure 50-100-29
3
1
P-48659
Installation: Install the pintle base (Item 1) onto the

pump shaft (Item 2). The top of the pintle base must be
level with the top of the pump shaft. Tighten the bolts
(Item 3) [Figure 50-100-29] to 47,5 - 54,2 N•m (35 - 40 ft-
lb) torque.
NOTE: After installing the linkage onto the

hydrostatic pumps the linkage neutral
adjusting procedure must be performed. (See
Linkage Neutral (Adjusting) on Page 50-100-
12.)

CONTROL PANEL (CONT’D) NOTE: Anti-sieze should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-30 Figure 50-100-32
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-32].

for damage [Figure 50-100-30].
Inspect the torsion bushing (Item 4) [Figure 50-100-30] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-32] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-31 arm should be the same.
4
2
P-54626
Remove the pintle base (Item 1) [Figure 50-100-31] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) [Figure 50-100-31]
from the pintle base.
Inspect parts for wear and damage, replace as needed.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
Kit - 7022042 Remote Start Tool (Service Tool) or 1

MEL1563 Remote Start Tool.
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10- P106719
1.)
Figure 50-100-33 Loosen the bolt / nut (Item 1) [Figure 50-100-34] only
until the tension is released from the torsion bushing.
3
Figure 50-100-35

2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
100-33].
To make this tool use a locking grip C-clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-100-35].
[Figure 50-100-33] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-100-33] is torsion bushing (Item 2) [Figure 50-100-35] to
also needed. The centering block is placed as shown and turn freely between the torsion bushing and
welded to the C-clamp. the steering linkage bar.
WARNING
W-2017-0286

Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-36
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.

[Figure 50-100-36] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-37
Tighten the bolts (Item 3) [Figure 50-100-37] to 47,5 -
54,2 N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-100-36] and
[Figure 50-100-37].
1
P-48451
A modified locking grip C-clamp and steering block

shown may be used to help in aligning the centering
blocks [Figure 50-100-33].
Install the centering block (Item 1) on the inside of the

pintle cams and the C-clamp (Item 2) [Figure 50-100-37]
around both centering blocks.
Lock the C-clamp in place.

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-38
2 1
1
P-54610

counterclockwise until forward creep is seen.
Turn the adjustment screw (Item 1) [Figure 50-100-39] to

a point between forward and reverse where there is zero
P-48632 creep.

Stroke the left steering lever to forward and allow the
Loosen the left pump pintle adjustment lock bolts lever to return to neutral. Stroke the left steering lever to
(Item 1). (The right pump pintle adjustment lock bolts are reverse and allow the lever to return to neutral. Check
(Item 2) [Figure 50-100-38].) Loosen the bolts enough to that there is zero creep when the lever returns from either
allow free movement between the pintle arm and the direction, on the left side. Turn the adjustment screw (if
pintle base. necessary) until zero creep is obtained.
NOTE: If the bolts are too loose or too tight, the

neutral adjustment may be affected.
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
neutral adjustment.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-40
2 1
2 1
P-48632
Torque the left pump pintle adjustment bolts (Item 1)

[Figure 50-100-40] to 47,5 - 54,2 N•m (35 - 40 ft-lb).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment bolts (Item 2)

[Figure 50-100-40] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the tires do not

come to a complete stop, repeat the adjustment
procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-40] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and reinstall the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with preapplied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-16.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, inspect the torsion
bushings at the pump and at the bell cranks to 1
be sure the bushings are not binding or too
loose, which will affect the procedure.
WARNING
P106719
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-41] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-42

WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-42].
Preload tension in the torsion bushings must be removed The bolts must be loose enough to allow the torsion
before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-42] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-43
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-45].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-43] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-44 Figure 50-100-46
3 2
2
4
1
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the pintle base bolt
10 mm (3/8 in) thick spacer (Item 1) between the pintle (Item 1) and both of the upper pintle bolts (Item 2) are
arm cam (Item 2) and the centering block (Item 3) tightened to 48 - 54 N•m (35 - 40 ft-lb) torque. There must
[Figure 50-100-44]. be no play between the pintle arm and the square pump
shaft [Figure 50-100-46].
Verify the cam mounting nuts (Item 4) [Figure 50-100-44]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-47
P-51132
1
Remove the spacer (Item 1) [Figure 50-100-49].
P106716
Figure 50-100-50
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
47] on each steering linkage bar. 2

Figure 50-100-48
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-50].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm WARNING
is rotated to the front as far as possible [Figure 50-100-
48]. Use a locking plier, clamp the two linkage bars Put jackstands under the front axles and rear corners
together. of the frame before running the engine for service.
Installation: Tighten the nuts and bolts to 47,5 - 54,2 fall or move and cause injury or death.
N•m (35 - 40 ft-lb) torque. W-2017-0286
Inspect the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-51
P-85878
Push the control lever to full stroke and turn drift

P106719 adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in until it contacts the bellcrank.
Tighten the two bolts and nuts (Items 1) [Figure 50-100- Repeat steps on the other control lever.
51] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering

bell cranks. Drive the loader forward and check for drift.
Installation: After removal, installation and adjusting of The traditional benchmark for drift is less than 3,0 m (10
the linkage, the Back-up Alarm must be inspected. (See ft) of “drift” in 30,5 m (100 ft) of travel distance.
Inspection on Page 60-210-1.)
If the drift is excessive to the left, turn the right
Figure 50-100-52 adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive. Only move
each bolt a maximum of one turn for each test
drive. This will help prevent over-correction
1 and excessive reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.

P-85877
Reinstall the plug in the drift bolt access hole after
adjustment.

Shock Removal And Installation
Figure 50-100-54
P106721

end of the shocks connected to the steering linkages.

other end of the shocks connected to the brackets on the
control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Figure 50-101-1
Description 1
The control panel is connected to the lower main frame

and wraps around the operator seat. There are no
mechanical linkages connecting to the hydrostatic pumps
or the control valve.
WARNING
P-85879
Failure to use jackstands can allow the machine to Remove the three bolts (Item 1) [Figure 50-101-1] that
fall or move and cause injury or death. secure the controller.
W-2017-0286
Figure 50-101-2

1
1
2
1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1 3 1
• Keep out of this area when lift arms are raised P-85881
D-1009-0409 Remove the ten panel bolts (Item 1) [Figure 50-101-2].
Remove the lift arm bypass knob and rubber washer

(Item 2) [Figure 50-101-2].
WARNING Remove the control panel (Item 3) [Figure 50-101-2].

W-2059-0598



CONTROL HANDLE / LEVER Boot Removal And Installation
Description Remove the control handle / lever. (See Lever Removal

The control handles / levers are used to control the
forward and reverse travel. Figure 50-110-2
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-110-1
2
3
1
P-85883A
4
1 Remove the rubber boot (Item 1) [Figure 50-110-2].

P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1].
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate until the

lever cannot be moved either right or left when seated in
the operator’s seat.


CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Description NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
Figure 50-111-1 sensor, actuator or ACS Controller. (See Lift
And Tilt Calibration (ACS) on Page 60-150-11.)
Figure 50-111-2
1
P-21879
The control handles / levers are used to control the

P-85882
forward and reverse travel and the lift and tilt

functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts until the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector [Figure 50-111-3].

Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two screws (Item 1) [Figure 50-111-

P-21861 6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two screws (Item 1) [Figure 50-111-
7] from the handle sensor.

Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, route the switch handle wire harness
4 (Item 1) [Figure 50-111-9] and [Figure 50-111-10] for
3 proper return of the control handle to neutral and
7 minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2
P-21882 [Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-8]

can only be replaced as a complete assembly.
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber boot (Item 1) [Figure 50-111-13]

P-21879 from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the screws (Item 2) [Figure 50-111-14]
P16534 from the handle assembly.
Installation: Tighten the screws to 4 N•m (35 in-lb)

Remove the switch handle (Item 1) [Figure 50-111-12]. torque.
(See Switch Handle Removal on Page 60-120-4.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.

Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-111-17].
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate until the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-111-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A

Remove the rubber boot (Item 1) [Figure 50-111-18].

CONTROL HANDLE / LEVER (SJC) Joystick Testing
Description See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to test function.
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.

CONTROL HANDLE / LEVER (SJC) (CONT’D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-2.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890

Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the four bolts (Item 1), washer (Item 2), and

remove the right access panel (Item 3) [Figure 50-120-
Remove the four bolts, (Item 1), washer (Item 2), and 2].
remove the left access panel (Item 3) [Figure 50-120-1].


ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Figure 50-121-1
P100731
Remove the two nuts (Item 1) and remove the footrest

(Item 2) [Figure 50-121-1].

Figure 50-121-2
1 1
P100732
Remove the four bolts (Item 1), and remove the access
panel (Item 2) [Figure 50-121-2].

ACCESS PANEL (INSIDE) (SJC) (CONT'D) Figure 50-121-5
Removal And Installation (Right)

1
Figure 50-121-3
2
1
P101583
Loosen the engine speed control cable clamps (Item 1).

P101581 Pry the cable (Item 2) [Figure 50-121-5] off of the stud.
Remove the panel from the loader.

Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-121-3].

Loosen the bolt (Item 3) and remove the engine speed
control pedal (Item 4) [Figure 50-121-3].
Figure 50-121-4
1
1
2 1
P101584
Remove the bolt (Item 1) and tilt the right access panel
(Item 2) [Figure 50-121-4] towards the center of the
loader.

WINDOW (REAR)
Rear Window Identification There are two different procedures for removing the rear
window from your machine:
Figure 50-130-1
1. This window is equipped with latches [Figure 50-130-
Latches Rubber Cord 1].
2. This window is equipped with a rubber cord and tag

2 [Figure 50-130-1].
NOTE: Use these procedures to remove the rear

1 window only under emergency conditions.
Damage to machine may occur.
P-85309B P-64994D
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 50-130-2 Figure 50-130-4

P-85309A P-64994C
Turn both latches (Item 1) [Figure 50-130-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 50-130-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 50-130-3 Figure 50-130-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 50-130- Exit through the rear of the operator cab [Figure 50-130-
3]. 5].

WINDOW (REAR) (CONT’D) Figure 50-130-7

8
Figure 50-130-6 7
1
6
1
2
3
4
5
P-85704A
Inspect and replace any damaged parts.

P-85705
The items listed below refer to [Figure 50-130-7].
Remove the screw (Item 1) from the latch [Figure 50- 1. Latch
130-6].
2. Spacer

Installation: Tighten the screw to 21 - 23 N•m (180 - 200 3. Bushing
in-lb) torque.
4. O-ring
5. Washer
6. Screw
7. Rear Window
8. Seal

WINDOW (REAR) (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 50-130-8
Figure 50-130-10
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 50-130-10] up and out

[Figure 50-130-8] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
OR
Figure 50-130-9
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.
Turn both knobs (Item 1) [Figure 50-130-9]

counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.


WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].

Figure 50-131-4
Figure 50-131-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].

Tighten the nuts (Item 1) [Figure 50-131-5] to 9 - 10 N•m
(80 - 90 in-lb) torque.
NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

Figure 50-132-1
1 1 2 3
P-85819
Remove the spring (Item 1), knob (Item 2), and sleeve
(Item 3) [Figure 50-132-3] from the window assembly.
Figure 50-132-4
P-85314A

Remove the plastic cap (Item 1) [Figure 50-132-1].
Figure 50-132-2 1 1
1
1
1
1 1
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-4].
P-85821 Installation: Tighten the bolts to 9 - 10 N•m (80 - 90 in-

lb) torque.
Remove the nut (Item 1) [Figure 50-132-2]. Remove the window assembly.
Installation: Tighten the nut flush to the end of the bolt. NOTE: The window assembly can only be replaced
as a complete unit.


CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Open the cab door.
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4

1 2
P-85781A
NOTE: Later models route the washer fluid hose

differently and will not require this step.
Disconnect the wire harness (Item 1) and washer fluid

hose (Item 2) (If equipped) [Figure 50-140-1].
Figure 50-140-2
3
2
1 2
1 P-85837
Remove the bolts (Item 1) [Figure 50-140-4] and nuts

from the cab.
P-85588A P-85589A
Remove the hinges (Item 2) [Figure 50-140-4] from the
Rotate and pull the clip (Item 1) out of the gas spring cab.
socket. Pull the gas spring socket (Item 2) straight off the
ball stud fitting (Item 3) [Figure 50-140-2]. Installation: Tighten the bolts to 9,6 - 10,7 N•m (85 - 90
in-lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor
assembly (Item 2) [Figure 50-140-7].
P-85829
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].
2

Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque. Tighten the nut (Item 2) to 9 - 11 N•m 1
(80 - 97 in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), latch (Item 2), and spring (Item
3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts to 31 - 34 N•m (270 - 300

in-lb) torque.
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4 1
P106481
3
4
P-85836
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
Remove the bolt (Item 1), latch (Item 2), and spring (Item door and the cab or the striker and the latch.
3) [Figure 50-140-9].
Adjust as needed. (See Adjusting on Page 50-140-4.)

9]. Figure 50-140-12
Installation: Tighten the nuts to 31 - 34 N•m (270 - 300 CORRECT CORRECT

in-lb) torque.
Figure 50-140-10
1 1
P106482
When the striker or latch is adjusted properly there will be

2 2 no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
P106380
After verifying alignment check for proper operation. (See

Disconnect the wire harness (Item 1) [Figure 50-140- Checking Operation on Page 50-140-4.)
10].
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
2
1
P-85413F
P-85830
Sit in operator’s seat. Turn the key ON, lower the seat bar
and close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P106587
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch inspect the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST Figure 50-150-3
Description 1
The armrests are located on each side of the seat. They

are adjustable for comfort.
2
Figure 50-150-1
1 4
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness (Item 2) [Figure 50-150-3].

P-90837
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.
Adjustable armrests (Item 1) [Figure 50-150-1].
Figure 50-150-4
Slide the seat and the backrest all the way forward.
Remove the seat belt. (See Seat Belt Removal And 1

Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1
Repeat for the other side.
P-90835

2].

ARMREST (CONT’D) Figure 50-150-7
Remove the joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-1.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8

1
P-90838
2
Lift up on one edge and remove the armrest cover (Item
1) [Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts, bolts (Item 1) and the support tube
(Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts, washers (Item 1) and the armrest

shell (Item 2) [Figure 50-150-6].

ARMREST (CONT’D) Figure 50-150-11
Figure 50-150-9
3
1 1
2
2
P-90844
1
Remove the two nuts, bolts (Item 1) and the side rail
P100825 (Item 2) [Figure 50-150-11] from the armrest mount.
Repeat for the other side.

Figure 50-150-10

7 4
3
6 2
5
1 P100824
Remove the nut (Item 1), washer (Item 2) spring (Item 3)

Remove the spacer (Item 4), washer (Item 5), plastic

washer (Item 6) and the bolt (Item 7) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.


LEFT SIDE LOWER PANEL Figure 50-160-3
Remove the seat. (See Removal And Installation on

Page 50-31-1.)
Remove the 3-Point seat belt retractor (If equipped). (See

3-Point Seat Belt Removal And Installation on Page 50-
31-4.)
Raise the operator cab.

1
Figure 50-160-1
1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1 [Figure 50-160-3] from the left side lower panel.
1 Figure 50-160-4

1
P-90897 1
1
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Lower the operator cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

[Figure 50-160-4] from the left side lower panel.
P-90867
Remove the storage compartment (Item 1) (if equipped)

[Figure 50-160-2] from the left side lower panel.

LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets, anchors (Item 1) and the
screw (Item 2) [Figure 50-160-5].

Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-9
1
1 1
P-90859
Disconnect the HVAC or radio wire harnesses (Item 1)

[Figure 50-160-9] (if equipped).

LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-12
Figure 50-160-10
1
1 1
1
1
1 1
P-90866
1
P-90860 remove the speaker from the left side lower panel.
Figure 50-160-13
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.

Figure 50-160-11
1
P-90864
Remove the three screws (Item 1) [Figure 50-160-13]

P-90865 and remove the washer tank from the left side lower
panel.
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Remove the seat. (See Removal And Installation on

Page 50-31-1.) 1
Raise the operator cab. 1
Figure 50-170-1
1 1
1 P-90870
1
Remove the three plastic rivets, anchors (Item 1) and the
screw (Item 2) [Figure 50-170-3].
1
Figure 50-170-4
1

P-90897
Remove the five plastic rivets (Item 1) [Figure 50-170-1].

2
1
Lower the operator cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-5
P-90872
Pull the right side lower panel (Item 1) [Figure 50-170-5]

rear out and away from the side of the cab.

NOTE: Pull the right side lower panel away from the
side of the cab far enough to access the wire
harness.
Figure 50-170-6
P-90873
Disconnect the wire harnesses (Item 1) and the antenna

(Item 2) [Figure 50-170-6] (if equipped with radio).
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D) Figure 50-170-9
Figure 50-170-7
1
1
P-90875
Remove the nut, washer and cover (Item 1) [Figure 50-

P-90879 170-9] from the headphone jack.
Remove the headphone jack from the right side lower

Remove the plastic nut and the lock washer (Item 1) panel.
[Figure 50-170-7] from power port. Remove the power

port from the right side lower panel. Figure 50-170-10
NOTE: The lock washer must be replaced with a new

lock washer when it has been removed.
Figure 50-170-8
2 1
1
1
P-90877
1
1
P-90876

remove the speaker from the right side lower panel.
P-90881
Depress the tab (Item 1) [Figure 50-170-8] and remove

the radio from the right side lower panel.
Installation: Insert a screwdriver into the slot (Item 2)

[Figure 50-170-8] to lock the tab into place.


HEADLINER Figure 50-180-3
Remove the cab light (if equipped). (See Cab Light

Figure 50-180-1
1 1
P-90895
Remove the air duct (Item 1) [Figure 50-180-3] (if

2 equipped).
Figure 50-180-4
P-90893

Remove the two screws (Item 1) and the rear shelf (Item
2) [Figure 50-180-1] (if equipped).
1
1
NOTE: The rear shelf has two panel clips on the
bottom. Lift vertically to remove the shelf.
Installation: Tighten the screws to 2,3 N•m (20 in-lb) 1

torque. 1
Figure 50-180-2
2
P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
Installation: Route the cab light wire harness in the

1
groove on the topside of the headliner (if equipped with
HVAC).
P-90894
Remove the air duct (Item 1) [Figure 50-180-2] (if

equipped).


ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors - Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Mainframe Harness Connectors - SJC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-4

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-11
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-11
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System 
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . . . 60-90-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . . 60-90-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-5
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-100-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-120-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-7
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-10
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-11
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-120-11
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-13
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-120-13
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-132-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-132-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2

PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1


Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-2


CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C434-1 LEFT WORKLIGHT 1 2 11 T1 BATT GROUND 4
C103 TAILGATE HARNESS 8 4,10,11,13 C434-2 LEFT WORKLIGHT 2 2 11 T2 BUZZER GROUND 8
C104 ENGINE COOLANT SENSOR 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T3 FLASHER 13
C105 HYD CHARGE PRESSURE 3 7 C435-2 RIGHT WORKLIGHT 2 2 11 T6 BATT GROUND 4
C106 ENGINE SPEED SENSOR 2 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13
C107 ENGINE OIL PRESSURE 3 6 C441 TWO SPEED 2 13 T8 BATT GROUND 4
C108 HYD TEMPERATURE SENDER 2 7 C446 HYDRAULIC FAN 2 7 T13 BUZZER POWER 8
C110 ALTERNATOR 2 6 C449 LEFT JOYSTICK (CAB HARN) 4 5 T14 PRE HEATER 6
C112 HYD OIL FILTER SWITCH 2 7 C450 RIGHT JOYSTICK (CAB HARN) 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C113 ENGINE HARNESS 10 6 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C126 HORN 2 13 C480 LEFT PANEL(GRAY) 12 8 T17 LEFT REAR WORK LIGHT (+) 11
C129 CAB ACCESSORY 3 9 C482 SEATBAR SENSOR 3 9 T18 LEFT REAR WORK LIGHT (-) 11
C209 DOME LIGHT 3 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C212 POWER SOCKET 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C252 WASHER 2 9 C489 MFR ACCESSORY 2 3,4
C277 AIR RIDE SEAT 6 13 C499 PTOL 4 8 SW1 BRAKE SWITCH 8
C278 RIGHT SPEAKER 2 13 C500 RH KEY SWITCH 6 8 SW2 BEACON SWITCH 13
C279 LEFT SPEAKER 2 13 C503 RH DLX PANEL 6 5,8 SW3 HAZARD SWITCH 13
C308 BRAKE SOLENOID 2 7 C602 LEFT REAR TAIL LIGHT 2 11 SW4 HAND/FOOT, H/ISO SWITCH 9
C350 AC EVAPORATOR SWITCH 2 12 C603 RIGHT REAR TAIL LIGHT 2 11 SW5 POWER BOBTACH SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C606 POWER BOBTACH OPEN 2 13 SW6 BUCKET POSITION SWITCH 13
C404 BACKUP ALARM 2 3,10 C607 POWER BOBTACH CLOSE 2 13 SW9 TRAVEL CONTROL SWITCH 8
C405 AIR FILTER SWITCH 2 6 C610 HVAC DUCT FAN 2 12 SW10 BLOWER SWITCH 12
C406 FUEL SENDER 2 6 C611 BLOWER MOTOR 4 12 SW11 AC SWITCH 12
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C630 THERMOSTAT 3 12
C409 RIGHT HANDLE 10 10 C635 HEATER VALVE 6 12
C410 LEFT HANDLE 10 10 C667 DOOR 6 9
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C670 EXTERIOR BEACON 6 13
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C676 RADIO 6 9
C415 HIGH FLOW SOLENOID 2 7
C418 FRONT ROD 2 7 J1A GATEWAY COTROLLER 34
C419 FRONT BASE 2 7 J1B GATEWAY CONTOLLER
Dealer Copy
26
-- Not for Resale
C420 HYD LOCK 2 7 J2A AUX CONTROLLER 34
C421 TILT SPOOL LOCK 3 10 J2B AUX CONTROLLER 26
C422 LIFT SPOOL LOCK 3 10
C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C425 BRAKE SOLENOID 3 7
C426 CAN (Remote Start Tool, ACD) 7 5
C428 CAB-MFR HARN CONN (LT GRY) 14 3,4,9,13
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
SCHEMATIC INDEX WIRING SCHEMATIC
OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT POWER PAGE 3 (MANUAL MACHINE)
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT GROUND PAGE 4
BATTERY GROUND
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
CAN BUS PAGE 5 S550 (S/N A3NL11001 - A3NL11184)
ENGINE PAGE 6
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN HYDRAULICS PAGE 7 (S/N A3NM11001 - A3NM11005)
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB DISPLAY PAGE 8
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
CAB PAGE 9 (S/N AZN811001 - AZN811040)
MANUAL CONTROLS PAGE 10
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR LIGHTS PAGE 11 (S/N AZN911001 - AZN911047)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT HVAC PAGE 12
OPTIONS PAGE 13 Sheet 1 of 13
Printed In U.S.A. (PRINTED NOVEMBER 2016)

7210762 (A)
645 of 1234
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE)
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 FAN 1 RELAY FDBK A-29
Dealer Copy -- Not forBUTTON
RH RIGHT ResaleDOWN
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP A-32
A-33 SPARE ANALOG A-33
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE
HARNESS PART NUMBER

MAIN FRAME 7210554
TRACTION
STARTER
PULL
FUEL SWITCH
POWER
STD CAB 7210557
PULL
DLX CAB 7210556
DLX FUEL 7175293 Printable Version Click Here
STD FUEL 7149219
GLOW
PLUG
REAR
LIGHT
FRONT
LIGHT HVAC ENG 2403
ENG 2607
7181036
7181037
WIRING SCHEMATIC
TAILGATE DOM
WHL 2 SPD ADP
7217484
7159366
(MANUAL MACHINE)
TRK BRAKE ADP 7165061
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
Printed In U.S.A. (S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 2 of 13
7210762 (A)
646 of 1234
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
POWER
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC PAGE 12
FRC1 FUSE RELAY CENTER ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
FUSE 1 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
25 A 1240 RED/WHT SHEET 8
1300 RED 1140 RED/WHT C503 RH DLX PANEL
SHEET 12 J2B
FRC1 HVAC RELAY 1150 RED/WHT 3 C408
AUX CTRLR 1400 RED/WHT
BATTERY MEGAFUSE
FUSE 4
1180 RED/WHT 2
(BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE RED 1025 RED 25 A 1160 RED/WHT 1450 RED/WHT 1450 RED/WHT
6 1420 RED/WHT SHEET 8
2 C500 RH KEY SWITCH
1110 RED/WHT
J1B
1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
FUSE 12 SHEET 8
OPEN C479 LH PANEL
SHEET 6
STARTER
1460 RED/WHT LEGEND
1010 RED
SHEET 13
FUSE 5 C412 LEFT HANDLE HORN PARTIAL CONNECTOR
25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
SHEET 13
C408 CAB-MFR CONN (OPTIONS)
FUSE 11 1165 RED/WHT
15 A SHEET 5 CONNECTOR
1290 RED 1370 RED/WHT C426 REMOTE RUN, ACD
SHEET 9
C408 CAB-MFR CONN (ACCESSORIES)
FUSE 9
1620 RNG/WHT
30 A 1360 RED/WHT SHEET 8 WIRE BREAK
SHEET 7 C479 LH PANEL
1050 RED (TWO WIRE BREAKS
FRC1 TRACTION LOCK RELAY
FUSE 10 JOIN ONE WIRE)
SHEET 6 1940 RNG/WHT
1030 RED 30 A 1350 RED/WHT SHEET 8 SHEET #
FRC1 STARTER RELAY SHEET 6 T13 LH PANEL BUZZER
1060 RED FUSE 2 FRC1 FUEL SHUTOFF RELAY
FRC1 GLOW PLUG RELAY 1340 RED
20 A 1330 RED/WHT
SHEET 11
Dealer Copy -- Not for Resale SHEET 8
C499 RH PANEL PTOL
FRC1 FRONT LIGHT RELAY
FUSE 3 C428
1775 RNG/WHT
15 A (LT GRAY) SHEET 8
1320 RED/WHT CAB-MFR HARN CONN 2 SW1 BRAKE SWITCH
SHEET 11
FRC1 REAR LIGHT RELAY
1660 RNG/WHT 2 1660 RNG/WHT 1590 RNG/WHT
SHEET 8
1520 RNG/WHT SHEET 10 C503 RH DELUXE PANEL
FUSE 6
5A C409 RIGHT HANDLE 1950 RNG/WHT
1570 RNG/WHT 1530 RNG/WHT SHEET 10 SHEET 8
C410 LEFT HANDLE C500 RH PANEL KEY SWITCH
1560 RNG/WHT 22 J2B
FUSE 8 AUX CTRLR 1785 RNG/WHT
SHEET 9
25 A 1730 RNG/WHT SHEET 5 SW4 H/ISO SWITCH
C426 REMOTE RUN, ACD C489
1780 RNG/WHT A 1960 RNG/WHT
MFR ACCESSORY SHEET 8
SW9 TRAVEL CONTROLS SWITCH
1550 RNG/WHT SHEET 13
FUSE 7 C408 CAB-MFR CONN (BKT POSITION)
25 A
1760 RNG/WHT 1750 RNG/WHT 1815 RNG/WHT SHEET 6
C110 ALT EXCITATION
B
C404 Printable Version Click Here
1720 RNG/WHT BACKUP ALARM HARN
1850 RNG/WHT
SHEET 9
WIRING SCHEMATIC
SWITCHED
1790 RNG/WHT C408 CAB-MFR CONN (FR WIPER)
+12V POWER
PWR
30
SHEET 12
FRC1 HVAC RELAY 1580 RNG/WHT SHEET 9
(MANUAL MACHINE)
1050 RED
J1A
GND 85
87
86
GWY CTRLR
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
S550 (S/N A3NL11001 - A3NL11184)
2030 BLK 3380 LBL 4
SHEET 4
(S/N A3NM11001 - A3NM11005)
C428
(LT GRAY)
CAB-MFR HARN CONN 2
(S/N AZN811001 - AZN811040)
1920 RNG/WHT 6 1920 RNG/WHT 1840 RNG/WHT SHEET 5
C449 LH JOYSTICK
(S/N AZN911001 - AZN911047)
C450 RH JOYSTICK
Sheet 3 of 13
Printed In U.S.A.
7210762 (A)
647 of 1234
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX LEGEND
GROUND
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR
POWER PAGE 3
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CAN BUS PAGE 5
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CONNECTOR
CAB DISPLAY PAGE 8
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CAB PAGE 9
LIGHTS PAGE 11 WIRE BREAK
HVAC PAGE 12 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT SHEET #
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 8
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500 BLK
2250 BLK
SHEET 8
C503 RH DELUXE PANEL
16 2540 BLK
C428 J2B
2930 BLK (LT GRAY)
15 2550 BLK 2090 BLK
SHEET 8 AUX CTRLR
SW1 BRAKE SWITCH CAB-MFR HARN CONN 2
2830 BLK 2900 BLK 1 2900 BLK

SHEET 13
SW6 BKT POSITION SWITCH 2765 BLK
2700 BLK 2710 BLK SHEET 11
SHEET 8 SHEET 5 C408 CAB-MFR CONN (FR LIGHTS)
C426 REMOTE RUN, ACD 2300 BLK
SW9 TRAVEL CONTROL SWITCH
SHEET 13 2455 BLK 2745 BLK
SHEET 13 2785 BLK SHEET 12
C421 BKT POSITION SOLENOID C408 CAB-MFR CONN (HVAC)
C126 HORN
C489 2790 BLK T8
2620 BLK B 2720 BLK SHEET 9 BATT GND
SHEET 11 MFR ACCESSORY C408 CAB-MFR CONN (ACCESSORIES)
T16 RH REAR LIGHT Dealer Copy -- Not for Resale 2780 BLK
2770 BLK
2630 BLK C103 SHEET 13 SHEET 13
SHEET 11 C355 FUEL HARN (PWR BOB, AC) T1 C408 CAB-MFR CONN (OPTIONS)
T18 LH REAR LIGHT TAILGATE HARN BATT GND
2650 BLK 2600 BLK B 2600 BLK 2730 BLK
SHEET 10 SHEET 9
T20 BU ALARM 2390 BLK C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2640 BLK SHEET 6 2810 BLK
SHEET 11 C113 ENG-MFR (FUEL SHUTOFF)
C602 LH REAR LIGHT
2200 BLK
SHEET 7
SHEET 11 2610 BLK C425 BRAKE
C603 RH REAR LIGHT
2005 BLK
SHEET 6
FRC1 STARTER RELAY
SHEET 6 2035 BLK
FRC1 FUEL PULLF RELAY
SHEET 11 2045 BLK
FRC1 FRONT WORK LIGHT RELAY
2055 BLK
SHEET 11
2320 BRN FRC1 REAR LIGHT RELAY
SHEET 7 2105 BLK
C112 HYD OIL FILTER SWITCH SHEET 6 2115 BLK
FRC1 GLOW PLUG RELAY Printable Version Click Here
SHEET 6 2145 BRN 2016 BLK
SHEET 12
C113 ENGINE HARN (ENG SPEED, ENG OIL PRESS) FRC1 HVAC RELAY
SHEET 9
2370 BRN SHEET 3
FRC1 SWITCHED PWR RELAY
2030 BLK WIRING SCHEMATIC
C408 CAB-MFR CONN (SEATBAR SENSOR)
SHEET 7
2220 BRN SHEET 7
2025 BLK
(MANUAL MACHINE)
C108 HYD TEMP SENDER
SHEET 7
2190 BRN
2230 BRN 17 J1B
S550 (S/N A3NL11001 - A3NL11184)
C105 HYD CHG PRESSURE SENDER GWY CTRLR
2180 BRN
(S/N A3NM11001 - A3NM11005)
SHEET 6
C355 FUEL HARN (FUEL SENDER)
(S/N AZN811001 - AZN811040)
2170 BRN
SHEET 6
C104 ENGINE COOLANT SENSOR (S/N AZN911001 - AZN911047)
2150 BRN
SHEET 6
C405 AIR FILTER SWITCH
Sheet 4 of 13
648 of 1234 7210762 (A)

LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3 PARTIAL CONNECTOR
CAN BUS
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
SHEET #
* DLX CAB HARN 7210556 ONLY
(NOT IN STD CAB HARN 7210557)
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1
8 9200 PUR 9270 PUR 9230 PUR 4 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR 4
CAN LO C479
9 9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 3 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
Remote Start Tool, ACD 9160 PUR/WHT 2 C503
14 9500 PUR/WHT A 9260 PUR 4 RIGHT DELUXE PANEL
CAN HI
20 9600 PUR B
CAN LO
21 3090 LBL D REMOTE RUN KEY Dealer Copy -- Not for Resale
1730 RNG/WHT
C
E 1830 RNG/WHT * C450
1
SHEET 3 SWITCHED POWER SHEET 3
1165 RED/WHT F 2070 BLK 2
SHEET 3 UNSWITCHED POWER SHEET 4 RIGHT JOYSTICK
2710 BLK G 9560 PUR/WHT 3 (SJC ONLY)
SHEET 4 GROUND 9660 PUR 4
C449
9220 PUR 8 SHEET 3
1840 RNG/WHT * 1
J2B 2080 BLK 2
9120 PUR/WHT 9 SHEET 4 LEFT JOYSTICK
AUX CTRLR
9540 PUR/WHT 3 (SJC ONLY)
9640 PUR 4
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 5 of 13
Printed In U.S.A.
7210762 (A)
649 of 1234
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 PARTIAL CONNECTOR
POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
ENGINE PAGE 6
HYDRAULICS PAGE 7 CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C113 FUEL SHUTOFF

FUEL MFR-ENG HARN C101 SOLENOID
+12V PULL
8120 TAN 8120 TAN 8 8120 TAN 8100 TAN B PULL 0.33 OHM
PWR 30
1350 RED/WHT
SHEET 3 87 3410 LBL D5
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
SHEET 4 2035 BLK A HOLD
8800 TAN 9 8800 TAN 24.5 OHM
+12V STARTER
STARTER
1030 RED PWR 30
SHEET 3 87 8200 TAN 8200 TAN 1 8200 TAN S M B SHEET 3
3560 LBL 2 3560 LBL R 1015 RED
GND 85 86 8210 TAN
2005 BLK C110
SHEET 4 B
ALTERNATOR S 1020 RED
G
2015 BLK L 1815 RNG/WHT
GLOW T14
+12V PLUG PRE HEATER 1815 RNG/WHT 7 1815 RNG/WHT EXCITATION
SHEET 3
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
2115 BLK GND 85 86 8510 TAN

SHEET 4
6 8510 TAN Dealer Copy -- Not for Resale

14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
2160 BRN B GND ENGINE SPEED SENSOR
C405 163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4 C107
2150 BRN B AIR FILTER
GND
SHEET 4 SWITCH (NC) 2140 BRN A GND
25 3140 LBL 3140 LBL 6 3140 LBL C SIG ENGINE OIL PRESSURE
5140 YEL 5 5140 YEL B +5V PWR SENDER (0.5 ~ 4.5V)
SHEET 9
4 8800 TAN

FUEL HARN
J1B C406
GWY CTRLR 12 3180 LBL C 3180 LBL A
SHEET 4
2180 BRN D 2180 BRN B
SIG
GND
FUEL SENDER
(30-270 OHM)
WIRING SCHEMATIC
2170 BRN
C104
B GND
(MANUAL MACHINE)
SHEET 4 ENGINE COOLANT
18 3170 LBL A SIG
SENSOR (500-3000 OHM) S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 6 of 13
650 of 1234 7210762 (A)
HYDRAULICS
CAB DISPLAY PAGE 8
CAB PAGE 9
TRACTION C425
+12V LOCK
PWR 30 4100 LGN B C308
1360 RED/WHT BRAKE
SHEET 3 87 3430 LBL 4200 LGN A 4200 RED A SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
2220 BRN B TEMPERATURE
SHEET 4
32 3220 LBL A SENDER
500 - 3000 OHM
C112
34 3320 LBL A
HYDRAULIC
J1A 2320 BRN B
GWY CTRLR SHEET 4 FILTER SWITCH (NC)
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYD LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12V
C105
HYDRAULIC
2190 BRN B GND CHARGE
3190 LBL C SIG PRESSURE
5190 YEL A +8V PWR 0.5-7.5V
4200 LGN
19 13 1 23 6 Printable Version Click Here

J1B +8V
GWY CTRLR
C418
WIRING SCHEMATIC
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
(MANUAL MACHINE)
3.3 OHM PWM
C419 S550 (S/N A3NL11001 - A3NL11184)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE) (S/N A3NM11001 - A3NM11005)
3.3 OHM PWM
(S/N AZN811001 - AZN811040)
19 13
(S/N AZN911001 - AZN911047)
J2B Sheet 7 of 13
AUX CTRLR

651 of 1234
CAB
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 PARTIAL CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7 CONNECTOR
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10
DISPLAY
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
T2 Press To Operate Loader
BUZZER (-) PTOL
C408
1930 RNG/WHT 1
(BLACK) SHEET 3 SWITCH POWER
CAB-MFR HARN CONN 1 2940 BLK 3
SHEET 4 GROUND
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
LEFT PANEL (BLACK) 19 2380 BRN 12 2380 BRN 4 PTOL LED
7040 WHT 10 J1A
BUZZER GWY CTRLR C500
2920 BLK 2 GROUND RIGHT H KEY SWITCH PANEL
SHEET 4
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
1960 RNG/WHT SHEET 3 BATTERY (+) START
SHEET 3
SW9 1620 RNG/WHT 5
*
TRAVEL CONTROL
SHEET 3
11
SWITCHED POWER
SWITCH (OPTIONAL) SHEET 13 3400 LBL LEFT BLINKER INPUT

J1B
5 6 3500 LBL
Dealer Copy GWY
-- Not
8 RIGHT BLINKER INPUT
for 22Resale
CTRLR
3040 LBL 14 3040 LBL 4
RUN/ENTER SW
4 SHEET 13
3650 LBL 7 TRAVEL CONTROL INPUT 1950 RNG/WHT 5 SWITCHED POWER
2700 BLK 2 3 SHEET 3
SHEET 4 1 1420 RED/WHT 1
9 SHEET 3 BATTERY (+)
3600 LBL PARK BREAK INPUT 2960 BLK 3
SW1 SHEET 4 GROUND
6
3 2 BRAKE SWITCH
1 C480
3610 LBL 4 LEFT PANEL (GRAY) C503
5
1775 RNG/WHT RIGHT DELUXE PANEL
SHEET 3 6 3620 LBL 12
SHEET 9 DOOR SIGNAL
2930 BLK 11 1590 RNG/WHT 5
SHEET 4 SHEET 3 SWITCHED POWER
10
1240 RED/WHT 1
3610 LBL 2 PARK BREAK OUTPUT 2250 BLK 3
SHEET 4 GROUND
8
7
6
5
3
1
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 8 of 13
7210762 (A)
Printed In U.S.A.
652 of 1234
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE SCHEMATIC INDEX LEGEND
CAB
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED OVERVIEW PAGE 1,2 PARTIAL CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT POWER PAGE 3
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK CAN BUS PAGE 5
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 CONNECTOR
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB DISPLAY PAGE 8 * DLX CAB HARN 7210556 ONLY
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 (TWO WIRE BREAKS
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR JOIN ONE WIRE)
OPTIONS PAGE 13
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN *C212
POWER
SOCKET
6 4550 LGN
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK *B
C209
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A DOME

SHEET 3 LIGHT
3640 LBL C
C129
CAB ACCESSORY
1210 RED/WHT A
+12V BATT PWR
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B
SHEET 3 Dealer Copy
2820 BLK
--SWNot
+12V
C
PWR for Resale
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK
SHEET 4 SHEET 13
2885 BLK SHEET 13
C428
(LT GRAY)
CAB-MFR HARN CONN 2
2060 BLK
SHEET 9 *C667
DOOR HARN
(SEE ADDITIONAL
2790 BLK 11 OPTIONS SHEET)
SHEET 4 2790 BLK
3620 LBL 3630 LBL 4 DOOR SIGNAL
SHEET 8
1400 RED/WHT 5 DOOR UNSW PWR
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND
1850 RNG/WHT 13 1850 RNG/WHT 1850 RNG/WHT 1
SHEET 3 WASHER SIGNAL
7310 WHT 3
WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR
J1B SENSOR
GWY CTRLR SHEET 4
2370 BRN 4 2370 BRN A GND
* C252
L SIG
WIRING SCHEMATIC
11 3370 LBL 5 3370 LBL B SIG WASHER
2845 BLK X GND MOTOR
+5V
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR (MANUAL MACHINE)
5140 YEL
SHEET 6
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 9 of 13

653 of 1234 7210762 (A)
PAGE 1,2
MANUAL
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW
CONTROLS
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C409
K
G RIGHT HANDLE
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
21 4920 LGN E DETENT FLOW
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
AUX CTRLR 18 4320 LGN D
PWM
23 4300 LGN B +
30
31 C410
C404 C103 13 K
BU ALARM HARN / SJC HARN TAILGATE HARN LEFT HANDLE
T19 TERMINAL (+) J2A D
(SEE ADDITIONAL A 7100 WHT C 7100 WHT AUX CTRLR 28 4840 LGN C
OPTIONS SHEET) BACK UP
Dealer Copy -- Not for Resale 22 4830 LGN B SKI CTRL
2650 BLK ALARM 12 4820 LGN G
SHEET 4
T20 TERMINAL (-) 11 4810 LGN F SIDE SHIFT
1530 RNG/WHT A
SHEET 3
J
C421 H
2670 BRN 3 GND E
10
J1A 1 TILT SPOOL LOCK
2 4670 LGN 7.8 OHM 12V
GWY CTRLR SIG C411
2
E
C422 C
7 GND
3 A
2680 BRN
J1B 5 1 LIFT SPOOL LOCK D TURN SIGNAL
4680 LGN
GWY CTRLR SIG 7.8 OHM 12V B
2
C412
B
A HORN
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 10 of 13 Printable Version Click Here

7210762 (A)
654 of 1234
LIGHTS
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C434-1
2735 BLK B GND LEFT FRONT
C408 6100 PNK A SIG WORK LIGHT
(BLACK) 37.00 Watts
CAB-MFR HARN CONN 1
C434-2
2765 BLK 9 2765 BLK 2750 BLK B BLK LEFT FRONT
SHEET 4
6110 PNK A SIG WORK LIGHT
50.00 Watts
C435-1
6000 PNK 8 6000 PNK 6120 PNK A SIG RIGHT FRONT
2760 BLK B BLK WORK LIGHT
37.00 Watts
C435-2
6130 PNK A SIG RIGHT FRONT
50.00 Watts
FRONT
WORK C103
C603
+12V LIGHTS TAILGATE HARN SHEET 4
PWR 30 2610 BLK 2 GND
1330 RED/WHT 6310 PNK RIGHT REAR
SHEET 3 87 6340 PNK 6310 PNK A 6320 PNK 1 SIG TAIL LIGHT
GND 85 86 C602
SHEET 4 2045 BLK
6330 PNK 1 SIG LEFT REAR
2640 BLK 2 BLK TAIL LIGHT
SHEET 4
5
31
6320 PNK
3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK BLK
SHEET 4
RIGHT REAR
6210 PNK SIG WORK LIGHT
REAR T15 TERMINAL (+)

+12V LIGHT
1320 RED/WHT PWR 30 T17 TERMINAL (+)
SHEET 3 87 6200 PNK H 6200 PNK 6220 PNK SIG
LEFT REAR
GND 85 86 2630 BLK GND WORK LIGHT
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 11 of 13
Printed In U.S.A.
655 of 1234 7210762 (A)
HVAC
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 (NOT IN STD CAB HARN 7210557)
HVAC PAGE 12
#
OPTIONS PAGE 13
DLX FUEL HARN 7184255 ONLY
(NOT IN STD FUEL HARN 7149219)
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
7420 WHT A DBL POTENTIOMETER
7425 WHT B WHT (TEMP CONTROL
SWITCH)
C635
* D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
B
E
C438
(DK GRAY)
F
*BLOWER
SW10
+12V HVAC CAB-MFR HARN CONN 3Dealer Copy -- Not for Resale SWITCH
PWR 30 OFF
1140 RED/WHT
SHEET 3 87 1500 RNG/WHT 7 1500 RNG/WHT 5 2
1
GND 85 86 4
2016 BLK
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
SHEET 3 7520 WHT 2 7.50 Amps Med BLOWER
21 3450 LBL 7510 WHT 3 5.00 Amps Low MOTOR
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
AC EVAPORATOR C350
SWITCH B 7023 WHT
A 7024 WHT
C355
SW11
*
AC SWITCH WIRING SCHEMATIC
FUEL HARN # C486
7015 WHT 1 C 7400 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH 2100 BLK
3
(MANUAL MACHINE)
(COMPRESSOR)
2290 BLK 2280 BLK
SHEET 13
D4
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 12 of 13
7210762 (A)
Printed
656 of 1234 In U.S.A.
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE SCHEMATIC INDEX
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED OVERVIEW PAGE 1,2
OPTIONS
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB PAGE 9
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
OPTIONS
C428
PAGE 13
# C355 (LT GRAY)
C607
FUEL HARN CAB-MFR HARN CONN 2 #
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
2 2470 BLK
2290 BLK
2770 BLK B 2770 BLK
SHEET 4 4480 LGN (NOT IN STD FUEL HARN 7149219)
SHEET 12
# C606 *POWER
SW5 2 1
3
PWR BOB OPEN BOBTACH
5 4
2 2480 BLK SWITCH 6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
1410 RED/WHT 12 1410 RED/WHT 1200 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
LEFT HANDLE D 6415 PNK 6400 PNK 14 6400 PNK D2 6430 PNK
(BLINKER/FLASHER) C
SHEET 8 3400 LBL
*BEACON
SW2
6570 PNK
5 PIN E 1550 RNG/WHT
1550 RNG/WHT 9
SHEET 3 SWITCH
A 6515 PNK
2725 BLK 6
C103
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
C438 (PINS 3 & 6
TAILGATE HARN 5 4 3
(DK GRAY) INTERNALLY
2850 BLK
CAB-MFR HARN CONN 3 INSULATED) 6
EURO TAIL LIGHTS ONLY E 3500 LBL C670
(SEE ADDITIONAL
OPTIONS SHEET)
D
6410 PNK
6510 PNK 6500 PNK 3 6500 PNK
SHEET 8 D1 6530 PNK * E
6540 PNK 2420 BLK D
6440 PNK F BEACON/FLASHER
B EXTERIOR HARNESS
C423
(SEE ADDITIONAL
3 C
2 *
BUCKET A 4450 LGN D3 4455 LGN 2 4455 LGN Dealer
1 Copy
SW6
BUCKET
-- Not for Resale A
OPTIONS SHEET)
POSITION 4
SOLENOID 2830 BLK 5 POSITION
B 2450 BLK 2455 BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6
2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C126
6540 PNK
* C676
RADIO
* C277
2 1
C412
CAB-MFR HARN CONN 1SHEET 4
2785 BLK B SHEET 9 2885 BLK
1885 RNG/WHT 1 2
LEFT HANDLE B 7210 WHT 13 7210 WHT A HORN SHEET 9 3
A 1460 RED/WHT
(HORN)
2 PIN
SHEET 3 *
+
C279
1 7820 WHT 3 SHEET 9 1510 RNG/WHT
2210 BLK
4 PWR
5 GND AIR RIDE
LEFT 2 7830 WHT 4 SHEET 9 SEAT
SPEAKER 6
-
C278
RIGHT
*- 2 7810 WHT 6
C415 1 7800 WHT 5
J2A HIGH FLOW SPEAKER +
26 2460 BRN B GND
AUX CTRLR SOLENOID
4460 LGN A SIG
7.5 OHM 12 V
J2B 26 Printable Version Click Here

AUX CTRLR
C441
J1A
GWY CTRLR
26 2350 BRN 2 GND TWO SPEED
SOLENOID
WIRING SCHEMATIC
4350 LGN 1 SIG
5.1 OHM 12V
J1B 26
(MANUAL MACHINE)
GWY CTRLR
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Sheet 13 of 13
657 of 1234
PINS PINS PINS
C209 DOME LIGHT 3 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C212 POWER SOCKET 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C252 WASHER 2 9 C489 MFR ACCESSORY 2 3,4
C277 AIR RIDE SEAT 6 13 C499 PTOL 4 8 SW1 BRAKE SWITCH 8
C278 RIGHT SPEAKER 2 13 C500 RH KEY SWITCH 6 8 SW2 BEACON SWITCH 13
C279 LEFT SPEAKER 2 13 C503 RH DLX PANEL 6 5,8 SW3 HAZARD SWITCH 13
C308 BRAKE SOLENOID 2 7 C602 LEFT REAR TAIL LIGHT 2 11 SW4 HAND/FOOT, H/ISO SWITCH 9
C350 AC EVAPORATOR SWITCH 2 12 C603 RIGHT REAR TAIL LIGHT 2 11 SW5 POWER BOBTACH SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C606 POWER BOBTACH OPEN 2 13 SW6 BUCKET POSITION SWITCH 13
C404 BACKUP ALARM 2 3,10 C607 POWER BOBTACH CLOSE 2 13 SW9 TRAVEL CONTROL SWITCH 8
C405 AIR FILTER SWITCH 2 6 C610 HVAC DUCT FAN 2 12 SW10 BLOWER SWITCH 12
C406 FUEL SENDER 2 6 C611 BLOWER MOTOR 4 12 SW11 AC SWITCH 12
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C630 THERMOSTAT 3 12
C409 RIGHT HANDLE 10 10 C635 HEATER VALVE 6 12
C410 LEFT HANDLE 10 10 C667 DOOR 6 9
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C670 EXTERIOR BEACON 6 13
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C676 RADIO 6 9
C415 HIGH FLOW SOLENOID 2 7
C418 FRONT ROD 2 7 J1A GATEWAY COTROLLER 34
C419 FRONT BASE 2 7 J1B GATEWAY CONTOLLER 26
C420 HYD LOCK 2 7 J2A AUX CONTROLLER 34
C421 TILT SPOOL LOCK 3 10 J2B AUX CONTROLLER 26
C422 LIFT SPOOL LOCK 3 10
C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12

WIRING SCHEMATIC
SCHEMATIC INDEX
GROUP DESCRIPTION
BATT FEED, GENERAL
GROUP NUMBER RANGE
1000 THROUGH 1499
WIRE COLOR
RED
COLOR CODE
RED
OVERVIEW
POWER
PAGE 1,2
PAGE 3
(MANUAL MACHINE)
BATT FEED, SWITCHED
BATTERY GROUND
1500 THROUGH 1999
2000 THROUGH 2999
ORANGE/WHITE
BLACK
RNG/WHT
BLK
GROUND
CAN BUS
PAGE 4
PAGE 5
S550 (S/N A3NL11185 - A3NL11630)
MONITORING
2000 THROUGH 2999
3000 THROUGH 3999
BROWN
LIGHT BLUE
BRN
LBL
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
CAB DISPLAY
CAB
PAGE 8
PAGE 9
(S/N AZN811041 - AZN811060)
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
MANUAL CONTROLS PAGE 10 (S/N AZN911048 - AZN911112)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR LIGHTS PAGE 11
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT HVAC PAGE 12 Sheet 1 of 13
OPTIONS PAGE 13

7210762 (B)
658 of 1234
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN
A-32 HYD OIL TEMP Dealer
A-32 Copy -- Not for Resale
HARNESS PART NUMBER

MAIN FRAME 7210554
STD CAB 7210557
DLX CAB 7231782
DLX FUEL 7175293
STD FUEL 7149219
ENG 2403 7181036
ENG 2607 7181037
TAILGATE DOM 7217484 Printable Version Click Here
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(MANUAL MACHINE)
TRACTION FUEL SWITCH
STARTER
PULL
PULL POWER
S550 (S/N A3NL11185 - A3NL11630)
REAR FRONT
(S/N AZN811041 - AZN811060)
GLOW
HVAC
PLUG LIGHT LIGHT
(S/N AZN911048 - AZN911112)

Sheet 2 of 13
Printed In U.S.A. 7210762 (B)
659 of 1234
POWER
1300 RED 1140 RED/WHT SHEET 12 C503 RH DLX PANEL
3 J2B C408
FRC1 HVAC RELAY 1150 RED/WHT 1400 RED/WHT
AUX CTRLR
BATTERY MEGAFUSE
FUSE 4
1180 RED/WHT 2
(BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
1110 RED/WHT
J1B
FUSE 12 SHEET 8
OPEN C479 LH PANEL
SHEET 6
STARTER
1460 RED/WHT LEGEND
1010 RED
SHEET 13
1040 RED 25 A 1410 RED/WHT
1490 RED/WHT
SHEET 13
SHEET 9
FUSE 9
1620 RNG/WHT
30 A 1360 RED/WHT SHEET 8 WIRE BREAK
1060 RED FUSE 2
FRC1 FUEL SHUTOFF RELAY
FRC1 GLOW PLUG RELAY 20 A SHEET 8
1340 RED 1330 RED/WHT
SHEET 11 C499 RH PANEL PTOL
FUSE 3 C428
1775 RNG/WHT
SHEET 11
SHEET 8
FUSE 6
1560 RNG/WHT 22 J2B
SHEET 9
25 A SHEET 5 SW4 H/ISO SWITCH
1730 RNG/WHT
25 A
C110 ALT EXCITATION
1720 RNG/WHT B
C404
BACKUP ALARM HARN
WIRING SCHEMATIC
SWITCHED
1850 RNG/WHT
SHEET 9
(MANUAL MACHINE)
+12V POWER
PWR
30
SHEET 12
S550 (S/N A3NL11185 - A3NL11630)
1050 RED
J1A
GND 85
87
86
GWY CTRLR
2030 BLK 3380 LBL 4
SHEET 4
(S/N AZN811041 - AZN811060)
C428
(LT GRAY)
CAB-MFR HARN CONN 2
(S/N AZN911048 - AZN911112)
C449 LH JOYSTICK
1830 RNG/WHT SHEET 5 (PRINTED NOVEMBER 2016)
Printed In U.S.A. C450 RH JOYSTICK
7210762 (B)
660 of 1234
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUND
ENGINE PAGE 6 CONNECTOR
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS PAGE 11 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 12
OPTIONS PAGE 13 SHEET #
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
SHEET 8
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428 J2B
2930 BLK (LT GRAY)
15 2550 BLK 2090 BLK
SHEET 8 AUX CTRLR
2830 BLK 2900 BLK 1 2900 BLK

SHEET 13
C126 HORN
2790 BLK T8
SHEET 11
2620 BLK C489
MFR ACCESSORY
B 2720 BLK Dealer Copy -- Not for Resale SHEET 9
BATT GND
T16 RH REAR LIGHT
2770 BLK 2780 BLK
2650 BLK 2600 BLK B 2600 BLK 2730 BLK
SHEET 10 SHEET 9
2810 BLK
2640 BLK SHEET 6
C602 LH REAR LIGHT
SHEET 7 2200 BLK
2610 BLK C425 BRAKE
SHEET 11
C603 RH REAR LIGHT
2005 BLK
SHEET 6
FRC1 STARTER RELAY
SHEET 6 2035 BLK
SHEET 11 2045 BLK
2055 BLK
SHEET 11
SHEET 7 2115 BLK 2105 BLK Printable Version Click Here
C112 HYD OIL FILTER SWITCH SHEET 6
FRC1 GLOW PLUG RELAY
2145 BRN
SHEET 6
C113 ENGINE HARN (ENG SPEED, ENG OIL PRESS)
SHEET 12
FRC1 HVAC RELAY
2016 BLK
WIRING SCHEMATIC
2370 BRN 2030 BLK
SHEET 9
SHEET 3
FRC1 SWITCHED PWR RELAY (MANUAL MACHINE)
2025 BLK
SHEET 7
2220 BRN
SHEET 7
FRC1 TRACTION LOCK RELAY S550 (S/N A3NL11185 - A3NL11630)
SHEET 7
2190 BRN
C105 HYD CHG PRESSURE SENDER
2230 BRN 17 J1B
GWY CTRLR
SHEET 6
2180 BRN (S/N AZN811041 - AZN811060)
2170 BRN
(S/N AZN911048 - AZN911112)
SHEET 6
C104 ENGINE COOLANT SENSOR
Sheet 4 of 13
2150 BRN
SHEET 6
C405 AIR FILTER SWITCH (PRINTED NOVEMBER 2016)
661 of 1234
LEGEND
PARTIAL CONNECTOR
CAN BUS
CAN BUS PAGE 5
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
CAN HI
CAN LO
20 9600 PUR B Dealer Copy -- Not for Resale
21 3090 LBL D REMOTE RUN KEY
1730 RNG/WHT
C
E SHEET 3
1830 RNG/WHT * C450
1
SHEET 3 SWITCHED POWER
9220 PUR 8 SHEET 3

1840 RNG/WHT * C449
1
J2B 2080 BLK 2
AUX CTRLR 9540 PUR/WHT 3 (SJC ONLY)
9640 PUR 4
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

Printed In U.S.A.
7210762 (B)
662 of 1234
LEGEND
POWER PAGE 3
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
C113 FUEL SHUTOFF

+12V PULL
PWR 30
1350 RED/WHT
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
SHEET 4 2035 BLK A
8800 TAN 9 8800 TAN HOLD
24.5 OHM
+12V STARTER
STARTER
1030 RED PWR 30
SHEET 3 8200 TAN 1 8200 TAN B SHEET 3
87 8200 TAN S M
3560 LBL 2 3560 LBL R 1015 RED

GND 85 86 8210 TAN
2005 BLK C110
SHEET 4 B
G
GLOW T14
+12V PLUG 1815 RNG/WHT 7 1815 RNG/WHT EXCITATION
PRE HEATER SHEET 3
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
GND 85 86
2115 BLK 8510 TAN
SHEET 4

6 8510 TAN
14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
C405
163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4
2150 BRN B AIR FILTER C107
GND
SHEET 9
4 8800 TAN
C355
WIRING SCHEMATIC
J1B
GWY CTRLR 12 3180 LBL
FUEL HARN
C 3180 LBL
C406
A
(MANUAL MACHINE)
SIG
FUEL SENDER
SHEET 4
2180 BRN D 2180 BRN B GND
(30-270 OHM) S550 (S/N A3NL11185 - A3NL11630)
SHEET 4
2170 BRN
C104
B GND
ENGINE COOLANT
18 3170 LBL A SIG
SENSOR (500-3000 OHM)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

7210762 (B)
663 of 1234
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 CONNECTOR
CAB PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 11
HVAC PAGE 12
TRACTION C425
+12V LOCK
PWR 30 4100 LGN B C308
1360 RED/WHT BRAKE
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
SHEET 4
500 - 3000 OHM
C112
34 3320 LBL A
HYDRAULIC Dealer Copy -- Not for Resale
J1A 2320 BRN B
C446
7.2 OHM 12 V
C420
9.8 OHM 12V
C105
HYDRAULIC
5190 YEL A +8V PWR 0.5-7.5V
4200 LGN Printable Version Click Here
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (MANUAL MACHINE)
GWY CTRLR
C418 S550 (S/N A3NL11185 - A3NL11630)
J2A 18 2330 BRN 2 GND FRONT ROD
AUX CTRLR 4330 LGN 1 SIG SOLENOID (MALE) (S/N A3NM11006 AND ABOVE)
3.3 OHM PWM
1 2340 BRN
C419
2 GND
(S/N AZN811041 - AZN811060)
FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM (S/N AZN911048 - AZN911112)
Sheet 7 of 13
19 13 (PRINTED NOVEMBER 2016)
Printed In U.S.A.
J2B 7210762 (B)
AUX CTRLR
664 of 1234
LEGEND
CAB
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 WIRE BREAK
DISPLAY
LIGHTS PAGE 11
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 13

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
BUZZER (-) PTOL
C408
1930 RNG/WHT 1
SHEET 4 GROUND
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
7040 WHT 10 J1A
2920 BLK 2 RIGHT H KEY SWITCH PANEL
SHEET 4 GROUND
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
SHEET 3
1620 RNG/WHT 5
*
SW9
TRAVEL CONTROL
SHEET 3
11
SWITCHED POWER
SWITCH (OPTIONAL) SHEET 13 3400 LBL LEFT BLINKER INPUT J1B 22 3040 LBL 14 3040 LBL 4
GWY CTRLR RUN/ENTER SW
5 6 3500 LBL 8 RIGHT BLINKER INPUT
4 SHEET 13
3650 LBL 7 1950 RNG/WHT 5
2700 BLK 2 3 TRAVEL CONTROL INPUT SHEET 3 SWITCHED POWER
SHEET 3 BATTERY (+)
3600 LBL 9 3
PARK BREAK INPUT
SHEET 4 2960 BLK GROUND
SW1 6
3 2 BRAKE SWITCH
1 C480
5
SHEET 3 6 3620 LBL 12 DOOR SIGNAL
2930 BLK SHEET 9
SHEET 4 11 1590 RNG/WHT 5
10
1240 RED/WHT 1
SHEET 4 GROUND
8
7
6
5 WIRING SCHEMATIC
4
3
1
(MANUAL MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
Sheet 8 of 13

665 of 1234
LEGEND
SCHEMATIC INDEX
PARTIAL CONNECTOR
CAB
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
CAN BUS PAGE 5
ENGINE PAGE 6
CONNECTOR
HYDRAULICS PAGE 7
CAB PAGE 9
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
HVAC PAGE 12 JOIN ONE WIRE)
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN *C212
POWER
SOCKET
6 4550 LGN
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK* B
C209
GND
SHEET 3 1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A +12V PWR DOME
3640 LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A
+12V BATT PWR
SHEET 3
1580 RNG/WHT 5 1580 RNG/WHT Dealer Copy
1865 RNG/WHT B -- PWR
+12V SW Not for Resale
2820 BLK C
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK
SHEET 4 SHEET 13
2885 BLK SHEET 13
C428
(LT GRAY)
CAB-MFR HARN CONN 2
2060 BLK
SHEET 9 *C667
DOOR HARN
(SEE ADDITIONAL
2790 BLK 11 OPTIONS SHEET)
SHEET 4 2790 BLK
SHEET 8
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND
7310 WHT 3
C482 SEATBAR
J1B SENSOR C252
GWY CTRLR SHEET 4
* L SIG WIRING SCHEMATIC
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

(MANUAL MACHINE)
+5V
SHEET 6
5140 YEL
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

Printed In U.S.A.
666 of 1234 7210762 (B)
PAGE 1,2
MANUAL
CONTROLS
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12
OPTIONS PAGE 13
C409
K
G RIGHT HANDLE
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
PWM
23 4300 LGN B +
30
31 C410
C404 C103 13 K
BU ALARM HARN / SJC HARN TAILGATE HARN
T19 TERMINAL (+)
J2A D LEFT HANDLE
OPTIONS SHEET) BACK UP 22 4830 LGN B SKI CTRL
SHEET 4
1530 RNG/WHT A
SHEET 3
J
C421 H
2670 BRN 3 GND E
10
2 4670 LGN 7.8 OHM 12V
GWY CTRLR SIG C411
2
E
C422 C
7 GND
3 A
2680 BRN
4680 LGN
2
WIRING SCHEMATIC
C412
(MANUAL MACHINE) B
A HORN
S550 (S/N A3NL11185 - A3NL11630)

(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
7210762 (B)
667 of 1234
LIGHTS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C434-1
(BLACK) 37.00 Watts
CAB-MFR HARN CONN 1
C434-2
SHEET 4
50.00 Watts
C435-1
2760 BLK B WORK LIGHT
BLK 37.00 Watts
C435-2
50.00 Watts
FRONT
WORK C103
C603
GND 85 86 C602
SHEET 4 2045 BLK
Dealer Copy -- Not for Resale 2640 BLK 2 BLK TAIL LIGHT
SHEET 4
5 6320 PNK
31 3460 LBL
J1A 17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK BLK
SHEET 4
RIGHT REAR

+12V LIGHT
LEFT REAR
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
668 of 1234
HVAC
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
HVAC PAGE 12
#
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS PAGE 13
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
SWITCH)
C635
* D SIG
B
E
C438
(DK GRAY)
F
*BLOWER
SW10
+12V HVAC SWITCH

CAB-MFR HARN CONN 3
PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2016 BLK
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT Printable Version Click Here
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
WIRING SCHEMATIC
AC EVAPORATOR C350
SWITCH B
A
7023 WHT
7024 WHT
(MANUAL MACHINE)
C355
SW11
*
AC SWITCH
S550 (S/N A3NL11185 - A3NL11630)
FUEL HARN # C486
7015 WHT 1 C 7400 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH
(COMPRESSOR)
2100 BLK
3 (S/N A3NM11006 AND ABOVE)
2290 BLK 2280 BLK
SHEET 13
D4 (S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
Sheet 12 of 13
7210762 (B)
Printed In U.S.A.
669 of 1234
OPTIONS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
OPTIONS
C428
PAGE 13
# C355 (LT GRAY)
C607
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
2 2470 BLK 2770 BLK 2770 BLK
2290 BLK
B
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480 BLK SWITCH 6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
(BLINKER/FLASHER)
5 PIN
C
SHEET 8 3400 LBL
*BEACON
SW2
6570 PNK
E 1550 RNG/WHT 9 1550 RNG/WHT
SHEET 3 SWITCH
A 6515 PNK
2725 BLK 6
C103
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
TAILGATE HARN C438 (PINS 3 & 6
(DK GRAY) INTERNALLY 5 4 3
2850 BLK
E 3500 LBL C670
EURO TAIL LIGHTS ONLY
(SEE ADDITIONAL
OPTIONS SHEET)
D
6410 PNK
6510 PNK 6500 PNK 3 6500 PNK
6540 PNK 2420 BLK D
Dealer Copy -- Not for Resale B EXTERIOR HARNESS
C423
3 (SEE ADDITIONAL
C
BUCKET
POSITION
A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6
A
OPTIONS SHEET)

2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C126
6540 PNK
* C676
RADIO
* C277
2 1
CAB-MFR HARN CONN SHEET
1 4 2885 BLK
C412 2785 BLK B SHEET 9 2
1885 RNG/WHT 1
LEFT HANDLE B 7210 WHT 13 7210 WHT A HORN SHEET 9 3
A 1460 RED/WHT C279
(HORN)
2 PIN
SHEET 3 *
+ 1 7820 WHT 3 SHEET 9 1510 RNG/WHT
2210 BLK
4
5
PWR
GND AIR RIDE
SPEAKER 6
-
C278
RIGHT
*
- 2 7810 WHT 6
C415 1 7800 WHT 5
J2A SPEAKER + Printable Version Click Here
26 2460 BRN B GND HIGH FLOW
AUX CTRLR SOLENOID
4460 LGN A SIG
7.5 OHM 12 V
26
WIRING SCHEMATIC
J2B
AUX CTRLR
C441
(MANUAL MACHINE)
J1A 26 2 GND
2350 BRN TWO SPEED
GWY CTRLR
4350 LGN 1 SIG SOLENOID S550 (S/N A3NL11185 - A3NL11630)
5.1 OHM 12V
J1B
GWY CTRLR
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
Sheet 13 of 13
670 of 1234
PINS PINS PINS
C212 POWER SOCKET 2 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C252 WASHER 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C277 AIR RIDE SEAT 6 13 C489 MFR ACCESSORY 2 3,4 T36 DOMELIGHT (-) 9
C278 RIGHT SPEAKER 2 13 C499 PTOL 4 8 T37 DOMELIGHT (+) 9
C279 LEFT SPEAKER 2 13 C500 RH KEY SWITCH 6 8
C308 BRAKE SOLENOID 2 7 C503 RH DLX PANEL 6 5,8 SW1 BRAKE SWITCH 8
C350 AC EVAPORATOR SWITCH 2 12 C602 LEFT REAR TAIL LIGHT 2 11 SW2 BEACON SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C603 RIGHT REAR TAIL LIGHT 2 11 SW3 HAZARD SWITCH 13
C404 BACKUP ALARM 2 3,10 C606 POWER BOBTACH OPEN 2 13 SW4 HAND/FOOT, H/ISO SWITCH 9
C405 AIR FILTER SWITCH 2 6 C607 POWER BOBTACH CLOSE 2 13 SW5 POWER BOBTACH SWITCH 13
C406 FUEL SENDER 2 6 C610 HVAC DUCT FAN 2 12 SW6 BUCKET POSITION SWITCH 13
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C611 BLOWER MOTOR 4 12 SW9 TRAVEL CONTROL SWITCH 8
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW10 BLOWER SWITCH 12
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW11 AC SWITCH 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C667 DOOR 6 9
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C670 EXTERIOR BEACON 6 13
C415 HIGH FLOW SOLENOID 2 7 C676 RADIO 6 9
C418 FRONT ROD 2 7 Dealer Copy -- Not for Resale
C419 FRONT BASE 2 7 J1A GATEWAY COTROLLER 34
C420 HYD LOCK 2 7 J1B GATEWAY CONTOLLER 26
C421 TILT SPOOL LOCK 3 10 J2A AUX CONTROLLER 34
C422 LIFT SPOOL LOCK 3 10 J2B AUX CONTROLLER 26
C423 BUCKET POSITION 2 13
C425 BRAKE SOLENOID 3 7 FRC1 FUSE RELAY CENTER 3,6,7,11,12

OVERVIEW PAGE 1,2
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK CAN BUS PAGE 5 WIRING SCHEMATIC
ENGINE PAGE 6
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN HYDRAULICS PAGE 7 (MANUAL MACHINE)
LIGHTS 6000 THROUGH 6999 PINK PNK CAB PAGE 9 S550 (S/N A3NL11631 - A3NL12191)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR LIGHTS PAGE 11 (S/N AZN811061 - AZN811162)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT HVAC PAGE 12
OPTIONS PAGE 13 (S/N AZN911113 - ANZ911229)
Sheet 1 of 13

7210762 (C)
671 of 1234
A-32 HYD OIL TEMP A-32Dealer Copy -- Not for Resale
HARNESS PART NUMBER

MAIN FRAME 7210554
STD CAB 7210557
DLX CAB 7231782
DLX FUEL 7175293
STD FUEL 7149219
ENG 2403 7181036
ENG 2607 7181037
TAILGATE DOM 7217484
TRACTION SWITCH
WIRING SCHEMATIC
STARTER FUEL
PULL POWER
PULL
(MANUAL MACHINE)
REAR FRONT
S550 (S/N A3NL11631 - A3NL12191)
GLOW
HVAC
LIGHT
(S/N AZN811061 - AZN811162)
PLUG LIGHT
(S/N AZN911113 - ANZ911229)

Sheet 2 of 13
672 of 1234
POWER
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
3 J2B C408
FRC1 HVAC RELAY 1150 RED/WHT 1400 RED/WHT
AUX CTRLR
BATTERY MEGAFUSE
FUSE 4
1180 RED/WHT 2
(BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE RED 25 A
1025 RED 1160 RED/WHT 1450 RED/WHT 6 1450 RED/WHT 1420 RED/WHT SHEET 8
1110 RED/WHT
J1B
FUSE 12 SHEET 8
OPEN C479 LH PANEL
SHEET 6
STARTER
1460 RED/WHT LEGEND
1010 RED
SHEET 13
25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
SHEET 13
SHEET 9
FUSE 9
30 A 1620 RNG/WHT
1360 RED/WHT SHEET 8 WIRE BREAK
1060 RED FRC1 FUEL SHUTOFF RELAY
SHEET 6
FUSE 2
20 A
Dealer Copy -- Not for Resale 1930 RNG/WHT
FRC1 GLOW PLUG RELAY 1340 RED 1330 RED/WHT SHEET 8
FUSE 3 C428
1775 RNG/WHT
SHEET 11
SHEET 8
FUSE 6
1560 RNG/WHT 22 J2B
SHEET 9
25 A SHEET 5 SW4 H/ISO SWITCH
1730 RNG/WHT
C426 REMOTE RUN, ACD
C489
25 A
C110 ALT EXCITATION
C404
1720 RNG/WHT B BACKUP ALARM HARN
1850 RNG/WHT
WIRING SCHEMATIC
SWITCHED SHEET 9
+12V POWER
PWR
1790 RNG/WHT
SHEET 12
FRC1 HVAC RELAY 1580 RNG/WHT
C408 CAB-MFR CONN (FR WIPER)
(MANUAL MACHINE)
1050 RED 30 SHEET 9
87
J1A
GWY CTRLR
S550 (S/N A3NL11631 - A3NL12191)
2030 BLK GND 85 86
4
SHEET 4 3380 LBL
(S/N AZN811061 - AZN811162)
C428
(LT GRAY) (S/N AZN911113 - ANZ911229)
CAB-MFR HARN CONN 2

C449 LH JOYSTICK
1830 RNG/WHT SHEET 5 (PRINTED NOVEMBER 2016)
7210762 (C)
673 of 1234
LEGEND
GROUND
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
SHEET 8
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428 J2B
2930 BLK (LT GRAY) 15 2550 BLK 2090 BLK
SHEET 8 AUX CTRLR
2830 BLK 2900 BLK 1 2900 BLK

SHEET 13
2785 BLK SHEET 12
SHEET 13 C421 BKT POSITION SOLENOID
C126 HORN C408 CAB-MFR CONN (HVAC)
C489 2790 BLK T8

2620 BLK B 2720 BLK SHEET 9
SHEET 11
T16 RH REAR LIGHT
MFR ACCESSORY Dealer Copy -- Not for Resale C408 CAB-MFR CONN (ACCESSORIES)
BATT GND
2770 BLK 2780 BLK

2650 BLK 2600 BLK B 2600 BLK 2730 BLK
SHEET 10 SHEET 9
C602 LH REAR LIGHT
2200 BLK
SHEET 7
2610 BLK C425 BRAKE
SHEET 11
C603 RH REAR LIGHT
2005 BLK
SHEET 6
FRC1 STARTER RELAY
SHEET 6 2035 BLK
SHEET 11 2045 BLK
2055 BLK
SHEET 11
SHEET 6 2145 BRN 2016 BLK
SHEET 12
SHEET 9
2370 BRN SHEET 3
SHEET 7
2220 BRN SHEET 7
2025 BLK
(MANUAL MACHINE)
SHEET 7
2190 BRN
2230 BRN 17 J1B
S550 (S/N A3NL11631 - A3NL12191)
C105 HYD CHG PRESSURE SENDER GWY CTRLR
2180 BRN
(S/N AZN811061 - AZN811162)
SHEET 6
(S/N AZN911113 - ANZ911229)
2170 BRN
SHEET 6
C104 ENGINE COOLANT SENSOR Sheet 4 of 13 Printable Version Click Here
2150 BRN
SHEET 6
674 of 1234
LEGEND
PARTIAL CONNECTOR
CAN BUS
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
CAN HI
CAN LO
21 3090 LBL D REMOTE RUN KEY
1730 RNG/WHT
C
E SHEET 3
1830 RNG/WHT * C450
1
9220 PUR 8 SHEET 3

1840 RNG/WHT * C449
1
J2B 2080 BLK 2
9640 PUR 4
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
Sheet 5 of 13
Printed In U.S.A.
7210762 (C)
675 of 1234
LEGEND
POWER PAGE 3
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
YEL
CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW
JOIN ONE WIRE)
C113 FUEL SHUTOFF

+12V PULL
PWR 30
1350 RED/WHT
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
SHEET 4 2035 BLK A
8800 TAN 9 8800 TAN HOLD
24.5 OHM
+12V STARTER
STARTER
1030 RED PWR 30
3560 LBL 2 3560 LBL R 1015 RED
GND 85 86 8210 TAN
2005 BLK C110
SHEET 4 B
G
GLOW T14
+12V PLUG 1815 RNG/WHT 7 1815 RNG/WHT EXCITATION
PRE HEATER SHEET 3
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
2115 BLK GND 85 86 8510 TAN

SHEET 4

6 8510 TAN
14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
C405 163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4 C107
GND
SHEET 9
4 8800 TAN
C355
J1B
FUEL HARN
C 3180 LBL
C406
A
WIRING SCHEMATIC
SIG
FUEL SENDER
SHEET 4
(30-270 OHM) (MANUAL MACHINE)
C104
SHEET 4
2170 BRN B GND
ENGINE COOLANT
S550 (S/N A3NL11631 - A3NL12191)
18 3170 LBL A SIG
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
Sheet 6 of 13
676 of 1234
7210762 (C)
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
TRACTION C425
+12V LOCK
PWR 30 4100 LGN B C308
1360 RED/WHT BRAKE
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
2220 BRN B
SHEET 4 TEMPERATURE
500 - 3000 OHM
C112
34 3320 LBL A
J1A 2320 BRN B
C446
7.2 OHM 12 V
C420
9.8 OHM 12V
C105
HYDRAULIC
5190 YEL A +8V PWR 0.5-7.5V
4200 LGN
19 13 1 23 6 WIRING SCHEMATIC
J1B +8V
GWY CTRLR
C418
(MANUAL MACHINE)
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
S550 (S/N A3NL11631 - A3NL12191)
C419
3.3 OHM PWM
(S/N AZN811061 - AZN811162)
1 2340 BRN 2 GND
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) (S/N AZN911113 - ANZ911229)
3.3 OHM PWM
Sheet 7 of 13
Printed In U.S.A.
J2B 7210762 (C)
AUX CTRLR
677 of 1234
LEGEND
CAB
DISPLAY
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
BUZZER (-) PTOL
C408
1930 RNG/WHT 1
SHEET 4 GROUND
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
7040 WHT 10 J1A
SHEET 4 GROUND
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
SHEET 3
SW9 1620 RNG/WHT 5
*
TRAVEL CONTROL
SHEET 3
11
SWITCHED POWER
SWITCH (OPTIONAL) 3400 LBL LEFT BLINKER INPUT J1B

SHEET 13 22 3040 LBL 14 3040 LBL 4
4 SHEET 13
3650 LBL 7 1950 RNG/WHT 5
SHEET 3 BATTERY (+)
3600 LBL 9 PARK BREAK INPUT 2960 BLK 3
SW1 SHEET 4 GROUND
6
3 2 BRAKE SWITCH
1 C480
5
2930 BLK SHEET 9
10
1240 RED/WHT 1
SHEET 4 GROUND
8
7
6
5
4
3
1 WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
Sheet 8 of 13
678 of 1234
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
PARTIAL CONNECTOR
CAB
CONNECTOR
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 SHEET #
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN *C212
POWER
SOCKET
6 4550 LGN
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
1210 RED/WHT A
SHEET 3
+12V BATT PWR
B
+12V SW PWR
* DOME LIGHT (-)
2820 BLK C
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK
SHEET 4 SHEET 13
2885 BLK SHEET 13
C428
(LT GRAY)
CAB-MFR HARN CONN 2
2060 BLK
SHEET 9 *
C667
DOOR HARN
(SEE ADDITIONAL
11 OPTIONS SHEET)
3630 LBL 4 DOOR SIGNAL
SHEET 8
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND

7310 WHT 3
C482 SEATBAR
J1B SENSOR C252
GWY CTRLR SHEET 4
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

(MANUAL MACHINE)
+5V
SHEET 6
5140 YEL
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
Sheet 9 of 13

Printed In U.S.A.
7210762 (C)
679 of 1234
PAGE 1,2
MANUAL
CONTROLS
LIGHTS PAGE 11
OPTIONS PAGE 13
C409
K
G RIGHT HANDLE
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
PWM
23 4300 LGN B +
30
31 C410
C404 C103 Dealer Copy -- Not for Resale 13 K
SHEET 4
1530 RNG/WHT A
SHEET 3
J
C421 H
GND E
10 2670 BRN 3
2 4670 LGN 7.8 OHM 12V
GWY CTRLR 2 SIG C411
E
C422 C
7 GND
3 A
2680 BRN
4680 LGN
2
WIRING SCHEMATIC B
C412
A HORN
(MANUAL MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
7210762 (C)
680 of 1234
LIGHTS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C434-1
(BLACK) 37.00 Watts
CAB-MFR HARN CONN 1
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRONT
WORK C103
C603
GND 85 86 C602
SHEET 4 2045 BLK
6330 PNK 1 SIG
Dealer Copy -- Not for Resale 2640 BLK 2 BLK
LEFT REAR
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A 17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK BLK
SHEET 4
RIGHT REAR

+12V LIGHT
LEFT REAR
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)

681 of 1234
HVAC
HYDRAULICS PAGE 7
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
HVAC PAGE 12
#
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS PAGE 13
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
SWITCH)
C635
* D SIG
B
E
C438
Dealer Copy -- Not for ResaleF *BLOWER
SW10
(DK GRAY) SWITCH
+12V HVAC CAB-MFR HARN CONN 3
PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2016 BLK
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
AC EVAPORATOR C350
SWITCH B
A
7023 WHT WIRING SCHEMATIC
7024 WHT
C355
SW11
*
AC SWITCH
(MANUAL MACHINE)
FUEL HARN # C486 1 C 7400 WHT
7015 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH
(COMPRESSOR)
2100 BLK
3 S550 (S/N A3NL11631 - A3NL12191)
2290 BLK 2280 BLK
SHEET 13
D4 (S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
Sheet 12 of 13
7210762 (C)
Printed In U.S.A.
682 of 1234
OPTIONS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
OPTIONS
C428
PAGE 13
# C355 (LT GRAY)
C607
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
2 2470 BLK
2290 BLK
2770 BLK B 2770 BLK
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480 BLK SWITCH 6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
(BLINKER/FLASHER)
5 PIN
C
SHEET 8
3400 LBL
*BEACON
SW2
6570 PNK
E 1550 RNG/WHT 9 1550 RNG/WHT
SHEET 3 SWITCH
A 6515 PNK
2725 BLK 6
C103
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
C438 (PINS 3 & 6
TAILGATE HARN 5 4 3
(DK GRAY) INTERNALLY
CAB-MFR HARN CONN 3 INSULATED)
2850 BLK
6
EURO TAIL LIGHTS ONLY E 3500 LBL C670
(SEE ADDITIONAL
OPTIONS SHEET)
D
6410 PNK
6510 PNK 6500 PNK 3 6500 PNK
6540 PNK 2420 BLK D
Dealer Copy -- Not for Resale 6440 PNK F BEACON/FLASHER
B EXTERIOR HARNESS
C423
3 (SEE ADDITIONAL
C
BUCKET
POSITION
A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6
A
OPTIONS SHEET)

2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C126
6540 PNK
* C676
RADIO
* C277
2 1
C412 SHEET 4
CAB-MFR HARN CONN 1
2785 BLK B SHEET 9 2885 BLK
1 2
B 7210 WHT A 1885 RNG/WHT
LEFT HANDLE 13 7210 WHT HORN SHEET 9 3
A 1460 RED/WHT C279
(HORN)
2 PIN
SHEET 3 *
2210 BLK
4 PWR
5 GND AIR RIDE
SPEAKER 6
-
C278
RIGHT
*
- 2 7810 WHT 6
C415 1 7800 WHT 5
J2A SPEAKER +
26 2460 BRN B GND HIGH FLOW
AUX CTRLR SOLENOID
4460 LGN A SIG
7.5 OHM 12 V
J2B
AUX CTRLR
26
WIRING SCHEMATIC
C441
J1A
GWY CTRLR
26 2350 BRN 2 GND TWO SPEED (MANUAL MACHINE)
4350 LGN 1 SIG SOLENOID
5.1 OHM 12V S550 (S/N A3NL11631 - A3NL12191)
J1B 26
GWY CTRLR
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - ANZ911229)
683 of 1234
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C428 CAB-MFR HARN CONN (LT GRY) 14 3,4,9,13 T1 BATT GROUND 4
C104 ENGINE COOLANT SENSOR 2 6 C434-2 LEFT WORKLIGHT 2 2 11 T3 FLASHER 13
C106 ENGINE SPEED SENSOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C107 ENGINE OIL PRESSURE 3 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13 T8 BATT GROUND 4
C108 HYD TEMPERATURE SENDER 2 7 C441 TWO SPEED 2 13 T13 BUZZER POWER 8
C110 ALTERNATOR 2 6 C446 HYDRAULIC FAN 2 7 T14 PRE HEATER 6
C112 HYD OIL FILTER SWITCH 2 7 C449 LEFT JOYSTICK (CAB HARN) 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C113 ENGINE HARNESS 10 6 C450 RIGHT JOYSTICK (CAB HARN) 4 5 T16 RIGHT REAR WORK LIGHT(-) 11
C126 HORN 2 13 C479 LEFT PANEL(BLACK) 12 5,8 T17 LEFT REAR WORK LIGHT (+) 11
C129 CAB ACCESSORY 3 9 C480 LEFT PANEL(GRAY) 12 8 T18 LEFT REAR WORK LIGHT (-) 11
C212 POWER SOCKET 2 9 C482 SEATBAR SENSOR 3 9 T19 BACKUP ALARM 10
C252 WASHER ADAPTER INTMD 2 9 C483 TEMP CONTROL SWITCH 3 12 T20 BACKUP ALARM (GND) 10
C253 WASHER PUMP 2 9 C486 AC COMPRESSOR 2 12 T36 DOMELIGHT (-) 9
C277 AIR RIDE SEAT 6 13 C489 MFR ACCESSORY 2 3,4 T37 DOMELIGHT (+) 9
C278 RIGHT SPEAKER 2 13 C499 PTOL 4 8
C279 LEFT SPEAKER 2 13 C500 RH KEY SWITCH 6 8 SW1 BRAKE SWITCH 8
C308 BRAKE SOLENOID 2 7 C503 RH DLX PANEL 6 5,8 SW2 BEACON SWITCH 13
C350 AC EVAPORATOR SWITCH 2 12 C602 LEFT REAR TAIL LIGHT 2 11 SW3 HAZARD SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C603 RIGHT REAR TAIL LIGHT 2 11 SW4 HAND/FOOT, H/ISO SWITCH 9
C404 BACKUP ALARM 2 3,10 C606 POWER BOBTACH OPEN 2 13 SW5 POWER BOBTACH SWITCH 13
C405 AIR FILTER SWITCH 2 6 C607 POWER BOBTACH CLOSE 2 13 SW6 BUCKET POSITION SWITCH 13
C406 FUEL SENDER 2 6 C610 HVAC DUCT FAN 2 12 SW9 TRAVEL CONTROL SWITCH 8
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C611 BLOWER MOTOR 4 12 SW10 BLOWER SWITCH 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW11 AC SWITCH 12
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C667 DOOR 6 9
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C670 EXTERIOR BEACON 6 13
C415 HIGH FLOW SOLENOID 2 13 C676 RADIO Dealer Copy --6 Not for13Resale
C418 FRONT ROD 2 7
C419 FRONT BASE 2 7 J1A GATEWAY COTROLLER 34 3,6,7,10,11
,12,13
J1B GATEWAY CONTOLLER 26 3,4,5,6,9,
C420 HYD LOCK 2 7
10,13
C421 TILT SPOOL LOCK 3 10 J2A AUX CONTROLLER 34 7,10,13
C422 LIFT SPOOL LOCK 3 10 J2B AUX CONTROLLER 26 3,4,5,7,10,
13
C423 BUCKET POSITION 2 13
C425 BRAKE SOLENOID 3 7 FRC1 FUSE RELAY CENTER 3,6,7,11,12

BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PAGE 1,2
OVERVIEW
BATTERY GROUND
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
GROUND
CAN BUS
PAGE 4
PAGE 5 WIRING SCHEMATIC
ENGINE PAGE 6
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
HYDRAULICS
CAB DISPLAY
PAGE 7
PAGE 8
(MANUAL MACHINE)
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 S550 (S/N A3NL12192 - A3NL12725)
LIGHTS PAGE 11
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR HVAC PAGE 12 (S/N AZN811163 - AZN811512)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT OPTIONS PAGE 13
(S/N AZN911230 - AZN911254)
Sheet 1 of 13

Printed In U.S.A.
7254944 (0)
684 of 1234
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 B-4
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 B-5
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 B-10
A-11 AC SENSE B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-18 HYD FAN RETURN B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER
A-25 ENGINE OIL PRESS B-25 A-25 B-25 BUCKET POSITION (SPARE)
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-29 A-29
A-31 LIGHT 1 RELAY FDBK
Dealer Copy -- Not forRH
A-31
Resale
LEFT DOWN
LEGEND
PARTIAL CONNECTOR HARNESS PART NUMBER
MFR CTRL 7210555
STD CAB 7210557
TRACTION FUEL SWITCH DLX CAB 7253409
STARTER PULL PULL POWER
CONNECTOR DLX FUEL 7240781
STD FUEL 7149219
ENG 2403 7181036
GLOW REAR FRONT HVAC WIRE BREAK
ENG 2607 7181037
PLUG LIGHT LIGHT
(TWO WIRE BREAKS TAILGATE DOM 7217484 Printable Version Click Here
JOIN ONE WIRE) TRK BRAKE ADP 7165061
SHEET #
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 2 of 13
Printed In U.S.A.
7254944 (0)
685 of 1234
1300/RED
FRC1 FUSE RELAY CENTER
FUSE 1
25 A
1140/RED/WHT SHEET 12
POWER
J2B
1240/RED/WHT SHEET 8
C503 RH DLX PANEL
FRC1 HVAC RELAY 1150/RED/WHT 3 C408
1400/RED/WHT
BATTERY MEGAFUSE
FUSE 4
1180/RED/WHT 2
AUX CTRLR (BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE/RED 25 A
1025/RED 1160/RED/WHT 1450/RED/WHT 6 1450/RED/WHT 1420/RED/WHT SHEET 8
1110/RED/WHT
J1B
1130/RED/WHT 3 GWY CTRLR 1440/RED/WHT
FUSE 12 SHEET 8
OPEN C479 LH PANEL
SHEET 6
STARTER
1460/RED/WHT
1010/RED
SHEET 13
FUSE 5 C412 LEFT HANDLE HORN
1040/RED 25 A 1410/RED/WHT
1490/RED/WHT
SHEET 13
FUSE 11 1165/RED/WHT
15 A SHEET 5
1290/RED 1370/RED/WHT C426 REMOTE RUN, ACD
SHEET 9
FUSE 9
1620/RNG/WHT
30 A 1360/RED/WHT SHEET 8
1050/RED FRC1 TRACTION LOCK RELAY
FUSE 10
SHEET 6 1940/RNG/WHT
1030/RED 30 A 1350/RED/WHT SHEET 8
1060/RED FUSE 2 FRC1 FUEL SHUTOFF RELAY
1340/RED 1330/RED/WHT
FUSE 3 C428
1775/RNG/WHT
1320/RED/WHT CAB-MFR HARN CONN 2 SW1 BRAKE SWITCH
SHEET 11
1660/RNG/WHT
Dealer Copy -- Not for 2Resale
1660/RNG/WHT 1590/RNG/WHT
SHEET 8
1520/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
FUSE 6
5A C409 RIGHT HANDLE 1950/RNG/WHT
1570/RNG/WHT 1530/RNG/WHT SHEET 10 SHEET 8
1560/RNG/WHT 22 J2B
FUSE 8 AUX CTRLR 1785/RNG/WHT
SHEET 9
25 A 1730/RNG/WHT SHEET 5 SW4 H/ISO SWITCH
1780/RNG/WHT A 1960/RNG/WHT
1550/RNG/WHT SHEET 13
25 A
1760/RNG/WHT 1750/RNG/WHT 1815/RNG/WHT SHEET 6
C110 ALT EXCITATION
C404
1720/RNG/WHT B BACKUP ALARM HARN
1850/RNG/WHT
SWITCHED SHEET 9
+12V POWER
1790/RNG/WHT
SHEET 12
C408 CAB-MFR CONN (FR WIPER) WIRING SCHEMATIC
1050/RED PWR
30 FRC1 HVAC RELAY 1580/RNG/WHT SHEET 9
87
J1A
GWY CTRLR
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) (MANUAL MACHINE)
GND 85 86
SHEET 4
2030/BLK 3380/LBL 4
S550 (S/N A3NL12192 - A3NL12725)
C428
(LT GRAY) (S/N AZN811163 - AZN811512)
CAB-MFR HARN CONN 2
1920/RNG/WHT 6 1920/RNG/WHT 1840/RNG/WHT SHEET 5 (S/N AZN911230 - AZN911254)

C449 LH JOYSTICK
1830/RNG/WHT SHEET 5 Sheet 3 of 13 Printable Version Click Here

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SHEET 5
SHEET 5
SHEET 8
C479 LH PANEL
SHEET 8
2080/BLK
C449 LH JOYSTICK
2070/BLK
C450 RH JOYSTICK
2920/BLK
2940/BLK
C408
(BLACK)
CAB-MFR HARN CONN 1
2950/BLK 10 2950/BLK
GROUND
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8
16 2540/BLK
C428 J2B
2930/BLK (LT GRAY) 15 2550/BLK 2090/BLK
SHEET 8 AUX CTRLR
2830/BLK 2900/BLK 1 2900/BLK

SHEET 13
SW6 BKT POSITION SWITCH 2765/BLK
2700/BLK 2710/BLK SHEET 11
C426 REMOTE RUN, ACD 2300/BLK
SHEET 13 2455/BLK 2745/BLK
SHEET 13 2785/BLK SHEET 12
C126 HORN
C489 2790/BLK T8
2620/BLK B 2720/BLK SHEET 9 BATT GND
SHEET 11 MFR ACCESSORY C408 CAB-MFR CONN (ACCESSORIES)
T16 RH REAR LIGHT
2770/BLK 2780/BLK
2630/BLK C103 SHEET 13 SHEET 13
2650/BLK 2600/BLK B 2600/BLK 2730/BLK
SHEET 10 SHEET 9
T20 BU ALARM 2390/BLK C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2640/BLK SHEET 6 2810/BLK
C602 LH REAR LIGHT Dealer Copy -- Not for Resale
SHEET 7 2200/BLK
SHEET 11 2610/BLK C425 BRAKE
C603 RH REAR LIGHT
2005/BLK
SHEET 6
FRC1 STARTER RELAY
SHEET 6 2035/BLK
SHEET 11 2045/BLK
2055/BLK
SHEET 11
2320/BRN FRC1 REAR LIGHT RELAY
SHEET 7 2115/BLK 2105/BLK
SHEET 6 2145/BRN 2016/BLK
SHEET 12
SHEET 9
2370/BRN
SHEET 3
2030/BLK
WIRING SCHEMATIC
2025/BLK
SHEET 7
2220/BRN
SHEET 7
FRC1 TRACTION LOCK RELAY (MANUAL MACHINE)
SHEET 7
2190/BRN
2230/BRN 17 J1B
GWY CTRLR
S550 (S/N A3NL12192 - A3NL12725)
SHEET 6
2180/BRN (S/N AZN811163 - AZN811512)
2170/BRN
(S/N AZN911230 - AZN911254)
SHEET 6
Sheet 4 of 13
2150/BRN Printable Version Click Here
SHEET 6
7254944 (0)
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CAN BUS
C408
J1B (BLACK)
8 9200/PUR 9270/PUR 9230/PUR 4 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4

CAN LO C479
9 9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 3 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
Remote Start Tool, ACD 9160/PUR/WHT 2 C503
14 9500/PUR/WHT A 9260/PUR 4 RIGHT DELUXE PANEL
CAN HI
20 9600/PUR B
CAN LO
21 3090/LBL D REMOTE RUN KEY
1730/RNG/WHT
C
E SHEET 3
1830/RNG/WHT * C450
1
1165/RED/WHT F 2070/BLK 2
2710/BLK G 9560/PUR/WHT 3 (SJC ONLY)
SHEET 4 GROUND 9660/PUR 4
9220/PUR 8
SHEET 3
1840/RNG/WHT * C449
1
J2B 2080/BLK 2
9120/PUR/WHT 9 SHEET 4 LEFT JOYSTICK
AUX CTRLR
9540/PUR/WHT 3 (SJC ONLY)
9640/PUR 4
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Printed In U.S.A.
7254944 (0)
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C113
ENGINE FUEL SHUTOFF
+12V PULL
8120/TAN 8120/TAN 8 8120/TAN 8100/TAN B PULL 0.33 OHM
PWR
1350/RED/WHT 30
SHEET 3 87 3410/LBL D5
2810/BLK 10 2810/BLK 2800/BLK C GND
SHEET 4
GND 85 86 8110/TAN
SHEET 4 2035/BLK A
8800/TAN 9 8800/TAN HOLD
24.5 OHM
+12V STARTER
STARTER
PWR 30
SHEET 3
1030/RED
87 8200/TAN 8200/TAN 1 8200/TAN S M B SHEET 3
3560/LBL 2 3560/LBL R 1015/RED
2005/BLK GND 85 86 8210/TAN C110
SHEET 4 B
ALTERNATOR S 1020/RED
G
2015/BLK L 1815/RNG/WHT
GLOW T14
+12V PLUG 1815/RNG/WHT 7 1815/RNG/WHT EXCITATION
PRE HEATER SHEET 3
1060/RED PWR 30 8500/TAN
SHEET 3 87 3420/LBL
2115/BLK GND 85 86 8510/TAN

SHEET 4
6 8510/TAN
14 3420/LBL
7 8210/TAN
3 8110/TAN Dealer Copy -- Not for Resale
J1A 30 3410/LBL
GWY CTRLR
22 3560/LBL C106
15 3160/LBL 3160/LBL 3 3160/LBL A SIG
2160/BRN B GND ENGINE SPEED SENSOR
C405
163 OHM
16 3150/LBL A SIG 2145/BRN 4 2145/BRN
SHEET 4 C107
2150/BRN B AIR FILTER
GND
SHEET 4 SWITCH (NC) 2140/BRN A GND
25 3140/LBL 3140/LBL 6 3140/LBL C SIG ENGINE OIL PRESSURE
5140/YEL 5 5140/YEL B +5V PWR SENDER (0.5 ~ 4.5V)
SHEET 9
4 8800/TAN
C355
FUEL HARN
J1B C406
GWY CTRLR 12 3180/LBL C 3180/LBL A SIG
2180/BRN D 2180/BRN B FUEL SENDER
GND
SHEET 4 (30-270 OHM)
C104 WIRING SCHEMATIC

2170/BRN B GND
SHEET 4
18 3170/LBL A SIG
ENGINE COOLANT
SENSOR (500-3000 OHM) (MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
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TRACTION
HYDRAULICS C425
+12V LOCK
PWR 30 4100/LGN B C308
1360/RED/WHT BRAKE
SHEET 3 87 3430/LBL 4200/LGN A 4200/RED A SOLENOID
2200/BLK C 2200/BLK B 9.8 OHM
GND 85 86 SHEET 4
2025/BLK 4110/LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108 HYDRAULIC
2220/BRN B TEMPERATURE
SHEET 4
32 3220/LBL A SENDER
500 - 3000 OHM
C112
34 3320/LBL A
HYDRAULIC
J1A 2320/BRN B
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYD LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12V
C105
HYDRAULIC
2190/BRN B GND CHARGE
3190/LBL C SIG PRESSURE
5190/YEL A +8V PWR 0.5-7.5V
4200/LGN
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (MANUAL MACHINE)

GWY CTRLR
C418 S550 (S/N A3NL12192 - A3NL12725)
J2A 18 2330/BRN 2 GND FRONT ROD
AUX CTRLR 4330/LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
(S/N AZN811163 - AZN811512)
1 2340/BRN
C419
2 GND FRONT BASE
(S/N AZN911230 - AZN911254)
4340/LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM Sheet 7 of 13

19 13 7254944 (0)
J2B
AUX CTRLR
Printed In U.S.A.
690 of 1234
CAB
DISPLAY
T13
SHEET 3
1940/RNG/WHT
BUZZER (+) (NOT IN STD CAB HARN 7210557)
C499
BUZZER (-) PTOL
C408
1930/RNG/WHT 1
CAB-MFR HARN CONN 1 2940/BLK 3
SHEET 4 GROUND
20 3030/LBL 1 3030/LBL 2
C479 PTOL OUTPUT
LEFT PANEL (BLACK) 19 2380/BRN 12 2380/BRN 4 PTOL LED
7040/WHT 10 J1A
2920/BLK 2 RIGHT H KEY SWITCH PANEL
SHEET 4 GROUND
1440/RED/WHT 1 24 8130/TAN 2 8130/TAN 2
1960/RNG/WHT SHEET 3 BATTERY (+) START
SHEET 3
*
SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5
11
SWITCHED POWER
SWITCH (OPTIONAL) 3400/LBL LEFT BLINKER INPUT J1B

SHEET 13 22 3040/LBL 14 3040/LBL 4
5 6
SHEET 13
3500/LBL 8 Dealer Copy
RIGHT BLINKER INPUT -- Not for Resale
4 5
3650/LBL 7 1950/RNG/WHT
2700/BLK 2 3 TRAVEL CONTROL INPUT SHEET 3 SWITCHED POWER
SHEET 4 1 1420/RED/WHT 1
SHEET 3 BATTERY (+)
3600/LBL 9 3
PARK BREAK INPUT
SHEET 4 2960/BLK GROUND
SW1 6
3 2 BRAKE SWITCH
1 C480
3610/LBL 4 5 LEFT PANEL (GRAY) C503
1775/RNG/WHT RIGHT DELUXE PANEL
SHEET 3 6 3630/LBL 12
SHEET 9 DOOR SIGNAL
2930/BLK 11 1590/RNG/WHT 5
SHEET 4 SHEET 3 SWITCHED POWER
10
1240/RED/WHT 1
3610/LBL 2 PARK BREAK OUTPUT 2250/BLK 3
SHEET 4 GROUND
8
7
6
5
4
3
1
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
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SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
CAB
SHEET 3
SHEET 9 2060/BLK 5
3
6 * DLX CAB HARN 7253409 ONLY
C438
(DK GRAY)
4
CAB-MFR HARN CONN 3
4 4235/LGN
5 4275/LGN *C212
POWER
SOCKET
6 4550/LGN
2795/BLK 1
GND
1375/RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1
1370/RED/WHT 7 1370/RED/WHT 1390/RED/WHT

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010/BLK LIGHT
CAB ACCESSORY
T38
1210/RED/WHT A
SHEET 3 1580/RNG/WHT 5 1580/RNG/WHT 1865/RNG/WHT B
+12V BATT PWR
+12V SW PWR * DOME LIGHT (-)
2820/BLK C
GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT
SHEET 13
2730/BLK 11 2730/BLK 2210/BLK
SHEET 4 SHEET 13
2885/BLK SHEET 13
C428
(LT GRAY)
CAB-MFR HARN CONN 2
2060/BLK SHEET 9 *
C667
DOOR HARN
(SEE ADDITIONAL
Dealer Copy -- Not for Resale OPTIONS DWG)
2790/BLK 11 2790/BLK
SHEET 4
3630/LBL 4 DOOR SIGNAL
SHEET 8
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
2840/BLK 2
WIPER MOTOR GROUND
1850/RNG/WHT 13 1850/RNG/WHT 1850/RNG/WHT 1

7310/WHT 3
C482 SEATBAR
J1B SENSOR
2370/BRN 4 2370/BRN A GND
GWY CTRLR SHEET 4
11 3370/LBL 5 3370/LBL B SIG
24 5100/YEL 5370/YEL 3 C +5V PWR

WIRING SCHEMATIC
5370/YEL
+5V
SHEET 6
5140/YEL HARNESS WASHER PUMP
7253378
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
* C252 C253
PWR
(S/N AZN811163 - AZN811512)
A 7310/WHT 1 WASHER
2845/BLK
MOTOR (S/N AZN911230 - AZN911254)
B 2845/BLK 2 GND
Sheet 9 of 13

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MANUAL C409
CONTROLS
K
G RIGHT HANDLE
1520/RNG/WHT A
SHEET 3
4940/LGN H
4930/LGN J SKI CTRL
21 4920/LGN E DETENT FLOW
4910/LGN F
TWO SPD
J2B 17 4310/LGN C -
AUX CTRLR 18 4320/LGN D
PWM
23 4300/LGN B +
30
31 C410
C404 C103 13 K
(SEE ADDITIONAL A 7100/WHT C 7100/WHT AUX CTRLR 28 4840/LGN C
OPTIONS SHEET) BACK UP 22 4830/LGN B SKI CTRL
2650/BLK ALARM 12 4820/LGN G
SHEET 4
T20 TERMINAL (-) 11 4810/LGN F SIDE SHIFT
1530/RNG/WHT A
SHEET 3
J
C421 Dealer Copy -- Not for Resale H
GND E
10 2670/BRN 3
2 4670/LGN 7.8 OHM 12V
GWY CTRLR SIG C411
2
E
C422 C
7 GND
2680/BRN 3 A
4680/LGN
2
C412
B
WIRING SCHEMATIC A HORN
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
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LIGHTS
C434-1
2735/BLK B GND LEFT FRONT
C408 6100/PNK A WORK LIGHT
SIG 37.00 Watts
(BLACK)
CAB-MFR HARN CONN 1
C434-2
2765/BLK 9 2765/BLK 2750/BLK B BLK LEFT FRONT
SHEET 4
6110/PNK A SIG WORK LIGHT
50.00 Watts
C435-1
6000/PNK 8 6000/PNK 6120/PNK A SIG RIGHT FRONT
2760/BLK B BLK WORK LIGHT
37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
2705/BLK B BLK WORK LIGHT
50.00 Watts
FRONT
WORK C103
C603
PWR 30 2610/BLK 2 GND
1330/RED/WHT 6310/PNK RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6320/PNK 1 SIG TAIL LIGHT
GND 85 86 C602
SHEET 4 2045/BLK
6330/PNK 1 SIG LEFT REAR
2640/BLK 2 BLK TAIL LIGHT
SHEET 4
5 6320/PNK
31 3460/LBL
J1A 17
GWY CTRLR
6210/PNK
28 3440/LBL
T16 TERMINAL (-)

2620/BLK BLK
SHEET 4
Dealer Copy -- Not for Resale RIGHT REAR
6210/PNK SIG WORK LIGHT

+12V LIGHT
1320/RED/WHT PWR 30 T17 TERMINAL (+)
SHEET 3 87 6200/PNK H 6200/PNK 6220/PNK SIG
LEFT REAR
GND 85 86 2630/BLK GND WORK LIGHT
2055/BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Printed In U.S.A.
Sheet 11 of 13

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HVAC
* DLX CAB HARN 7253409 ONLY 2560/BLK
*
*
C610
2
1
C483
C
GND
SIG
BLK
HVAC DUCT
FAN
(NOT IN STD CAB HARN 7210557) 7420/WHT

7425/WHT
A
B
DBL
WHT
POTENTIOMETER
(TEMP CONTROL
SWITCH)
#
DLX FUEL HARN 7240781 ONLY *
C635
D SIG
(NOT IN STD FUEL HARN 7149219) 2130/BLK
7430/WHT
C
A
GND
+12V PWR
HEATER
VALVE
B
E
C438
(DK GRAY)
F
*BLOWER
SW10
+12V HVAC SWITCH

CAB-MFR HARN CONN 3
PWR 30 OFF
1140/RED/WHT
SHEET 3 87 1500/RNG/WHT 7 1500/RNG/WHT 5 2
1
GND 85 86 4
2016/BLK
SHEET 4
1790/RNG/WHT
7410/WHT 6
3 7530/WHT * C611
1 14.00 Amps High
SHEET 3 7520/WHT 2 7.50 Amps Med BLOWER
21 3450/LBL 7510/WHT 3 5.00 Amps Low MOTOR
2745/BLK 8 2745/BLK 2580/BLK 4
SHEET 4 Dealer Copy -- Not for Resale
J1A
GWY CTRLR
2570/BLK
* C630
2 THERMOSTAT
11 7021/WHT 7020/WHT 9 7020/WHT 1
3
AC EVAPORATOR C350
SWITCH B 7023/WHT
A 7024/WHT
C355
SW11
AC SWITCH* Printable Version Click Here
FUEL HARN # C486
A 7024/WHT 7025/WHT 1
MAGNET CLUTCH
7015/WHT
2100/BLK
1 C 7400/WHT
3
WIRING SCHEMATIC
2
(COMPRESSOR)
SHEET 13
2290/BLK
D4
2280/BLK
(MANUAL MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 12 of 13
7254944 (0)
Printed In U.S.A.
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# C607
PWR BOB CLOSE
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
OPTIONS * DLX CAB HARN 7253409 ONLY
1
2
4470/LGN
2470/BLK 2770/BLK
E
B
4470/LGN
2770/BLK
8 4470/LGN
4480/LGN
SHEET 4
2290/BLK
SHEET 12
# C606
*POWER
SW5 2 1
3
#
2 2480/BLK SWITCH 5 4
6 (NOT IN STD FUEL HARN 7149219)
1 4480/LGN F 4480/LGN 7
1380/RED/WHT
SHEET 3
C411
B 6010/PNK 10
1430/RED/WHT
6010/PNK
X
L
* FLASHER
T3
CONN
LEFT HANDLE D 6415/PNK 6400/PNK 14 6400/PNK D2 6430/PNK

(BLINKER/FLASHER)
5 PIN
C
SHEET 8 3400/LBL
*BEACON
SW2
6570/PNK
E 1550/RNG/WHT 9 1550/RNG/WHT
SHEET 3 SWITCH
A 6515/PNK
2725/BLK 6
C103
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
3 2
TAILGATE HARN C438 (PINS 3 & 6
(DK GRAY) INTERNALLY 5 4 3
2850/BLK
(SEE ADDITIONAL
OPTIONS DWG)
E
D
6410/PNK
6510/PNK 6500/PNK 3 6500/PNK
SHEET 8
3500/LBL
D1 6530/PNK * C670E
6540/PNK 2420/BLK D
6440/PNK F BEACON/FLASHER
B EXTERIOR HARNESS
C423
(SEE ADDITIONAL
BUCKET
POSITION
A 4450/LGN D3 4455/LGN 2 4455/LGN
3
1
4
2 *BUCKET
SW6 C
A
OPTIONS DWG)
SOLENOID B 2450/BLK
2830/BLK DealerPOSITION
Copy -- Not for Resale
5
9.8 OHM 2455/BLK SHEET 4 6 SWITCH
SHEET 4
2780/BLK 1 2780/BLK
SHEET 4
C408
(BLACK) C126
6540/PNK
*RADIO
C676
* C2771
CAB-MFR HARN CONN SHEET
1 4 2885/BLK 2
C412 2785/BLK B SHEET 9 2
1885/RNG/WHT 1
LEFT HANDLE B 7210/WHT 13 7210/WHT A HORN SHEET 9 3
(HORN)
2 PIN
A 1460/RED/WHT
SHEET 3 *+ C279
1 7820/WHT 3 SHEET 9 1510/RNG/WHT
2210/BLK
4
5
PWR
GND AIR RIDE
LEFT 2 7830/WHT 4 SHEET 9 SEAT
SPEAKER 6
-
RIGHT
*- C278
2 7810/WHT 6
C415 1 7800/WHT 5
J2A HIGH FLOW SPEAKER +
26 2460/BRN B GND
AUX CTRLR SOLENOID
4460/LGN A SIG
7.5 OHM 12 V
J2B 26 WIRING SCHEMATIC

AUX CTRLR
J1A
C441 (MANUAL MACHINE)
26 2350/BRN 2 GND TWO SPEED
GWY CTRLR
4350/LGN 1 SIG SOLENOID
5.1 OHM 12V
S550 (S/N A3NL12192 - A3NL12725)
J1B
GWY CTRLR
26 (S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Printed In U.S.A.
7254944 (0)
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Index Diagram
1
2
SH01 - INDEX
SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND
5 SH05 - CAN BUS BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
6 SH06 - ENGINE
7 SH07 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT LEGEND
8 SH08 - CAB DISPLAY
9 SH09 - CAB
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CONNECTOR
10 SH10 - MANUAL CONTROLS
11 SH11 - LIGHTS 1 1
12 SH12 - HVAC
13 SH13 - OPTIONS 1
14 SH14 - OPTIONS 2
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL 1 1

HARNESS PART NUMBER LGN
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN
MFR MAN 7307216
1 1
STD CAB 7210557 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
DLX CAB 7304511 WIRE BREAK
STD FUEL 7149219 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
ENG 2403 7181036 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
SHT1/F2 SHT1/F2
ENG 2607 7181037

TRK BRAKE ADP 7165061 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
SUSP JSTK 7163706
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
ACS/AWS/SJC
COMPUTER ATTACHMENT
UNSWITCHED
TRACTION FUEL SWITCHED
STARTER
PULL PULL POWER
POWER PLUG REAR LIGHT ALT & KITS
FUEL PULL FRONT LIGHT SWITCHED
GLOW REAR FRONT

HVAC
PLUG LIGHT LIGHT
TRACTION HVAC UNSWITCHED
Wiring Schematic S510 S/NWARNING

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
PROPRIETARY NOTICE TOLERANCES: ECN 102711 Printed On November 2017
csf
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
Standard Machine S/N AZN811513
B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC MF MAN
Click Here For Interactive PDF S/NCOPYRIGHT
AZN911255 & Above C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Printable Version Click Here Sheet 1 of 14
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV DESCRIPTION
102711 MSE
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 14
7307215
697 of 1234
UNSWITCHED
BATT POWER
FUSE RELAY CENTER
1300 RED
FUSE 1 25 A 1140 RED/WHT
1A 1B SHT12/F8
AUX CTRLR
1180 RED/WHT
2
1150 RED/WHT
3
J2B 1240 RED/WHT
+12V BATTERY C408 SHT8/E3
100.0 Amps FUSE 4 25 A MFR HARN CONN 1 (BLACK) 1400 RED/WHT
HW11 1 1 1025 RED 1160 RED/WHT SP2 1450 RED/WHT 1450 RED/WHT SHT9/D3
4A 4B 6 6 1420 RED/WHT
T4 SP7 SHT8/E3
T5
1440 RED/WHT
GWY CTRLR SHT8/G8
1110 RED/WHT
2
1130 RED/WHT
3
J1B
SHT6/G1
FUSE 12 25 A

12A 12B
1010 RED
1460 RED/WHT
SHT13/B7
1040 RED
FUSE 5 25 A 1490 RED/WHT 1410 RED/WHT
5A 5B SHT13/G7
SP24 1165 RED/WHT
SHT5/C8
BUS BAR
9A 9B SHT7/H8
SP26 1290 RED

11A 11B SHT9/F8
BUS BAR
10A 10B SHT6/D1
1340 RED
2A 2B SHT11/D8
BUS BAR
3A 3B SHT11/B8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/E8
1060 RED
SHT6/E1

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM
Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Printable Version Click
Sheet 2 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 2 / 14
7307215
698 of 1234
SWITCHED
POWER
1560 RNG/WHT
22 AUX CTRLR
J2B
1520 RNG/WHT
SHT10/G3
FUSE RELAY CENTER 1570 RNG/WHT SP11 1530 RNG/WHT
SHT10/D3
1620 RNG/WHT
SHT8/G8
FUSE 6 5 A
1940 RNG/WHT
6A 6B C428 SHT8/H8
MFR HARN CONN 2 1930 RNG/WHT
SHT8/H3
(LT GRAY) 1775 RNG/WHT
1660 RNG/WHT 1660 RNG/WHT SHT8/D8
2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
BUS BAR
SHT8/E8
1565 RNG/WHT
SHT14/F4
1815 RNG/WHT

SHT6/G5
FRC1 1550 RNG/WHT
SWITCHED SHT13/F7
C489
POWER
MFR ACCESSORY
RELAY - A 1780 RNG/WHT
A A
C404
1050 RED 30 BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)
SHT2/C1 F4 87 1765 RNG/WHT
FUSE 7 25 A 1750 RNG/WHT SP52 1720 RNG/WHT
F1 7A 7B B B
2030 BLK 86 85
SHT4/B8 F5 F2 1850 RNG/WHT
SHT9/D8
BUS BAR
FRC1 FRC1 1580 RNG/WHT
SHT9/F8
1575 RNG/WHT
SHT14/G4
FUSE 8 25 A 1730 RNG/WHT

8A 8B SHT5/C8
FRC1 FRC1
1920 RNG/WHT
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
SHT12/E8 21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
MFR HARN CONN 2 (LT GRAY) 1830 RNG/WHT
1920 RNG/WHT SP37 SHT5/E3
6 6 1840 RNG/WHT
SHT5/E3

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM
Printable Version Click Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 3 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 3 / 14
7307215
699 of 1234
GROUND
2150 BRN
SHT6/G7
2145 BRN
2080 BLK SHT6/F5 GWY CTRLR
SHT5/D3
2170 BRN
SHT6/B7
2070 BLK 2180 BRN SP12 2230 BRN
SHT5/E3 SHT6/B7 17 SENSOR GND
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
MFR HARN CONN 1 (BLACK) SHT7/F7
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

SHT8/D3 16 BATTERY GROUND
GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
SHT14/D4 2550 BLK SP28 2090 BLK 2730 BLK
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
2830 BLK MFR HARN CONN 2 (LT GRAY) SHT11/H8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK

2700 BLK 1 1 SHT13/D8
SHT8/F8 SP47 2790 BLK
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/C8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

SHT11/C4 MFR ACCESSORY B B
2650 BLK
SHT10/F8 C103
TAILGATE HARN 2015 BLK 1
2600 BLK SP6 2390 BLK T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B 1 T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2810 BLK
SHT6/C7 2185 BRN
SHT14/E7 SP58 2995 BRN
2195 BRN 17 SENSOR GND
SHT10/G3
2005 BLK J2B
SHT6/G8
2016 BLK
SHT12/E8
2025 BLK
SHT7/H5
2055 BLK
SHT11/B8 SP1 2105 BLK
2035 BLK
SHT6/D1
2045 BLK
SHT11/D8
2030 BLK
SHT3/D8
2115 BLK
SHT6/E1
2505 BLK
SHT14/G4
2155 BLK
SHT14/F4

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT Printable Version ClickSCHEM
Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 4 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 4 / 14
7307215
700 of 1234
CAN BUS
RE016 RE019 C479

C408
GWY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP18 R1-1 (BLACK)
TP-09 9200 PUR TP-09 TP-10 9270 PUR TP-10 SP31TP-16 TP-16 TP-01 9230 PUR TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 TP-08 9630 PUR TP-08
9230 PUR 9240 PUR 9250 PUR 9650 PUR
CAN LO 8 4 4 4
SP30 SP17 SP38 SP34

9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
CAN HI 9 3 3 3
R3-2 TP-11 R1-2
TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
9260 PUR TP-06
4
9160 PUR/WHT
2
C503
AUX CTRLR C450 C460

RIGHT JOYSTICK CONN RIGHT JOYSTICK RIGHT JOYSTICK
TP-11 1830 RNG/WHT
9220 PUR 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/C1 1 1 1 1
2070 BLK 2070 BLK GND

9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
J2B 9660 PUR 9660 PUR CAN LO
4 4 4 4
C426
Remote Run Tool, ACD
TP-17 9500 PUR/WHT TP-17
CAN HI 14 A A CAN HI C449 C459
LEFT JOYSTICK CONN LEFT JOYSTICK LEFT JOYSTICK
1840 RNG/WHT 1840 RNG/WHT +12V PWR
9600 PUR SHT3/C1 1 1 1 1
CAN LO 20 B B CAN LO
SHT4/H8 2 2 2 2
9540 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
9640 PUR 9640 PUR CAN LO
4 4 4 4
SUSP SEAT JOYSTICK HARNESS
3090 LBL SP93 3085 LBL

REMOTE RUN KEY 21 D D REMOTE RUN KEY
J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/D1 E E SWITCHED POWER
1165 RED/WHT
SHT2/E1 F F UNSWITCHED POWER
2710 BLK
SHT4/E8 G G GROUND

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT Printable Version Click Here ELEC MF MAN
SCHEM
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 5 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 5 / 14
7307215
701 of 1234
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C113
MFR-ENG HARN T21 S
1030 RED
SHT2/C1 J4 87 8200 TAN 8220 TAN
30 J1 1 1
8210 TAN 85 3560 LBL
J2 J5 2 2 T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
GWY CTRLR
C110 ALTERNATOR
1015 RED 1020 RED
STARTER RELAY SIGNAL 7 S
1815 RNG/WHT 1815 RNG/WHT
3560 LBL SHT3/E1 7 7 L
STARTER RELAY FEEDBACK 22
2015 BLK 1
2150 BRN GND GND SHT4/D3
SHT4/H3 B T11
AIR FILTER
3150 LBL SWITCH (NC) 1
AIR FILTER SENDER SIGNAL 16 A SIG
T12
C405
3160 LBL 3160 LBL
ENGINE SPEED SENDER SIGNAL 15 3 3 A
ENGINE SPEED
2160 BRN SENSOR (163 OHMS)
B
2145 BRN 2145 BRN SP99 C106
SHT4/H3 4 4
2140 BRN
A ENGINE OIL PRESSURE
SENDER (0.5-4.5V)
3140 LBL 3140 LBL
ENGINE OIL PRESS SENDER SIGNAL 25 6 6 C
5140 YEL 5140 YEL

SHT9/B8 5 5 B
C107

FRC1 GLOW PLUG
RELAY - F
1 8500 TAN
1060 RED
T14 3420 LBL B1 SHT2/C1
GLOW PLUG RELAY FEEDBACK 14 B4
8510 TAN 2115 BLK
GLOW PLUG RELAY SIGNAL 6 B5 B2 SHT4/B8
FRC1 FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL G4 SHT2/D1
FUEL RELAY FEEDBACK 30 G1
8110 TAN 2035 BLK
FUEL RELAY SIGNAL 3 G2 G5 SHT4/C8
J1A FRC1 FRC1

C113 C101
MFR-ENG HARN FUEL SHUTOFF SOLENOID
8120 TAN 8120 TAN 8100 TAN PULL
8 8 B B 0.33 OHM
D1
2810 BLK 2400 BLK 2800 BLK GND
SHT4/C8 10 10 C C
8800 TAN 8800 TAN HOLD

FUEL SHUTOFF SOLENOID HOLD 4 9 9 A A 24.5 OHM
C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
ENGINE COOLANT SENSOR SIGNAL 18 A
ENGINE COOLANT SENSOR
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM
Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 6 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 6 / 14
7307215
702 of 1234
FRC1
TRACTION LOCK RELAY - D
C425 HYDRAULICS
4100 LGN
1360 RED/WHT B B
SHT2/E1 H4 87 4200 LGN C308
30 H1 A A A
BRAKE
85 2025 BLK SOLENOID 9.8
H2 H5 SHT4/C8 2200 BLK 2200 BLK
86 SHT4/D8 C C B OHM 12 V TRACK 2 SPEED ADAPTER
FRC1 FRC1 (SEE ADDITIONAL OPTIONS DWG)
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
TRACTION LOCK 13 C425
RELAY FEEDBACK PULL
B B 0.3 OHMS
2220 BRN GND
SHT4/G3 B 10.9 OHMS
HYDRAULIC TEMPERATURE SENDER HOLD
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
HYD TEMP SIGNAL 32 A
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
HYD FILTER DIFF PRESS 34 A
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1

HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446
HYD LOCK VALVE 2410 BRN GND

SOL GROUND
1 2
HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
J1A
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
6
HYD CHARGE PRESS
SENDER SIGNAL
HYD CHARGE PRESS

SENDER POWER
HYD LOCK
SOLENOID SIGNAL
HYDRAULIC FAN
SIGNAL
TRACTION
SOLENOID OUTPUT
4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID (MALE)
FRONT ROD 2330 BRN SIG 3.3 OHM PWM
SOLENOID GROUND 18 2
C418
4340 LGN GND
GWY CTRLR 1
FRONT BASE SOLENOID (FEMALE)
FRONT BASE 2340 BRN SIG 3.3 OHM PWM
SOLENOID GROUND
1 2
J2A C419
J2B
19
13
FRONT BASE
SOLENOID SIGNAL
FRONT ROD
SOLENOID SIGNAL
AUX CTRLR

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
Printable Version ClickSCHEM
Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 7 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 7 / 14
7307215
703 of 1234
1940 RNG/WHT
LEFT PANEL BUZZER CAB DISPLAY
SHT3/F1 1
T13
7040 WHT 1
C499
T2 PTOL CONN
C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/F1 1
2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
MFR HARN CONN 1 (BLACK)
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/F1 1 PTOL LED 19 12 12 4
1620 RNG/WHT SWITCHED POWER
SHT3/G1 5 C499
C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT13/F5 11
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT13/F5 8 START ENGINE 24 2 2 2
J1A
6
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/F1 5
6
1
1420 RED/WHT UNSWITCHED POWER
5 4 SHT2/F1 1
3600 LBL PARK BRAKE INPUT

SW9 SW9 9
1960 RNG/WHT 2960 BLK GROUND
SHT3/F1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4 SHT2/F1 1
3
SW1 C480 2250 BLK GROUND
SW1 SHT4/G8 3
1775 RNG/WHT LEFT PANEL CONN (GRAY)
SHT3/F1
3630 LBL DOOR SIGNAL
6
SHT9/D3 12
C503 SHT5/F1
3610 LBL PARK BRAKE OUTPUT

2
C480

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215

Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 8 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 8 / 14
7307215
704 of 1234
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/F1 2 1
6
2060 BLK (NOT IN STD CAB HARN 7210557)
SHT9/E3 5
4
SW4 3
SW4
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
HAND CONTROL LIGHT 4 4
FOOT CONTROL LIGHT 4275 LGN

5 5
FOOT CONTROL SIGNAL 6 6

4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
1375 RED/WHT +12V PWR
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/D1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT SP41 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT SP8 1865 RNG/WHT
SHT3/D1 5 5 B B +12V SW PWR
* T38
2820 BLK

C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
2885 BLK
C428
MFR HARN CONN 2 (LT GRAY)
SHT13/B3
* C667
DOOR HARNESS
2790 BLK 2790 BLK
SHT4/E3 11 11 (SEE ADDITIONAL
OPTIONS DWG)
3630 LBL
SHT8/D8 4 4 DOOR SIGNAL
1400 RED/WHT
SHT2/F1 5 5 DOOR UNSW PWR
2840 BLK
2 2 WIPER MOTOR GROUND
SHT3/D1 13 13 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
6 6
2370 BRN 2370 BRN 7310 WHT
SHT4/G3 4 4 SEATBAR 3 3 WASHER SIGNAL
SENSOR
GWY CTRLR GND

A
SEATBAR SENSOR 3370 LBL 3370 LBL SIG
SIGNAL 11 5 5 B
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
5V CTRLR POWER 24 3 3 HARNESS WASHER PUMP
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/E5 A A PWR 1
WASHER
2845 BLK 2845 BLK
MOTOR
B B GND 2

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 9 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 9 / 14
7307215
705 of 1234
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/G1 A
RIGHT HANDLE LEFT 4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE 30 H LEFT POSITION SWITCH
LEFT ROCKER UP 2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT
13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GWY CTRLR
TILT SPOOL LOCK 2670 BRN GND

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
AUX CTRLR
7.8 OHM 12V LIFT (ACS/AHC ONLY)
4670 LGN SIG
1
C421
HANDLE LOCK (ACS ONLY)

H
LIFT SPOOL LOCK 2680 BRN GND
SOLENOID GROUND 2 3 E
LIFT SPOOL LOCK
J1A D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/G1 A
LEFT HANDLE RIGHT
C422 ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
LEFT HANDLE RIGHT 4840 LGN
ROCKER UP
28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7
LEFT HANDLE PADDEL LEFT 12 G

C410
TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
J2A LEFT POSITION SWITCH
TRIGGER
GWY CTRLR

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 10 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 10 / 14
7307215
706 of 1234
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2

FRC1
FRONT WORK 2610 BLK GND
SHT4/D8 2
LIGHTS RELAY - B
C103 RIGHT REAR
TAIL LIGHT
1330 RED/WHT TAILGATE HARN
SHT2/D1 D1 6340 PNK SP10 6310 PNK 6310 PNK SP49 6320 PNK SIG
D4 A A 1
2045 BLK
C603
SHT4/C8 D2 D5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
TAIL LIGHT
GWY CTRLR
MRKR LIGHT PWR 2640 BLK GND
6320 PNK SHT4/D8 2
RELAY SIGNAL 5
C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK
31
REAR LIGHT 6210 PNK

RELAY SIGNAL 17 T16 TERMINAL (-)
2620 BLK
3440 LBL SHT4/E8
REAR LIGHT GND 1
RELAY FEEDBACK
28
RIGHT REAR
FRC1 WORK LIGHT
J1A
REAR LIGHT 6210 PNK SIG 1
RELAY - C T15 TERMINAL (+)
1320 RED/WHT T17 TERMINAL (+)

SHT2/C1 C1 87 6200 PNK 6200 PNK SP96 6220 PNK
30 C4 H H SIG 1
2055 BLK 85 LEFT REAR
SHT4/C8 C2 C5 WORK LIGHT
86
FRC1 FRC1 2630 BLK GND 1
SHT4/D8
T18 TERMINAL (-)

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 11 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 11 / 14
7307215
707 of 1234
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
M (NOT IN STD CAB HARN 7210557)
7440 WHT SIG
C610
1
* DLX FUEL HARN 7266824 ONLY
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
2130 BLK HEATER VALVE
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
1140 RED/WHT (DK GRAY) 1
SHT2/G1 E1 87 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT
MED
30 E4 7 7 5 1 2
4 7510 WHT
LOW

2016 BLK 85 SW10 3
SHT4/C8 E2 E5 7400 WHT
86 3
FRC1 FRC1 M
SW10
1790 RNG/WHT 7410 WHT
SHT3/D1 4
3450 LBL
SHT3/C6 C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
SWITCH 7024 WHT 7024 WHT 7025 WHT SIG
A A A 1
D4
C350 MAGNET CLUTCH

2290 BLK (COMPRESSOR)
SHT13/H7 2280 BLK GND
2
C486

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
Printable Version Click SCHEM ELEC MF MAN

Here
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 12 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 12 / 14
7307215
708 of 1234
C428
# C355
FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP332770
2470 BLK BLK 2770 BLK
2 GND SW5
C607
B B SHT4/E8
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
2290 BLK (NOT IN STD FUEL HARN 7149219)
SHT12/B8 1380 RED/WHT 1
# 2
3 DLX CAB HARN 7304511 ONLY
1 SIG
4480 LGN
F F
4480 LGN
7 7
SW5
* (NOT IN STD CAB HARN 7210557)
POWER BOB
SW5
OPEN 2480 BLK
2 GND
LEFT HANDLE 6010 PNK 6010 PNK
C606 10 10
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY 1405 RED/WHT
SHT14/D6
(SEE ADDITIONAL OPTIONS DWG)
1410 RED/WHT 1410 RED/WHT 1430 RED/WHT
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
FLOAT (ACS/AHC ONLY)
SHT3/E1
1550 RNG/WHT
9 9
1550 RNG/WHT * SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
RIGHT POSTION SWITCH 6500 PNK 6530 PNK
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
6415 PNK MFR HARN CONN 3 (DK GRAY)
D 6500 PNK 3

LEFT POSITION SWITCH
6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
E E INTERNALLY INSULATED)
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG) D D * SW6
BUCKET POSITION SWITCH
2850 BLK
SP46 2725 BLK
SIG 4450 LGN 4455 LGN 4455 LGN 6570 PNK

BUCKET A 2 2 1
POSITION 2
D3
2905 BLK
SOLENOID 3 SHT14/F6
9.8 OHM B GND 2450 BLK 2455 BLK

SHT4/E8
2830 BLK
4 SHT14/F4
2970 BLK
6700 PNK
*
2810 BLK
C423 SHT4/E8 6 5 SHT14/D4 E E
2420 BLK C670
SW6 SW6 D D
2780 BLK 2780 BLK 6540 PNK BEACON/FLASHER
SHT4/E3 1 1 B B EXTERIOR HARNESS
LEFT HANDLE 6440 PNK
F F (SEE ADDITIONAL
LIFT (ACS/AHC ONLY) OPTIONS DWG)
C C
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG) A A
C676 *
1
LEFT SPEAKER
* * RADIO CONN
2
7820 WHT LEFT L010
AUX CTRLR 1 3 SPEAKER (+)
3 AIR RIDE SEAT
1510 RNG/WHT PWR
FLOAT (ACS/AHC ONLY) HIGH FLOW 2460 BRN 7830 WHT SHT9/E3 4
LEFT PWR
SOLENOID GROUND 26 2 4 SPEAKER (-)
J2A C279
GND
B RIGHT SPEAKER 2210 BLK GND GND
RIGHT POSTION SWITCH HIGH FLOW SHT9/E3 5
SIG
SOLENOID
7.5 OHM 12 V
* 7810 WHT RIGHT 6
PADDLE A GWY CTRLR 2 6 SPEAKER (-) C277
C415 7800 WHT
HIGH FLOW 4460 LGN RIGHT
26 1 5 SPEAKER (+)
SOLENOID SIGNAL
J2B TWO SPEED GROUND 26 C278 1885 RNG/WHT
SHT9/E3 1
C408 J1A
MFR HARN CONN 1 C126 2885 BLK
1460 RED/WHT SHT9/D3 2
A SHT2/E1 (BLACK) HORN CONNECTOR
TRIGGER
7210 WHT SIG 2350 BRN
C676
7210 WHT GND
B 13 13 A A _ 2
TWO SPEED TRACK 2 SPEED
C412 SOLENOID (SEE ADDITIONAL
HORN
4350 LGN OPTIONS DWG)
+ TWO SPEED SIGNAL 26 SIG
1 5.1 OHM 12 V
2785 BLK GND
SHT4/E8 B B
J1B C441

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215

Here ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 13 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 13 / 14
7307215
709 of 1234
AUX CTRLR C438
* SW7
RIDE CONTROL
RIDE CONTROL SW AUTO 23

3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8
OPTIONS 2
SW7 SW7 (NOT IN STD CAB HARN 7210557)
3480 LBL
RIDE CONTROL RELAY SIGNAL 7
RIDE CONTROL
RELAY - RC1
1575 RNG/WHT
3415 LBL SP9 3425 LBL 30 SHT3/D1
RIDE CONTROL COIL SIGNAL 21 87
3435 LBL 3445 LBL 2505 BLK
1 1 85 86 SHT4/B8
RIDE CONTROL RIDE CONTROL RC1 RC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/B8
C438
*
SW13
REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIGNAL 16 12 12 3
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIGNAL 29 11 11 6
1565 RNG/WHT
5 SHT3/F1
C443 4
2175 BRN
2 SW13 SW13

27
J2A REVERSING
FAN COIL
3485 LBL
25 1
2185
BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
10 C
5105 YEL
PRESSURE SENSOR
24 B
J2B C442
*SIDELIGHT
SW8 C672
SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307215
SCHEM ELEC MF MAN
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 14 of 14
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 14 / 14
7307215
710 of 1234
Index Diagram
1
2
SH01 - INDEX
4 SH04 - GROUND
6 SH06 - ENGINE
7 SH07 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT LEGEND
8 SH08 - CAB DISPLAY
9 SH09 - CAB
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CONNECTOR
10 SH10 - MANUAL CONTROLS
11 SH11 - LIGHTS 1 1
12 SH12 - HVAC
13 SH13 - OPTIONS 1
14 SH14 - OPTIONS 2
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL 1 1

HARNESS PART NUMBER LGN
MFR MAN 7322226
1 1
STD CAB 7210557 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
DLX CAB 7304511 WIRE BREAK
STD FUEL 7149219 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
ENG 2403 7181036 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
SHT1/F2 SHT1/F2
ENG 2607 7181037

TRK BRAKE ADP 7165061 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
SUSP JSTK 7163706

A3NL12900 & Above PROPRIETARY NOTICE TOLERANCES: ECN 108481 Printed On November 2017
csf

Standard Machine 7322225
SCHEM
Here ELEC MF MAN
Sheet 1 of 14
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Printable Version Click
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
0
REV DESCRIPTION
108481 MMM
SHT 1 / 14
7322225
711 of 1234
UNSWITCHED
BATT POWER
FUSE RELAY CENTER
1300 RED
1A 1B SHT12/F8
AUX CTRLR
1180 RED/WHT
2
1150 RED/WHT
3
J2B 1240 RED/WHT
4A 4B 6 6 1420 RED/WHT
T4 SP7 SHT8/E3
T5
1440 RED/WHT
GWY CTRLR SHT8/G8
1110 RED/WHT
2
1130 RED/WHT
3
J1B
SHT6/G1
FUSE 12 25 A

12A 12B
1010 RED
1460 RED/WHT
SHT13/B7
1040 RED
5A 5B SHT13/G7
SP24 1165 RED/WHT
SHT5/C8
BUS BAR
9A 9B SHT7/H8
SP26 1290 RED

11A 11B SHT9/F8
BUS BAR
10A 10B SHT6/D1
1340 RED
2A 2B SHT11/D8
BUS BAR
3A 3B SHT11/B8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/D8
1060 RED
SHT6/E1
1205 RED
SHT3/G8

csf


Here ELEC MF MAN
Sheet 2 of 14
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 2 / 14
7322225
712 of 1234
SWITCHED
POWER
SWITCHED POWER
RELAY - RC1
1205 RED FUSE 25A

SHT2/C1 30 87 1585 RNG/WHT 1580 RNG/WHT
A B SHT9/F8
3385 LBL
C171 C171 2065 BLK
86 85 SHT4/C8
RC1 RC1
1560 RNG/WHT
22 AUX CTRLR
J2B
1520 RNG/WHT
SHT10/G3
SHT10/D3
1620 RNG/WHT
SHT8/G8
FUSE 6 5 A
1940 RNG/WHT
6A 6B C428 SHT8/H8
SHT8/H3

2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
BUS BAR
SHT8/E8
1565 RNG/WHT
SHT14/F4
1815 RNG/WHT
SHT6/G5
1550 RNG/WHT
SHT13/F7
C489
MFR ACCESSORY
SWITCHED POWER 1780 RNG/WHT
A A
RELAY - RC2
C404
1050 RED
FUSE 7 25 A BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)
SHT2/C1 30 87 1770 RNG/WHT SP101 1765 RNG/WHT 1750 RNG/WHT SP52 1720 RNG/WHT
7A 7B B B
SP100 3390 LBL 2030 BLK
86 85 SHT4/B8 1850 RNG/WHT
SHT9/D8
BUS BAR
RC2 RC2
1575 RNG/WHT
SHT14/G4

8A 8B SHT5/C8
FRC1 FRC1
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
3380 LBL
J1A
C428
1920 RNG/WHT 1920 RNG/WHT SP37 SHT5/E3
6 6 1840 RNG/WHT
SHT5/E3

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SCHEM ELEC MF MAN
COPYRIGHT C
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 3 / 14
7322225
713 of 1234
GROUND
2150 BRN
SHT6/G7
2145 BRN
2080 BLK SHT6/F5 GWY CTRLR
SHT5/D3
2170 BRN
SHT6/B7
2070 BLK 2180 BRN SP12 2230 BRN
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK

2700 BLK 1 1 SHT13/D8
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/C8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

2650 BLK
SHT10/F8 C103
2600 BLK SP6 2390 BLK T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B 1 T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2810 BLK
SHT6/C7 2185 BRN
2065 BLK 2195 BRN 17 SENSOR GND
SHT3/G1 SHT10/G3
2005 BLK
SHT6/G8 J2B
2016 BLK
SHT12/E8
2025 BLK
SHT7/H5
2055 BLK
SHT11/B8 SP55 2105 BLK
2035 BLK
SHT6/D1
2045 BLK
SHT11/D8
2030 BLK
SHT3/D6
2115 BLK
SHT6/E1
2505 BLK
SHT14/G4
2155 BLK
SHT14/F4

csf

SCHEM
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Sheet 4 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 4 / 14
7322225
714 of 1234
CAN BUS
C479
LEFT PANEL
GWY CTRLR Z3 C408
MFR HARN CONN 1 (BLACK) Z1 (BLACK)
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR
SP31 SP39 SP35
9200 PUR 9270 PUR 9230 PUR 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
CAN HI 9 3 3 3 CAN HI
C479
C503
RH DLX PANEL
9260 PUR
4
9160 PUR/WHT
2
C503
AUX CTRLR C450 C460

9220 PUR 1830 RNG/WHT 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/B1 1 1 1 1

9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT 9560 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
C426
9500 PUR/WHT
9600 PUR SHT3/B1 1 1 1 1
SHT4/H8 2 2 2 2
9540 PUR/WHT 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
3090 LBL SP93 3085 LBL

J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/C1 E E SWITCHED POWER
1165 RED/WHT
2710 BLK
SHT4/E8 G G GROUND

csf


Here ELEC MF MAN
Sheet 5 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 5 / 14
7322225
715 of 1234
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C113
MFR-ENG HARN T21 S
1030 RED
SHT2/C1 J4 87 8200 TAN 8220 TAN
30 J1 1 1
8210 TAN 85 3560 LBL
J2 J5 2 2 T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
GWY CTRLR
C110 ALTERNATOR
1015 RED 1020 RED
3560 LBL SHT3/D1 7 7 L
2015 BLK 1
SHT4/H3 B T11
AIR FILTER
T12
C405
3160 LBL 3160 LBL
ENGINE SPEED
B
2145 BRN 2145 BRN SP99 C106
SHT4/H3 4 4
2140 BRN
SENDER (0.5-4.5V)
3140 LBL 3140 LBL
5140 YEL 5140 YEL

SHT9/B8 5 5 B
C107

FRC1 GLOW PLUG
RELAY - F
1 8500 TAN
1060 RED
T14 3420 LBL B1 SHT2/C1
8510 TAN 2115 BLK
FRC1 FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL G4 SHT2/D1
8110 TAN 2035 BLK
J1A FRC1 FRC1

C113 C101
8 8 B B 0.33 OHM
D1
SHT4/C8 10 10 C C

C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

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Sheet 6 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 6 / 14
7322225
716 of 1234
FRC1
C425 HYDRAULICS
4100 LGN
1360 RED/WHT B B
SHT2/E1 H4 87 4200 LGN C308
30 H1 A A A
BRAKE
H2 H5 SHT4/C8 2200 BLK 2200 BLK
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
RELAY FEEDBACK PULL
B B 0.3 OHMS
2220 BRN GND
SHT4/G3 B 10.9 OHMS
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1

C446
HYD LOCK VALVE 2410 BRN GND

SOL GROUND
1 2
HYDRAULIC LOCK SOLENOID
1
J1A
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT9/B8 B
C105
4200 LGN
J1B
19
13
6
HYD CHARGE PRESS
SENDER SIGNAL
HYD LOCK
SOLENOID SIGNAL
HYDRAULIC FAN
SIGNAL
TRACTION
SOLENOID OUTPUT
4330 LGN GND

AUX CTRLR 1
FRONT ROD 2330 BRN SIG 3.3 OHM PWM
C418
4340 LGN GND
GWY CTRLR 1
FRONT BASE 2340 BRN SIG 3.3 OHM PWM
SOLENOID GROUND
1 2
J2A C419
J2B
19
13
FRONT BASE
SOLENOID SIGNAL
FRONT ROD
SOLENOID SIGNAL
AUX CTRLR

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Sheet 7 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 7 / 14
7322225
717 of 1234
1940 RNG/WHT
SHT3/F1 1
T13
7040 WHT 1
C499
T2 PTOL CONN

LEFT PANEL (BLACK) SHT3/E1 1
2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
SHT2/F1 1 PTOL LED 19 12 12 4
SHT3/F1 5 C499
C500
SHT13/F5 11
J1A
6
SW9

SHT3/E1 5
6
1
5 4 SHT2/F1 1

SW9 SW9 9
SHT3/E1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/E1 5
5 6
4 SHT2/F1 1
3
SW1 SHT4/G8 3
SHT3/E1
6
SHT9/D3 12
C503 SHT5/F1

2
C480

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SCHEM
Sheet 8 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 8 / 14
7322225
718 of 1234
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT9/E3 5
4
SW4 3
SW4
C438
4235 LGN
HAND CONTROL LIGHT 4 4
FOOT CONTROL LIGHT 4275 LGN

5 5

4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
2
C212
C408
SHT2/D1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
SHT3/G1 5 5 B B +12V SW PWR
* T38
2820 BLK

C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
2885 BLK
C428
MFR HARN CONN 2 (LT GRAY)
SHT13/B3
* C667
DOOR HARNESS
2790 BLK 2790 BLK
OPTIONS DWG)
3630 LBL
1400 RED/WHT
2840 BLK
SHT3/C1 13 13 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
6 6
2370 BRN 2370 BRN 7310 WHT
SENSOR
GWY CTRLR GND

A
SIGNAL 11 5 5 B
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/E5 A A PWR 1
WASHER
5190 YEL
SHT7/D7 2845 BLK 2845 BLK
MOTOR
B B GND 2

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Sheet 9 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 9 / 14
7322225
719 of 1234
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/F1 A
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE 30 H LEFT POSITION SWITCH
LEFT ROCKER UP 2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GWY CTRLR

10 3
TILT SPOOL LOCK
AUX CTRLR
7.8 OHM 12V LIFT (ACS/AHC ONLY)
4670 LGN SIG
1
C421

H
LIFT SPOOL LOCK 2680 BRN GND
SOLENOID GROUND 2 3 E
LIFT SPOOL LOCK
J1A D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/F1 A
LEFT HANDLE RIGHT
C422 ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
ROCKER UP
28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7

C410
TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
TRIGGER
GWY CTRLR

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Here ELEC MF MAN
Sheet 10 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 10 / 14
7322225
720 of 1234
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2

FRC1
SHT4/D8 2
LIGHTS RELAY - B
C103 RIGHT REAR
TAIL LIGHT
D4 A A 1
2045 BLK
C603
SHT4/C8 D2 D5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
TAIL LIGHT
GWY CTRLR
6320 PNK SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK
31
REAR LIGHT 6210 PNK

2620 BLK
3440 LBL SHT4/E8
REAR LIGHT GND 1
RELAY FEEDBACK
28
RIGHT REAR
FRC1 WORK LIGHT
J1A

30 C4 H H SIG 1
86
SHT4/D8
T18 TERMINAL (-)

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Sheet 11 of 14
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Here
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 11 / 14
7322225
721 of 1234
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
C610
1
* DLX FUEL HARN 7266824 ONLY
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
MED
30 E4 7 7 5 1 2
4 7510 WHT
LOW

2016 BLK 85 SW10 3
86 3
FRC1 FRC1 M
SW10
SHT3/C1 4
3450 LBL
SHT3/B6 C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
A A A 1
D4
C350 MAGNET CLUTCH

2
C486

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Sheet 12 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 12 / 14
7322225
722 of 1234
C428
# C355
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP332770
2 GND SW5
C607
B B SHT4/E8
# 2
3 DLX CAB HARN 7304511 ONLY
1 SIG
4480 LGN
F F
4480 LGN
7 7
SW5
* (NOT IN STD CAB HARN 7210557)
POWER BOB
SW5
OPEN 2480 BLK
2 GND
C606 10 10
SHT14/D6
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
SHT3/D1
1550 RNG/WHT
9 9
1550 RNG/WHT * SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
D 6500 PNK 3

6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
EURO TAIL LIGHTS
(SEE ADDITIONAL
2850 BLK
SP46 2725 BLK
SIG 4450 LGN 4455 LGN 4455 LGN 6570 PNK

BUCKET A 2 2 1
POSITION 2
D3
2905 BLK
SOLENOID 3 SHT14/F6

SHT4/E8
2830 BLK
4 SHT14/F4
2970 BLK
6700 PNK
*
2810 BLK
C423 SHT4/E8 6 5 SHT14/D4 E E
2420 BLK C670
SW6 SW6 D D
LEFT HANDLE 6440 PNK
F F (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY
C676 * L010
HEATED SEAT
LEFT SPEAKER
* * RADIO CONN SHT9/E3
1510 RNG/WHT
PWR
4 PWR
7820 WHT LEFT

AUX CTRLR 1 3 SPEAKER (+)
2210 BLK GND GND
FLOAT (ACS/AHC ONLY) HIGH FLOW 2460 BRN 7830 WHT SHT9/E3 5
LEFT
SOLENOID GROUND 26 2 4 SPEAKER (-) C277
J2A C279
GND
B RIGHT SPEAKER
RIGHT POSTION SWITCH HIGH FLOW
SIG
SOLENOID
7.5 OHM 12 V
* 7810 WHT RIGHT
PADDLE A GWY CTRLR 2 6 SPEAKER (-)
C415 7800 WHT
HIGH FLOW 4460 LGN RIGHT
26 1 5 SPEAKER (+)
SOLENOID SIGNAL
J2B TWO SPEED GROUND 26 C278 1885 RNG/WHT
SHT9/E3 1
C408 J1A
MFR HARN CONN 1 C126 2885 BLK
1460 RED/WHT SHT9/D3 2
TRIGGER
7210 WHT SIG 2350 BRN
C676
7210 WHT GND
B 13 13 A A 2
+ TWO SPEED TRACK 2 SPEED
HORN OPTIONS DWG)
2785 BLK GND
_ TWO SPEED SIGNAL 26 1
SHT4/E8 B B
J1B C441

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Sheet 13 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 13 / 14
7322225
723 of 1234
AUX CTRLR C438
* SW7
RIDE CONTROL

3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8
OPTIONS 2
SW7 SW7 (NOT IN STD CAB HARN 7210557)
3480 LBL
RIDE CONTROL RELAY SIGNAL 7 RIDE CONTROL
RELAY - F
FUSE RELAY CENTER
1575 RNG/WHT
3415 LBL SP9 3425 LBL F4 F1 SHT3/C1
RIDE CONTROL COIL SIGNAL 21
3435 LBL 3445 LBL 2505 BLK
1 1 F5 F2 SHT4/B8
RIDE CONTROL RIDE CONTROL
FRC1 FRC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440 2155 BLK
SHT4/B8
C438
*
SW13
REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIGNAL 16 12 12 3
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/E1
C443 4
2175 BRN
2 SW13 SW13

27
J2A REVERSING
FAN COIL
3485 LBL
25 1
2185
BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
10 C
5105 YEL
PRESSURE SENSOR
24 B
J2B C442
*SIDELIGHT
SW8 C672
SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8

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Sheet 14 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 14 / 14
7322225
724 of 1234
PINS PINS PINS
C106 ENGINE SPEED SENSOR 2 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13 T8 BATT GROUND 4
C107 ENGINE OIL PRESSURE 3 6 C441 TWO SPEED 2 13 T13 BUZZER POWER 8
C108 HYD TEMPERATURE SENDER 2 7 C446 HYDRAULIC FAN 2 7 T14 PRE HEATER 6
C110 ALTERNATOR 2 6 C449 LEFT JOYSTICK (CAB HARN) 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C112 HYD OIL FILTER SWITCH 2 7 C450 RIGHT JOYSTICK (CAB HARN) 4 5 T16 RIGHT REAR WORK LIGHT(-) 11
C113 ENGINE HARNESS 10 6 C479 LEFT PANEL(BLACK) 12 5,8 T17 LEFT REAR WORK LIGHT (+) 11
C126 HORN 2 13 C480 LEFT PANEL(GRAY) 12 8 T18 LEFT REAR WORK LIGHT (-) 11
C129 CAB ACCESSORY 3 9 C482 SEATBAR SENSOR 3 9 T19 BACKUP ALARM 10
C209 DOME LIGHT 3 9 C483 TEMP CONTROL SWITCH 3 12 T20 BACKUP ALARM (GND) 10
C212 POWER SOCKET 2 9 C486 AC COMPRESSOR 2 12
C252 WASHER 2 9 C489 MFR ACCESSORY 2 3,4 SW1 BRAKE SWITCH 8
C277 AIR RIDE SEAT 6 13 C492 ACS/SJC HARNESS 8 3,5,9 SW2 BEACON SWITCH 13
C278 RIGHT SPEAKER 2 13 C493 ACS/SJC HARNESS 4 3,4 SW3 HAZARD SWITCH 13
C279 LEFT SPEAKER 2 13 C499 PTOL 4 8 SW4 HAND/FOOT, H/ISO SWITCH 9
C308 BRAKE SOLENOID 2 7 C500 RH KEY SWITCH 6 8 SW5 POWER BOBTACH SWITCH 13
C350 AC EVAPORATOR SWITCH 2 12 C503 RH DLX PANEL 6 5,8 SW6 BUCKET POSITION SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C602 LEFT REAR TAIL LIGHT 2 11 SW9 TRAVEL CONTROL SWITCH 8
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11 SW10 BLOWER SWITCH 12
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13 SW11 AC SWITCH 12
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C610 HVAC DUCT FAN 2 12
C409 RIGHT HANDLE 10 10 C611 BLOWER MOTOR 4 12
C410 LEFT HANDLE 10 10 C630 THERMOSTAT 3 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C635 HEATER VALVE 6 12
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C667 DOOR 6 9
C415 HIGH FLOW SOLENOID 2 7 C670 EXTERIOR BEACONDealer Copy
6 -- Not
13 for Resale
C418 FRONT ROD 2 7 C676 RADIO 6 9
C419 FRONT BASE 2 7
C420 HYD LOCK 2 7 J1A GATEWAY COTROLLER 34
C421 TILT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26
C422 LIFT SPOOL LOCK 3 10 J2A AUX CONTROLLER 34
C423 BUCKET POSITION 2 13 J2B AUX CONTROLLER 26
C426 CAN (Remote Start Tool, ACD) 7 5 FRC1 FUSE RELAY CENTER 3,6,7,11,12

SCHEMATIC INDEX
PAGE 1,2
WIRING SCHEMATIC
OVERVIEW
BATT FEED, FUSED
BATT FEED, SWITCHED
1000 THROUGH 1499
1500 THROUGH 1999
RED/WHITE
ORANGE/WHITE
RED/WHT
RNG/WHT
POWER
GROUND
PAGE 3
PAGE 4
(ACS / SJC MACHINE)
BATTERY GROUND
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
CAN BUS
ENGINE
PAGE 5
PAGE 6
S550 (S/N A3NL11001 - A3NL11184)
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
HYDRAULICS PAGE 7 (S/N A3NM11001 - A3NM11005)
CAB DISPLAY PAGE 8
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
CAB PAGE 9 (S/N AZN811001 - AZN811040)
ACS / SJC CONTROLS PAGE 10
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
LIGHTS PAGE 11 (S/N AZN911001 - AZN911047)
HVAC PAGE 12
OPTIONS PAGE 13 Sheet 1 of 15
ACS PAGE 14
SJC PAGE 15
7210761 (A)
725 of 1234
A-32 HYD OIL TEMP
Dealer
A-32
Copy -- Not for Resale
HARNESS PART NUMBER

MAIN FRAME 7210555
STD CAB 7210557
DLX CAB 7210556
DLX FUEL 7175293
STD FUEL 7149219
ENG 2403 7181036
ENG 2607 7181037
WHL 2 SPD ADP 7159366 Printable Version Click Here
ACS 7196667
SJC 7196668 WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
TRACTION SWITCH
(S/N A3NM11001 - A3NM11005)
STARTER FUEL
PULL POWER
PULL
(S/N AZN811001 - AZN811040)

REAR FRONT
(S/N AZN911001 - AZN911047)
GLOW
HVAC
LIGHT
Sheet 2 of 15
PLUG LIGHT

726 of 1234
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE HARNESS PART NUMBER
LEGEND
MAIN FRAME 7210555
PARTIAL CONNECTOR BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT STD CAB 7210557
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT DLX CAB 7210556
POWER
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK DLX FUEL 7175293
STD FUEL 7149219
CONNECTOR MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN ENG 2403 7181036
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL ENG 2607 7181037
LIGHTS 6000 THROUGH 6999 PINK PNK TAILGATE DOM 7217484
WIRE BREAK OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
(TWO WIRE BREAKS WHL 2 SPD ADP 7159366
JOIN ONE WIRE) COMMUNICATION 9000 THROUGH 9999 PURPLE PUR TRK BRAKE ADP 7165061
SHEET # COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS 7196667
SJC 7196668
FUSE 1
FRC1 HVAC RELAY 1150 RED/WHT 3 J2B C408
1400 RED/WHT
BATTERY MEGAFUSE
FUSE 4
1180 RED/WHT 2 AUX CTRLR (BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE RED 25 A
1110 RED/WHT
J1B
1 C493 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
FUSE 12 1170 RED/WHT SHEET 8
ACS / SJC HARNESS
25 A 2 C479 LH PANEL
SHEET 6 1270 RED 1120 RED/WHT 1235 RED/WHT (4 PIN)
STARTER
1460 RED/WHT
1010 RED
SHEET 13
1040 RED 25 A 1410 RED/WHT
1490 RED/WHT
SHEET 13
15 A SHEET 5
SHEET 9
FUSE 9
1620 RNG/WHT
1050 RED FRC1 TRACTION LOCK RELAY
FUSE 10
1030 RED 30 A 1350 RED/WHT SHEET 8
FRC1 STARTER RELAY
1060 RED
SHEET 6 Dealer Copy -- Not for Resale
FRC1 FUEL SHUTOFF RELAY
T13 LH PANEL BUZZER
FUSE 2
1340 RED 1330 RED/WHT
FRC1 FRONT LIGHT RELAY C428
FUSE 3 1775 RNG/WHT
(LT GRAY)
15 A SHEET 8
SHEET 11
SHEET 8
FUSE 6
1560 RNG/WHT 22 J2B
SHEET 9
25 A
C110 ALT EXCITATION
1720 RNG/WHT B
C404
BACKUP ALARM HARN
WIRING SCHEMATIC
1850 RNG/WHT
SHEET 9
(ACS / SJC MACHINE)
SWITCHED
+12V POWER
PWR
1790 RNG/WHT
SHEET 12
S550 (S/N A3NL11001 - A3NL11184)
1050 RED 30 SHEET 9
87 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
(S/N A3NM11001 - A3NM11005)
2030 BLK GND 85 86 C492
1740 RNG/WHT 6
SHEET 4 ACS/SJC HARNESS
(8 PIN)
(S/N AZN811001 - AZN811040)
3380 LBL 4 J1A
GWY CTRLR
(S/N AZN911001 - AZN911047)
C428 Sheet 3 of 15 Printable Version Click Here
(LT GRAY)
CAB-MFR HARN CONN 2
C449 LH JOYSTICK (PRINTED NOVEMBER 2016)
Printed In U.S.A. 1920 RNG/WHT 6 1920 RNG/WHT
1830 RNG/WHT SHEET 5 7210761 (A)
727 of 1234 C450 RH JOYSTICK
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE LEGEND
OVERVIEW PAGE 1,2
GROUND
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 SHEET #
SJC PAGE 15
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
C450 RH JOYSTICK C493 3 2235 BLK
(BLACK)
2920 BLK CAB-MFR HARN CONN 1 ACS / SJC HARNESS 4
SHEET 8 2240 BLK
(4 PIN)
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428
J2B 15
2930 BLK (LT GRAY) AUX CTRLR
2550 BLK 2090 BLK
SHEET 8 CAB-MFR HARN CONN 2
SW1 BRAKE SWITCH
2765 BLK
2830 BLK 2900 BLK 1 2900 BLK SHEET 11
SHEET 13 C408 CAB-MFR CONN (FR LIGHTS)
SW6 BKT POSITION SWITCH
2700 BLK SHEET 5 2710 BLK 2745 BLK
SW9 TRAVEL CONTROL SWITCH C426 REMOTE RUN, ACD C408 CAB-MFR CONN (HVAC)
SHEET 13 2455 BLK
2785 BLK 2790 BLK T8
SHEET 13 C421 BKT POSITION SOLENOID SHEET 9
C126 HORN Dealer Copy -- Not for Resale C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
BATT GND
2620 BLK C489
SHEET 11 B 2720 BLK 2780 BLK
T16 RH REAR LIGHT MFR ACCESSORY SHEET 13
2630 BLK 2770 BLK
SHEET 11 C103 SHEET 13
T18 LH REAR LIGHT TAILGATE HARN C355 FUEL HARN (PWR BOB, AC) T1 2730 BLK
BATT GND
SHEET 9
2650 BLK 2600 BLK B 2600 BLK C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 10
T20 BU ALARM 2390 BLK
2810 BLK
2640 BLK SHEET 6
SHEET 11 SHEET 6 2005 BLK C113 ENG-MFR (FUEL SHUTOFF)
C602 LH REAR LIGHT FRC1 STARTER RELAY 2200 BLK
2035 BLK SHEET 7
SHEET 6 C425 BRAKE
SHEET 11 2610 BLK FRC1 FUEL PULL RELAY
C603 RH REAR LIGHT SHEET 11 2045 BLK
SHEET 11
FRC1 REAR LIGHT RELAY C409 RIGHT HANDLE
2115 BLK 2105 BLK 2000 BLK
SHEET 6
2320 BRN 2016 BLK SHEET 10 2520 BLK
SHEET 7 SHEET 12
C410 LEFT HANDLE Printable Version Click Here
C112 HYD OIL FILTER SWITCH FRC1 HVAC RELAY
2030 BLK
2145 BRN SHEET 3
SHEET 6
SHEET 7
2370 BRN FRC1 TRACTION LOCK RELAY
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) (ACS / SJC MACHINE)
2220 BRN
SHEET 7
C108 HYD TEMP SENDER 2230 BRN 17
J1B
GWY CTRLR
S550 (S/N A3NL11001 - A3NL11184)
SHEET 7
2190 BRN
(S/N A3NM11001 - A3NM11005)
SHEET 6
2180 BRN (S/N AZN811001 - AZN811040)
SHEET 6
2170 BRN (S/N AZN911001 - AZN911047)
2150 BRN
Sheet 4 of 15
SHEET 6
728 of 1234
POWER PAGE 3
CAN BUS
CAN BUS PAGE 5
CAB DISPLAY PAGE 8
CAB PAGE 9
JOIN ONE WIRE)
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS
ACS
PAGE 13
7196667 SHEET # * DLX CAB HARN 7210556 ONLY
SJC 7196668
C408
J1B (BLACK)
8 9200 PUR 9270 PUR 9210 PUR 9280 PUR 9230 PUR 4 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR 4
CAN LO C479
9 9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 3 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
Remote Start Tool, ACD C492 9160 PUR/WHT 2 C503
14 9500 PUR/WHT A ACS/SJC HARNESS 9260 PUR 4 RIGHT DELUXE PANEL
CAN HI
(8 PIN)
CAN LO
21 3090 LBL D 1
REMOTE RUN KEY 9240 PUR
1730 RNG/WHT
C
E
9140 PUR/WHT 4 ACS CTRLR
SHEET 3
1830 RNG/WHT * C450
1
SHEET 3 UNSWITCHED POWER 9290 PUR 7 SHEET 4 RIGHT JOYSTICK
SHEET 4 GROUND 9190 PUR/WHT 8 DRIVE CTRLR
9660 PUR 4
9220 PUR 8 SHEET 3

1840 RNG/WHT * C449
1
J2B 2080 BLK 2
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
Printed In U.S.A.
7210761 (A)
729 of 1234
POWER PAGE 3
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK ACS / SJC CONTROLS PAGE 10
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 WIRE BREAK
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS 7196667 SHEET #
SJC 7196668
C113 FUEL SHUTOFF

+12V PULL
PWR 30
1350 RED/WHT
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
8800 TAN 9 8800 TAN 24.5 OHM
+12V STARTER STARTER

1030 RED PWR 30
3560 LBL 2 3560 LBL R 1015 RED
2005 BLK GND 85 86 8210 TAN C110
SHEET 4 B
G
GLOW T14
PLUG 1815 RNG/WHT 7 1815 RNG/WHT EXCITATION
+12V PRE HEATER SHEET 3
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
2115 BLK GND 85 86 8510 TAN

SHEET 4

6 8510 TAN
14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
C405 163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4 C107
GND
SHEET 9
4 8800 TAN
C355
WIRING SCHEMATIC
J1B
FUEL HARN
C 3180 LBL
C406
A
(ACS / SJC MACHINE)
SIG
FUEL SENDER
SHEET 4
(30-270 OHM) S550 (S/N A3NL11001 - A3NL11184)
SHEET 4
2170 BRN
C104
B GND
ENGINE COOLANT
(S/N A3NM11001 - A3NM11005)
18 3170 LBL A SIG
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)

7210761 (A)
730 of 1234
HYDRAULICS
CAB DISPLAY PAGE 8
CAB PAGE 9
ACS 7196667 SHEET #
SJC 7196668
TRACTION C425
+12V LOCK
4100 LGN B C308
1360 RED/WHT PWR 30 BRAKE
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
SHEET 4
500 - 3000 OHM
C112
34 3320 LBL A
HYDRAULIC
J1A 2320 BRN B
C446
7.2 OHM 12 V
C420
9.8 OHM 12V
C105
HYDRAULIC
5190 YEL A +8V PWR 0.5-7.5V
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (ACS / SJC MACHINE)
GWY CTRLR
C418 S550 (S/N A3NL11001 - A3NL11184)
AUX CTRLR 4330 LGN 1 SIG SOLENOID (MALE) (S/N A3NM11001 - A3NM11005)
3.3 OHM PWM
1 2340 BRN
C419
2 GND
(S/N AZN811001 - AZN811040)
FRONT BASE
3.3 OHM PWM (S/N AZN911001 - AZN911047)
Sheet 7 of 15
Printed In U.S.A. J2B 7210761 (A)
AUX CTRLR
731 of 1234
CAB
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 LEGEND
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 CONNECTOR
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL ACS / SJC CONTROLS PAGE 10
DISPLAY
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN (TWO WIRE BREAKS
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR JOIN ONE WIRE)
ACS PAGE 14
SHEET #
SJC PAGE 15

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
BUZZER (-) PTOL
C408 1930 RNG/WHT 1
SHEET 3 SWITCH POWER
(BLACK) 2940 BLK 3
CAB-MFR HARN CONN 1 SHEET 4 GROUND
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
7040 WHT 10 J1A
SHEET 4 GROUND
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
SHEET 3
SW9 1620 RNG/WHT 5
*
TRAVEL CONTROL
SHEET 3
11
SWITCHED POWER
SWITCH (OPTIONAL) 3400 LBL LEFT BLINKER INPUT

SHEET 13 J1B 22 3040 LBL 14 3040 LBL 4
SHEET 13
4 5
3650 LBL 7 1950 RNG/WHT
SHEET 3 BATTERY (+)
3600 LBL 9 3
PARK BRAKE INPUT
SW1 6
3 2 BRAKE SWITCH
1 C480
3610 LBL 4 5 LEFT PANEL (GRAY) C503
2930 BLK SHEET 9
10
1240 RED/WHT 1
3610 LBL 2 PARK BRAKE OUTPUT 2250 BLK 3
SHEET 4 GROUND
8
7
6
5
4 WIRING SCHEMATIC
3
1
(ACS / SJC MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
732 of 1234
PARTIAL CONNECTOR
CAB
CONNECTOR
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ACS / SJC CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
ACS PAGE 14
SJC PAGE 15
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
SHEET 10 4230 LGN (DK GRAY)
CAB-MFR HARN CONN 3
SHEET 10 4240 LGN
5 4220 LGN 4235 LGN 4 4235 LGN
C492
ACS/SJC HARNESS
3 4275 LGN 5 4275 LGN
(8 PIN) 2 4550 LGN 6 4550 LGN * C212
POWER
SOCKET
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK* B
C209
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A DOME

SHEET 3 LIGHT
3640 LBL C
C129
CAB ACCESSORY
1210 RED/WHT A
+12V BATT PWR
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B
SHEET 3 Dealer Copy+12V
2820 BLK
-- Not for Resale
SW PWR
C
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK
SHEET 4 SHEET 13
2885 BLK SHEET 13
C428 2060 BLK SHEET 9
(LT GRAY)
CAB-MFR HARN CONN 2
*C667
DOOR HARN
(SEE ADDITIONAL
2790 BLK 11 2790 BLK OPTIONS SHEET)
SHEET 4
SHEET 8
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND
7310 WHT 3
C482 SEATBAR
J1B SENSOR C252
GWY CTRLR SHEET 4
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

(ACS / SJC MACHINE)
+5V
SHEET 6
5140 YEL
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)

Printed In U.S.A.
7210761 (A)
733 of 1234
PAGE 1,2
MANUAL
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL ACS / SJC CONTROLS PAGE 10
CONTROLS
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
C409
2530 BLK K
SHEET 4 RIGHT HANDLE
4230 LGN G
SHEET 9
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
PWM
23 4300 LGN B +
30
31 C410
C404 C103 13 K
TAILGATE HARN
BU ALARM HARN / SJC HARN
T19 TERMINAL (+) Dealer Copy -- Not for ResaleJ2A 20 4640 LGN D LEFT HANDLE
SHEET 4
1530 RNG/WHT A
SHEET 3
J
C421 4240 LGN H
SHEET 9
10 2670 BRN 3 GND 2520 BLK E
SHEET 4
2 4670 LGN SIG 7.8 OHM 12V
GWY CTRLR 2 C411
E
C422 C
7
3 GND A
2680 BRN
4680 LGN SIG
GWY CTRLR 7.8 OHM 12V B
2
WIRING SCHEMATIC
C412
(ACS / SJC MACHINE) B
A HORN
S550 (S/N A3NL11001 - A3NL11184)

(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
7210761 (A)
734 of 1234
LIGHTS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14
SJC PAGE 15
C434-1
C408 WORK LIGHT
(BLACK) 6100 PNK A SIG 37.00 Watts
CAB-MFR HARN CONN 1
C434-2
2765 BLK 9 2765 BLK 2750 BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
2760 BLK B GND WORK LIGHT
37.00 Watts
C435-2
50.00 Watts
FRONT
WORK C103
+12V LIGHTS C603
TAILGATE HARN SHEET 4
GND 85 86 C602
2045 BLK
SHEET 4
Dealer Copy -- Not for Resale 2640 BLK 2 GND TAIL LIGHT
SHEET 4
5 6320 PNK
31 3460 LBL
J1A 17
GWY CTRLR
6210 PNK
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4
RIGHT REAR

+12V LIGHT
PWR 30 T17 TERMINAL (+)
1320 RED/WHT
LEFT REAR
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)

735 of 1234
HVAC
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ACS / SJC CONTROLS
LIGHTS
PAGE 10
HVAC PAGE 12
#
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS
ACS
PAGE 13
PAGE 14
SJC PAGE 15
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
SWITCH)
C635
* D SIG
B
E
C438 Dealer Copy -- Not for Resale F
*BLOWER
SW10
(DK GRAY)
+12V HVAC CAB-MFR HARN CONN 3 SWITCH
PWR 30 OFF
1140 RED/WHT
1
2016 BLK GND 85 86 4
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
WIRING SCHEMATIC
AC EVAPORATOR C350
SWITCH B
A
7023 WHT
7024 WHT
(ACS / SJC MACHINE)
C355
SW11
*
AC SWITCH
S550 (S/N A3NL11001 - A3NL11184)
FUEL HARN # C486 1 C 7400 WHT
7015 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH
(COMPRESSOR)
2100 BLK
3 (S/N A3NM11001 - A3NM11005)
2290 BLK 2280 BLK
SHEET 13
D4 (S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
7210761 (A)
Printed In U.S.A.
736 of 1234
OPTIONS
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS
ACS
PAGE 13
PAGE 14
SJC
C428
PAGE 15
# C355 (LT GRAY)
C607
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
2 2470 BLK
2290 BLK
2770 BLK B 2770 BLK
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480 BLK SWITCH
6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
SHEET 3
X
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* T3
FLASHER CONN
LEFT HANDLE D 6415 PNK 6400 PNK 14 D2 6430 PNK

6400 PNK
(BLINKER/FLASHER)
5 PIN
C
SHEET 8 3400 LBL *BEACON
SW2
6570 PNK
E
1550 RNG/WHT 9 1550 RNG/WHT SWITCH
A 6515 PNK SHEET 3
2725 BLK 6
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
(PINS 3 & 6
C103 C438 INTERNALLY 5 4 3
TAILGATE HARN (DK GRAY) 2850 BLK
INSULATED) 6
C670
(SEE ADDITIONAL
E 6410 PNK
CAB-MFR HARN CONN 3
SHEET 8
3500 LBL
D1
* E
D 6510 PNK 6500 PNK 3 6500 PNK 6530 PNK D
2420 BLK
OPTIONS SHEET) Dealer Copy -- Not for Resale
6540 PNK 6540 PNK B EXTERIOR HARNESS
(SEE ADDITIONAL
C423 C
3 OPTIONS SHEET)
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6 A

GND B 2450 BLK 2455 BLK SWITCH
2780 BLK 1 2780 BLK
SHEET 4
C408 * C676
RADIO
* C277
(BLACK) 2885 BLK 2 1
CAB-MFR HARN CONN 1 SHEET 9 2
C126 1885 RNG/WHT 1
SHEET 4 SHEET 9 3
C412 2785 BLK B
LEFT HANDLE
(HORN)
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A HORN *C279
2210 BLK
4 PWR
5 GND AIR RIDE
SHEET 3 LEFT 2 7830 WHT 4 SHEET 9 SEAT
2 PIN SPEAKER 6
-
C278
5 7200 WHT
C497
C SJC
RIGHT
*
- 2 7810 WHT 6
4 6420 PNK A HORN/BLINKER 1 7800 WHT 5
SPEAKER +
6520 PNK B (SEE ADDITIONAL
J2A 3
OPTIONS SHEET)
AUX CTRLR
C415
HIGH FLOW
WIRING SCHEMATIC
26 2460 BRN B GND
SOLENOID
4460 LGN A SIG
7.5 OHM 12 V (ACS / SJC MACHINE)
26
J2B
AUX CTRLR S550 (S/N A3NL11001 - A3NL11184)
C441
J1A
GWY CTRLR
26 2350 BRN 2 GND TWO SPEED (S/N A3NM11001 - A3NM11005)
J1B
5.1 OHM 12V
(S/N AZN811001 - AZN811040)
26
GWY CTRLR
(S/N AZN911001 - AZN911047)
737 of 1234
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
K TILT PEDAL K TILT MOTOR 2
ACS AND AHC HARNESS 7190593

J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE ACS / SJC CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 1 LIFT C TWO SPD
4260 LGN 4280 LGN
B 1740 RNG/WHT 6 2 SOLENOID D
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
4270 LGN 1 TILT D
SOLENOID
FLOAT
C
B SKI CTRL
J2-ACS
CONTROLLER 2650 BRN
C472
B B
Dealer Copy -- Not for Resale C429 LIFT ACTUATOR
G
GRD F SIDE
F 4650 LGN C C SIG D 4610 LGN 8 SHIFT
LIFT HANDLE A
A A HALL SENSOR 7
5650 YEL +5V PWR J
6
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GRD LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GRD
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GRD
C
J 4660 LGN 3 SIG K 4645 LGN 8
LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 GRD 4
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
5760 YEL 1 +5V PWR HALL SENSOR 2990 BRN 1 GND
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H 3980 LBL
WIRING SCHEMATIC
E 3990 LBL
(ACS / SJC MACHINE)
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
(S/N AZN811001 - AZN811040)
(S/N AZN911001 - AZN911047)
738 of 1234
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN
SJC A
B
C
D
E
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
A
B
C
D
E
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
A
B
C
D
E
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
2
3
4
5
6
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
CONTROLS
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
SJC 7210505 LIFT 14 RF ANGLE
C429 ACTUATOR
A22 PUMP 7188448 15 LR ANGLE
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
2980 BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
C454 3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 2880 BRN 3 7
GND 21 L FWD DRIVE
5880 YEL 1 +5V PWR 5980 YEL 3 +5V PWR
LEFT SPEED 22 CAN LOW
33 3880 LBL 2 SIG SENSOR
C428 23 R QUAD A DRIVE
34 3885 LBL 4 SIG TILT ACTUATOR
NOTE: SPEED SENSORS NO LONGER 5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL C453 FACTORY INSTALLED. SEE SERVICE 4 25 TWO SPEED 1
5970 YEL
5870 YEL 1 +5V PWR LETTER SL5323 OR BTI 410 3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870 BRN 3 GND 6
23 3870 LBL 2 RIGHT SPEED 27 GROUND
SIG 2990 BRN 1 GND
SENSOR 28 GROUND
24 3875 LBL 4 SIG 4640 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN OR BLK 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E 35
5860 YEL 2 C542 SWASHPLATE SAFETY OUT
H
2860/BRN OR BLK BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL OR 4950/LGN 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660/BRN OR BLK 2 2 Dealer Copy -- Not for Resale A
ACS CONTROLLER
2660 BRN 41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
45 2650/BRN OR BLK 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN OR BLK 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H
49 SPARE PWN COIL 6
C544 C
21 4270 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670/BRN OR BLK 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A 1 1
C474 1830 RNG/WHT +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
2 2080 BLK 2 GND
16 4275 LGN 3
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1
JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493 WIRING SCHEMATIC

28 2490 BLK 2235 BLK 3
47
48
1250 RED/WHT
1260 RED/WHT
1235 RED/WHT
1170 RED/WHT
2
1
(ACS / SJC MACHINE)
2240 BLK 4
S550 (S/N A3NL11001 - A3NL11184)
(S/N A3NM11001 - A3NM11005)
1760 RNG/WHT
2280 BLK (S/N AZN811001 - AZN811040)
2270 BLK
2260 BLK (S/N AZN911001 - AZN911047)
1180 RED/WHT
1190 RED/WHT Sheet 15 of 15 Printable Version Click Here
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED NOVEMBER 2016)
HARNESS)
PrintedInInU.S.A.
Printed U.S.A. 7210761 (A)
739 of 1234
PINS PINS PINS
C209 DOME LIGHT 3 9 C483 TEMP CONTROL SWITCH 3 12 T20 BACKUP ALARM (GND) 10
C212 POWER SOCKET 2 9 C486 AC COMPRESSOR 2 12
C252 WASHER 2 9 C489 MFR ACCESSORY 2 3,4 SW1 BRAKE SWITCH 8
C277 AIR RIDE SEAT 6 13 C492 ACS/SJC HARNESS 8 3,5,9 SW2 BEACON SWITCH 13
C278 RIGHT SPEAKER 2 13 C493 ACS/SJC HARNESS 4 3,4 SW3 HAZARD SWITCH 13
C279 LEFT SPEAKER 2 13 C499 PTOL 4 8 SW4 HAND/FOOT, H/ISO SWITCH 9
C308 BRAKE SOLENOID 2 7 C500 RH KEY SWITCH 6 8 SW5 POWER BOBTACH SWITCH 13
C350 AC EVAPORATOR SWITCH 2 12 C503 RH DLX PANEL 6 5,8 SW6 BUCKET POSITION SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C602 LEFT REAR TAIL LIGHT 2 11 SW9 TRAVEL CONTROL SWITCH 8
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11 SW10 BLOWER SWITCH 12
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13 SW11 AC SWITCH 12
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C610 HVAC DUCT FAN 2 12
C409 RIGHT HANDLE 10 10 C611 BLOWER MOTOR 4 12
C410 LEFT HANDLE 10 10 C630 THERMOSTAT 3 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C635 HEATER VALVE 6 12
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C667 DOOR 6 9
C415 HIGH FLOW SOLENOID 2 7 C670 EXTERIOR BEACONDealer Copy
6 -- Not for
13 Resale
C418 FRONT ROD 2 7 C676 RADIO 6 9
C419 FRONT BASE 2 7
C420 HYD LOCK 2 7 J1A GATEWAY COTROLLER 34
C421 TILT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26
C422 LIFT SPOOL LOCK 3 10 J2A AUX CONTROLLER 34
C423 BUCKET POSITION 2 13 J2B AUX CONTROLLER 26
WIRING SCHEMATIC
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX (ACS / SJC MACHINE)
OVERVIEW PAGE 1,2
BATT FEED, GENERAL
BATT FEED, FUSED
1000 THROUGH 1499
1000 THROUGH 1499
RED
RED/WHITE
RED
RED/WHT POWER PAGE 3 S550 (S/N A3NL11185 - A3NL11630)
GROUND PAGE 4
BATT FEED, SWITCHED
BATTERY GROUND
1500 THROUGH 1999
2000 THROUGH 2999
ORANGE/WHITE
BLACK
RNG/WHT
BLK CAN BUS PAGE 5
ENGINE PAGE 6
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN HYDRAULICS PAGE 7
(S/N AZN811041 - AZN811060)
CAB DISPLAY PAGE 8
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK CAB PAGE 9
(S/N AZN911048 - AZN911112)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT HVAC PAGE 12 Printable Version Click Here
OPTIONS PAGE 13
7210761 (B)
740 of 1234
A-32 HYD OIL TEMP Dealer Copy -- Not for Resale
A-32
HARNESS PART NUMBER

MAIN FRAME 7210555
STD CAB 7210557
DLX CAB 7231782
DLX FUEL 7175293
STD FUEL 7149219
ENG 2403 7181036
ENG 2607 7181037
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
TRACTION SWITCH
STARTER FUEL
PULL POWER
PULL
(S/N AZN811041 - AZN811060)
REAR FRONT
(S/N AZN911048 - AZN911112)
GLOW
HVAC
LIGHT
PLUG LIGHT

741 of 1234
POWER
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
1400 RED/WHT
BATTERY MEGAFUSE
FUSE 4
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
1110 RED/WHT
J1B
ACS / SJC HARNESS
SHEET 6 1270 RED 1120 RED/WHT 1235 RED/WHT (4 PIN)
STARTER
1460 RED/WHT LEGEND
1010 RED
SHEET 13
1040 RED 25 A 1410 RED/WHT
1490 RED/WHT
SHEET 13
SHEET 9
FUSE 9
1620 RNG/WHT
C479 LH PANEL WIRE BREAK
SHEET 7
SHEET 6 1030 RED 1940 RNG/WHT
30 A 1350 RED/WHT SHEET 8 SHEET #
1060 RED FRC1 FUEL SHUTOFF RELAY
SHEET 6
FUSE 2
20 A
FRC1 GLOW PLUG RELAY 1340 RED 1330 RED/WHT SHEET 8
FUSE 3 (LT GRAY) 1775 RNG/WHT
15 A SHEET 8
SHEET 11
SHEET 8
FUSE 6
1560 RNG/WHT 22 J2B
SHEET 9
1780 RNG/WHT A MFR ACCESSORY 1960 RNG/WHT
SHEET 8
25 A
C110 ALT EXCITATION
1720 RNG/WHT
C404
B BACKUP ALARM HARN WIRING SCHEMATIC
SWITCHED
1850 RNG/WHT
SHEET 9
(ACS / SJC MACHINE)
+12V POWER
PWR
SHEET 12
S550 (S/N A3NL11185 - A3NL11630)
1050 RED 30
GND 85
87
86 C492
2030 BLK 1740 RNG/WHT 6
(8 PIN) (S/N AZN811041 - AZN811060)
3380 LBL 4 J1A
GWY CTRLR
(S/N AZN911048 - AZN911112)
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C449 LH JOYSTICK
1830 RNG/WHT SHEET 5 7210761 (B)
C450 RH JOYSTICK
742 of 1234
LEGEND
GROUND
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
(BLACK)
SHEET 8 2240 BLK
(4 PIN)
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428 J2B
2930 BLK (LT GRAY) 15 2550 BLK 2090 BLK
SHEET 8 AUX CTRLR
CAB-MFR HARN CONN 2
SW1 BRAKE SWITCH
2765 BLK
2830 BLK 2900 BLK 1 2900 BLK SHEET 11
SHEET 13 2455 BLK
SHEET 13 2785 BLK 2790 BLK T8
C421 BKT POSITION SOLENOID SHEET 9 BATT GND
C126 HORN Dealer Copy -- Not for Resale C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2620 BLK C489
2630 BLK 2770 BLK
SHEET 11 C103 SHEET 13
BATT GND SHEET 9
SHEET 10
SHEET 6 2810 BLK
2640 BLK 2005 BLK
SHEET 11 SHEET 6 C113 ENG-MFR (FUEL SHUTOFF)
2610 BLK C425 BRAKE
SHEET 11 FRC1 FUEL PULL RELAY
SHEET 11
2115 BLK 2105 BLK 2000 BLK
SHEET 6
SHEET 7 SHEET 12
C410 LEFT HANDLE Printable Version Click Here
C112 HYD OIL FILTER SWITCH FRC1 HVAC RELAY
2030 BLK
2145 BRN SHEET 3
SHEET 6
SHEET 7
2025 BLK
WIRING SCHEMATIC
2370 BRN FRC1 TRACTION LOCK RELAY
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) (ACS / SJC MACHINE)
SHEET 7
2220 BRN
C108 HYD TEMP SENDER 2230 BRN 17
J1B S550 (S/N A3NL11185 - A3NL11630)
GWY CTRLR
SHEET 7
2190 BRN
SHEET 6
2180 BRN (S/N AZN811041 - AZN811060)
2170 BRN
(S/N AZN911048 - AZN911112)
SHEET 6
Sheet 4 of 15
2150 BRN
SHEET 6
743 of 1234
LEGEND
PARTIAL CONNECTOR
CAN BUS
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
CAN HI (8 PIN)
20 9600 PUR B
CAN LO
21 3090 LBL D Dealer Copy
1
-- Not for Resale
1730 RNG/WHT
C
E
SHEET 3
1830 RNG/WHT * C4501
9660 PUR 4
9220 PUR 8 SHEET 3

1840 RNG/WHT * C4491
J2B 2080 BLK 2
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

Printed In U.S.A.
7210761 (B)
744 of 1234
LEGEND
POWER PAGE 3
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
JOIN ONE WIRE)
C113 FUEL SHUTOFF

+12V PULL
PWR
1350 RED/WHT 30
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
8800 TAN 9 8800 TAN 24.5 OHM

1030 RED PWR 30
87 8200 TAN S M
3560 LBL 2 3560 LBL R 1015 RED

GND 85 86 8210 TAN
2005 BLK C110
SHEET 4 B
G
GLOW T14
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
2115 BLK GND 85 86 8510 TAN

SHEET 4

6 8510 TAN
14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
C405 163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4 C107
GND
SHEET 9
4 8800 TAN
C355
WIRING SCHEMATIC
FUEL HARN
J1B
GWY CTRLR 12 3180 LBL C 3180 LBL
C406
A SIG
(ACS / SJC MACHINE)
FUEL SENDER
SHEET 4
(30-270 OHM) S550 (S/N A3NL11185 - A3NL11630)
SHEET 4
2170 BRN
C104
B GND
ENGINE COOLANT
18 3170 LBL A SIG
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

7210761 (B)
745 of 1234
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
TRACTION C425
+12V LOCK
4100 LGN B C308
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
SHEET 4
32 3220 LBL A
SENDER
500 - 3000 OHM
C112
34 3320 LBL A
HYDRAULIC
J1A 2320 BRN B
C446
7.2 OHM 12 V
C420
9.8 OHM 12V
C105
HYDRAULIC
5190 YEL A +8V PWR 0.5-7.5V
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (ACS / SJC MACHINE)
GWY CTRLR
C418 S550 (S/N A3NL11185 - A3NL11630)
AUX CTRLR 4330 LGN 1 SIG SOLENOID (MALE) (S/N A3NM11006 AND ABOVE)
3.3 OHM PWM
1 2340 BRN
C419
2 GND
(S/N AZN811041 - AZN811060)
FRONT BASE
3.3 OHM PWM (S/N AZN911048 - AZN911112)
Sheet 7 of 15
Printed In U.S.A. J2B 7210761 (B)

AUX CTRLR
746 of 1234
LEGEND
CAB
DISPLAY
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 (TWO WIRE BREAKS
HVAC PAGE 12
OPTIONS PAGE 13

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
BUZZER (-) PTOL
C408 1930 RNG/WHT 1
2940 BLK 3
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
7040 WHT 10 J1A
SHEET 4 GROUND
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
SHEET 3
SW9 1620 RNG/WHT 5
*
TRAVEL CONTROL
SHEET 3
11
SWITCHED POWER
SWITCH (OPTIONAL) 3400 LBL LEFT BLINKER INPUT J1B

SHEET 13 22 3040 LBL 14 3040 LBL 4
SHEET 13
4
3650 LBL 7 1950 RNG/WHT 5
SHEET 3 BATTERY (+)
3600 LBL 9 3
PARK BREAK INPUT
SW1 6
3 2 BRAKE SWITCH
1 C480
2930 BLK SHEET 9
10
1240 RED/WHT 1
SHEET 4 GROUND
8
7
6
5 WIRING SCHEMATIC
4
3
1
(ACS / SJC MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
Sheet 8 of 15
747 of 1234
PARTIAL CONNECTOR
CAB
CONNECTOR
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
CAB-MFR HARN CONN 3
SHEET 10 4240 LGN
5 4220 LGN 4235 LGN 4 4235 LGN
C492
ACS/SJC HARNESS
3 4275 LGN 5 4275 LGN
(8 PIN) 2 4550 LGN 6 4550 LGN *C212
POWER
SOCKET
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK
* B
C209
GND
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A +12V PWR DOME
SHEET 3 LIGHT
3640 LBL C DOOR SIG
C129
CAB ACCESSORY
1210 RED/WHT A
+12V BATT PWR
SHEET 3
1580 RNG/WHT 5 1580 RNG/WHT Dealer Copy
1865 RNG/WHTB -- Not for Resale
+12V SW PWR
2820 BLK C
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK
SHEET 4 SHEET 13
2885 BLK SHEET 13
(LT GRAY)
CAB-MFR HARN CONN 2
*C667
DOOR HARN
(SEE ADDITIONAL
SHEET 4
SHEET 8
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND
7310 WHT 3
C482 SEATBAR
J1B SENSOR C252
GWY CTRLR SHEET 4
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

(ACS / SJC MACHINE)
+5V
SHEET 6
5140 YEL
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

Printed In U.S.A.
7210761 (B)
748 of 1234
PAGE 1,2
MANUAL
CONTROLS
LIGHTS PAGE 11
OPTIONS PAGE 13
C409
2530 BLK K
4230 LGN G
SHEET 9
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
PWM
23 4300 LGN B +
30
31 C410
C404 C103
BU ALARM HARN / SJC HARN TAILGATE HARN Dealer Copy -- Not for Resale 13 K
LEFT HANDLE
T19 TERMINAL (+) J2A 20 4640 LGN D
SHEET 4
1530 RNG/WHT A
SHEET 3
J
C421 4240 LGN H
SHEET 9
10 2670 BRN 3 2520 BLK E
GND SHEET 4
2 4670 LGN SIG 7.8 OHM 12V
GWY CTRLR 2 C411
E
C422 C
7
3 A
2680 BRN GND
4680 LGN SIG
2
WIRING SCHEMATIC
C412
(ACS / SJC MACHINE) B
A HORN
S550 (S/N A3NL11185 - A3NL11630)

(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
7210761 (B)
749 of 1234
LIGHTS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C434-1
C408 WORK LIGHT
CAB-MFR HARN CONN 1
C434-2
SHEET 4
50.00 Watts
C435-1
2760 BLK B WORK LIGHT
GND 37.00 Watts
C435-2
50.00 Watts
FRONT
WORK C103
C603
GND 85 86 C602
2045 BLK
SHEET 4
6330 PNK 1 SIG
Dealer Copy -- Not for Resale 2640 BLK 2 GND
LEFT REAR
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4
RIGHT REAR

+12V LIGHT
1320 RED/WHT
LEFT REAR
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
750 of 1234
HVAC
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
HVAC PAGE 12
#
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS PAGE 13
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
SWITCH)
C635
* D SIG
B
E
C438
(DK GRAY)
F
*BLOWER
SW10

PWR 30 OFF
1140 RED/WHT
1
2016 BLK GND 85 86 4
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
WIRING SCHEMATIC
AC EVAPORATOR C350
SWITCH B
A
7023 WHT
7024 WHT
(ACS / SJC MACHINE)
C355
SW11
*
AC SWITCH
S550 (S/N A3NL11185 - A3NL11630)
FUEL HARN # C486
7015 WHT 1 C 7400 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH
(COMPRESSOR)
2100 BLK
2290 BLK 2280 BLK
SHEET 13
D4 (S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)
Sheet 12 of 15
7210761 (B)
Printed In U.S.A.
751 of 1234
OPTIONS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
OPTIONS
C428
PAGE 13
# C607 C355 (LT GRAY)
FUEL HARN CAB-MFR HARN CONN 2
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
#
2 2470 BLK 2770 BLK 2770 BLK
2290 BLK
B
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480 BLK SWITCH 6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
(BLINKER/FLASHER)
5 PIN
C
SHEET 8 3400 LBL *BEACON
SW2
6570 PNK
E
A 6515 PNK SHEET 3
2725 BLK 6
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
(PINS 3 & 6
TAILGATE HARN (DK GRAY) INSULATED)
2850 BLK
6
C670
(SEE ADDITIONAL
E 6410 PNK
CAB-MFR HARN CONN 3
SHEET 8 3500 LBL
D1
* E
D 6510 PNK 6500 PNK 3 6500 PNK 6530 PNK 2420 BLK D
OPTIONS SHEET)
EXTERIOR HARNESS
6540 PNK 6540 PNK B
(SEE ADDITIONAL
C423 C
3 OPTIONS SHEET)
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6 A

2780 BLK 1 2780 BLK
SHEET 4
C408 * C676
RADIO
* C277
(BLACK) 2885 BLK 2 1
CAB-MFR HARN CONN 1 SHEET 9 2
C126 1885 RNG/WHT 1
SHEET 4 2785 BLK SHEET 9 3
C412 B
LEFT HANDLE
(HORN)
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A HORN *C279
2210 BLK
4 PWR
5 GND AIR RIDE
2 PIN SPEAKER 6
-
C278
5 7200 WHT
C497
C SJC
RIGHT
*
- 2 7810 WHT 6
(SEE ADDITIONAL
SPEAKER + Printable Version Click Here
J2A 3 6520 PNK B
OPTIONS SHEET)
AUX CTRLR
C415
HIGH FLOW
WIRING SCHEMATIC
26 2460 BRN B GND
SOLENOID
4460 LGN A SIG
7.5 OHM 12 V (ACS / SJC MACHINE)
26
J2B
AUX CTRLR S550 (S/N A3NL11185 - A3NL11630)
C441
J1A
GWY CTRLR
26 2350 BRN 2 GND TWO SPEED (S/N A3NM11006 AND ABOVE)
5.1 OHM 12V (S/N AZN811041 - AZN811060)
J1B 26
GWY CTRLR
(S/N AZN911048 - AZN911112)
Sheet 13 of 15
752 of 1234
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
H 2280 BLK
2280 BLK
2240 BLK
1170 RED/WHT C409 C466
C492 C493 K A
4275 LGN
4220 LGN 5 4 2240 BLK G B HANDLE
3 3 B 1190 RED/WHT LOCK
4275 LGN A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
8 J 2260 BLK C467 E DETENT
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 LIFT TWO SPD
G 4260 LGN 4280 LGN 1 C
B 1740 RNG/WHT 6 SOLENOID
2 D
A 5970 YEL PWM
13 OHM B
G 2250 BRN 12V
C468
FOR PEDAL LOCK C410
2
3 K
2500 BLK TILT
1 D
4270 LGN SOLENOID FLOAT
C
B SKI CTRL
C472
2650 BRN B B GND
G
SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A HALL SENSOR 2980 BRN 1 GND
+5V PWR
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
3990 LBL 2 SIG
5750 YEL
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H 3980 LBL
WIRING SCHEMATIC
E 3990 LBL
(ACS / SJC MACHINE)
S550 (S/N A3NL11185 - A3NL11630)
(S/N AZN811041 - AZN811060)
(S/N AZN911048 - AZN911112)

753 of 1234
SJC A
B
C
D
E
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
A
B
C
D
E
FLOAT-SPARE
A
B
C
D
E
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
2
3
4
5
6
TWO SPEED SWITCH
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
CONTROLS
12 CAN HIGH
C429 ACTUATOR
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4 19 L JOYSTICK Y
29 2890 BRN 2880 BRN 3 7
GND 21 L FWD DRIVE
5880 YEL 1 5980 YEL 3 +5V PWR
+5V PWR LEFT SPEED 22 CAN LOW
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL C453 4 25 TWO SPEED 1
5970 YEL
5870 YEL 1 +5V PWR 3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870 BRN 3 GND 6
SIG 2990 BRN 1 GND
SENSOR 28 GROUND
24 3875 LBL 4 SIG 4640 LGN 5
7 29 SENSOR GROUND
C536
30 SENSOR SUPPLY . 2 +5V
2970 BRN
5810 YEL 2 C543 A22 PUMP HARNESS 4650 LGN 8
2810 BRN 4 2810 BRN 1 GND
31 L REV DRIVE ..
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E 35
5860 YEL 2 C542 SWASHPLATE SAFETY OUT
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38 SPARE ANALOG 1
C
LEFT
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
Dealer Copy -- Not for Resale 41 L REV RETURN
42 R FWD RETURN
C547
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1 D
9140 PUR/WHT 47 UNSWITCHED BATTERY
41 2680/BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
2280 BLK H 49 SPARE PWN COIL 6
C544 C
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A 1 1830 RNG/WHT 1
C474 +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO
RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 9560 PUR/WHT 3
C492 CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
27 2470 BLK C493 WIRING SCHEMATIC

28 2490 BLK 2235 BLK 3
47
48
1250 RED/WHT
1260 RED/WHT
1235 RED/WHT
1170 RED/WHT
2
1
(ACS / SJC MACHINE)
2240 BLK 4
S550 (S/N A3NL11185 - A3NL11630)
1760 RNG/WHT
2280 BLK (S/N AZN811041 - AZN811060)
2270 BLK
2260 BLK (S/N AZN911048 - AZN911112)
1180 RED/WHT
1190 RED/WHT Sheet 15 of 15 Printable Version Click Here
HARNESS)
PrintedInInU.S.A.
Printed U.S.A. 7210761 (B)
754 of 1234
PINS PINS PINS
C212 POWER SOCKET 2 9 C483 TEMP CONTROL SWITCH 3 12 T20 BACKUP ALARM (GND) 10
C252 WASHER 2 9 C486 AC COMPRESSOR 2 12 T36 DOMELIGHT (-) 9
C277 AIR RIDE SEAT 6 13 C489 MFR ACCESSORY 2 3,4 T37 DOMELIGHT (+) 9
C278 RIGHT SPEAKER 2 13 C492 ACS/SJC HARNESS 8 3,5,9
C279 LEFT SPEAKER 2 13 C493 ACS/SJC HARNESS 4 3,4
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8 SW1 BRAKE SWITCH 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8 SW2 BEACON SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8 SW3 HAZARD SWITCH 13
C404 BACKUP ALARM 2 3,10 C602 LEFT REAR TAIL LIGHT 2 11 SW4 HAND/FOOT, H/ISO SWITCH 9
C405 AIR FILTER SWITCH 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 SW5 POWER BOBTACH SWITCH 13
C406 FUEL SENDER 2 6 C606 POWER BOBTACH OPEN 2 13 SW6 BUCKET POSITION SWITCH 13
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C607 POWER BOBTACH CLOSE 2 13 SW9 TRAVEL CONTROL SWITCH 8
C409 RIGHT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 SW10 BLOWER SWITCH 12
C410 LEFT HANDLE 10 10 C611 BLOWER MOTOR 4 12 SW11 AC SWITCH 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C630 THERMOSTAT 3 12
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C635 HEATER VALVE 6 12
C415 HIGH FLOW SOLENOID 2 7 C667 DOOR 6 9
C418 FRONT ROD 2 7 C670 EXTERIOR BEACON Dealer Copy
6 -- Not13for Resale
C419 FRONT BASE 2 7 C676 RADIO 6 9
C420 HYD LOCK 2 7
C421 TILT SPOOL LOCK 3 10 J1A GATEWAY COTROLLER 34
C422 LIFT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26
C423 BUCKET POSITION 2 13 J2A AUX CONTROLLER 34
C425 BRAKE SOLENOID 3 7 J2B AUX CONTROLLER 26
C428 CAB-MFR HARN CONN (LT GRY) 14 3,4,9,13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX WIRING SCHEMATIC
OVERVIEW PAGE 1,2
BATT FEED, GENERAL
BATT FEED, FUSED
1000 THROUGH 1499
1000 THROUGH 1499
RED
RED/WHITE
RED
RED/WHT POWER PAGE 3 (ACS / SJC MACHINE)
BATTERY GROUND
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
CAN BUS PAGE 5 S550 (S/N A3NL11631 - A3NL12191)
ENGINE PAGE 6
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN HYDRAULICS PAGE 7 (S/N AZN811061 - AZN811162)
LIGHTS 6000 THROUGH 6999 PINK PNK CAB PAGE 9 (S/N AZN911113 - AZN911229)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR LIGHTS PAGE 11 Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT HVAC PAGE 12 Printable Version Click Here
OPTIONS PAGE 13
7210761 (C)
755 of 1234
A-32 HYD OIL TEMP Dealer Copy -- Not for Resale
A-32
HARNESS PART NUMBER

MAIN FRAME 7210555
STD CAB 7210557
DLX CAB 7231782
DLX FUEL 7175293
STD FUEL 7149219
ENG 2403 7181036
ENG 2607 7181037
WIRING SCHEMATIC
(ACS / SJC MACHINE)
STARTER
TRACTION
PULL
FUEL SWITCH
POWER
S550 (S/N A3NL11631 - A3NL12191)
PULL
(S/N AZN811061 - AZN811162)

GLOW REAR FRONT
HVAC
(S/N AZN911113 - AZN911229)
PLUG LIGHT LIGHT
Sheet 2 of 15
756 of 1234
POWER
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
1400 RED/WHT
BATTERY MEGAFUSE
FUSE 4
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE RED 25 A
1110 RED/WHT
J1B
ACS / SJC HARNESS
25 A C479 LH PANEL
SHEET 6 1270 RED 1120 RED/WHT 1235 RED/WHT 2 (4 PIN)
STARTER
1460 RED/WHT LEGEND
1010 RED
SHEET 13
1040 RED 25 A 1410 RED/WHT
1490 RED/WHT
SHEET 13
SHEET 9
FUSE 9
1620 RNG/WHT
C479 LH PANEL WIRE BREAK
SHEET 7
1060 RED FUSE 2 FRC1 FUEL SHUTOFF RELAY
SHEET 6
FRC1 GLOW PLUG RELAY 20 A 1330 RED/WHT
SHEET 8
1340 RED C499 RH PANEL PTOL
SHEET 11
FUSE 3 1775 RNG/WHT
(LT GRAY) SHEET 8
15 A
SHEET 11
SHEET 8
FUSE 6
1560 RNG/WHT 22 J2B
SHEET 9
25 A
C110 ALT EXCITATION
B
1720 RNG/WHT BACKUP ALARM HARN
1850 RNG/WHT
WIRING SCHEMATIC
SWITCHED SHEET 9
+12V POWER
PWR
1790 RNG/WHT
SHEET 12
(ACS / SJC MACHINE)
1050 RED 30 SHEET 9
87 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
S550 (S/N A3NL11631 - A3NL12191)
2030 BLK GND 85 86 C492
1740 RNG/WHT 6
(8 PIN)
(S/N AZN811061 - AZN811162)
3380 LBL 4 J1A
GWY CTRLR
(S/N AZN911113 - AZN911229)
C428 Sheet 3 of 15
(LT GRAY)
CAB-MFR HARN CONN 2
C449 LH JOYSTICK (PRINTED NOVEMBER 2016)
1830 RNG/WHT SHEET 5 7210761 (C)
C450 RH JOYSTICK
757 of 1234
LEGEND
GROUND
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5 C408
(BLACK)
SHEET 8 2240 BLK
(4 PIN)
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428
J2B 15
2930 BLK (LT GRAY) AUX CTRLR 2550 BLK 2090 BLK
SHEET 8 CAB-MFR HARN CONN 2
SW1 BRAKE SWITCH
2765 BLK
2830 BLK 2900 BLK 1 2900 BLK SHEET 11
SHEET 13 2455 BLK
2785 BLK 2790 BLK T8
SHEET 13
C126 HORN Dealer Copy -- Not for Resale
C421 BKT POSITION SOLENOID SHEET 9
BATT GND
2620 BLK C489
2630 BLK C103 2770 BLK
SHEET 11 SHEET 13
BATT GND SHEET 9
SHEET 10
2810 BLK
2640 BLK SHEET 6
SHEET 11 SHEET 6 2005 BLK C113 ENG-MFR (FUEL SHUTOFF)
2035 BLK SHEET 7
SHEET 6 C425 BRAKE
SHEET 11 2610 BLK FRC1 FUEL PULL RELAY
SHEET 11
2115 BLK 2105 BLK 2000 BLK
SHEET 6
SHEET 7 SHEET 12
C112 HYD OIL FILTER SWITCH FRC1 HVAC RELAY C410 LEFT HANDLE
2030 BLK
2145 BRN SHEET 3 Printable Version Click Here
SHEET 6 FRC1 SWITCHED PWR RELAY
C113 ENGINE HARN (ENG SPEED, ENG OIL PRESS) 2025 BLK
SHEET 7
SHEET 9
2370 BRN FRC1 TRACTION LOCK RELAY WIRING SCHEMATIC
SHEET 7
2220 BRN
J1B
(ACS / SJC MACHINE)
C108 HYD TEMP SENDER 2230 BRN 17 GWY CTRLR
SHEET 7
2190 BRN S550 (S/N A3NL11631 - A3NL12191)
2180 BRN
(S/N AZN811061 - AZN811162)
SHEET 6
(S/N AZN911113 - AZN911229)
2170 BRN
SHEET 6
C104 ENGINE COOLANT SENSOR Sheet 4 of 15
2150 BRN
SHEET 6
758 of 1234
LEGEND
PARTIAL CONNECTOR
CAN BUS
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
CAN HI
(8 PIN)
CAN LO
21 3090 LBL D 1
1730 RNG/WHT
C
E
SHEET 3
1830 RNG/WHT * C450
1
9660 PUR 4
9220 PUR 8 SHEET 3

1840 RNG/WHT * C449
1
J2B 2080 BLK 2
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 5 of 15
Printed In U.S.A.
7210761 (C)
759 of 1234
LEGEND
POWER PAGE 3
GROUND PAGE 4
ENGINE
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
JOIN ONE WIRE)
C113 FUEL SHUTOFF

+12V PULL
PWR
1350 RED/WHT 30
2810 BLK 10 2810 BLK 2800 BLK C GND
SHEET 4
GND 85 86 8110 TAN
8800 TAN 9 8800 TAN 24.5 OHM

1030 RED PWR 30
87 8200 TAN S M
3560 LBL 2 3560 LBL R 1015 RED

GND 85 86 8210 TAN
2005 BLK C110
SHEET 4 B
G
GLOW T14
1060 RED PWR 30 8500 TAN
SHEET 3 87 3420 LBL
2115 BLK GND 85 86 8510 TAN

SHEET 4

6 8510 TAN
14 3420 LBL
7 8210 TAN
3 8110 TAN
J1A 30 3410 LBL
GWY CTRLR
22 3560 LBL C106
15 3160 LBL 3160 LBL 3 3160 LBL A SIG
C405 163 OHM
16 3150 LBL A SIG 2145 BRN 4 2145 BRN
SHEET 4 C107
GND
SHEET 9
4 8800 TAN Printable Version Click Here

C355
J1B
FUEL HARN
C 3180 LBL
C406
A
WIRING SCHEMATIC
SIG
FUEL SENDER
SHEET 4
(30-270 OHM) (ACS / SJC MACHINE)
C104
SHEET 4
2170 BRN B GND
ENGINE COOLANT
S550 (S/N A3NL11631 - A3NL12191)
18 3170 LBL A SIG
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 6 of 15
7210761 (C)
760 of 1234
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
TRACTION C425
+12V LOCK
4100 LGN B C308
2200 BLK C 2200 BLK B 9.8 OHM
GND 85 86 SHEET 4
2025 BLK 4110 LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108
HYDRAULIC
2220 BRN B
SHEET 4 TEMPERATURE
500 - 3000 OHM
C112
34 3320 LBL A
J1A 2320 BRN B
C446
7.2 OHM 12 V
C420
9.8 OHM 12V
C105
HYDRAULIC
5190 YEL A +8V PWR 0.5-7.5V
19 13 1 23 6 WIRING SCHEMATIC
J1B +8V
GWY CTRLR
C418
(ACS / SJC MACHINE)
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
S550 (S/N A3NL11631 - A3NL12191)
3.3 OHM PWM
C419 (S/N AZN811061 - AZN811162)
1 2340 BRN 2 GND
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) (S/N AZN911113 - AZN911229)
3.3 OHM PWM
Printed In U.S.A. J2B 7210761 (C)

AUX CTRLR
761 of 1234
LEGEND
CAB
DISPLAY
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13

T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
C499
BUZZER (-) PTOL
C408 1930 RNG/WHT 1
SHEET 3 SWITCH POWER
(BLACK) 2940 BLK 3
20 3030 LBL 1 3030 LBL 2

C479 PTOL OUTPUT
7040 WHT 10 J1A
SHEET 4 GROUND
1440 RED/WHT 1 24 8130 TAN 2 8130 TAN 2
SHEET 3
SW9
* SHEET 3
1620 RNG/WHT 5 Dealer Copy -- Not for Resale
SWITCHED POWER
TRAVEL CONTROL
SWITCH (OPTIONAL) 3400 LBL 11
SHEET 13 LEFT BLINKER INPUT J1B 22 3040 LBL 14 3040 LBL 4
SHEET 13
4
3650 LBL 7 1950 RNG/WHT 5
3600 LBL 9 SHEET 3 BATTERY (+)
PARK BREAK INPUT 2960 BLK 3
SW1 SHEET 4 GROUND
6
3 2 BRAKE SWITCH
1 C480
2930 BLK SHEET 9
10
1240 RED/WHT 1
SHEET 4 GROUND
8
7
6
5
4
3
1 WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
762 of 1234
PARTIAL CONNECTOR
CAB
CONNECTOR
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
SHEET 9
4
C438
CAB-MFR HARN CONN 3
SHEET 10 4240 LGN
5 4220 LGN 4235 LGN 4 4235 LGN
C492
ACS/SJC HARNESS
3 4275 LGN 5 4275 LGN
(8 PIN) 2 4550 LGN 6 4550 LGN * C212
POWER
SOCKET
2795 BLK 1
GND
1375 RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
1210 RED/WHT A
SHEET 3
+12V BATT PWR
B
+12V SW PWR * DOME LIGHT (-)
2820 BLK C
GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
(LT GRAY)
CAB-MFR HARN CONN 2
*C667
DOOR HARN
(SEE ADDITIONAL
SHEET 4
3630 LBL 4 DOOR SIGNAL
SHEET 8
SHEET 3
2840 BLK 2
WIPER MOTOR GROUND
7310 WHT 3
C482 SEATBAR
J1B SENSOR C252
GWY CTRLR SHEET 4
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

(ACS / SJC MACHINE)
+5V
SHEET 6
5140 YEL
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 9 of 15

Printed In U.S.A.
7210761 (C)
763 of 1234
PAGE 1,2
MANUAL
CONTROLS
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C409
2530 BLK K
4230 LGN G
SHEET 9
1520 RNG/WHT A
SHEET 3
4940 LGN H
4930 LGN J SKI CTRL
4910 LGN F
TWO SPD
J2B 17 4310 LGN C -
PWM
23 4300 LGN B +
30
31 C410
C404 C103
TAILGATE HARN
Dealer Copy -- Not for Resale 13 K
BU ALARM HARN / SJC HARN J2A LEFT HANDLE
T19 TERMINAL (+) 20 4640 LGN D
SHEET 4
1530 RNG/WHT A
SHEET 3
J
C421 4240 LGN H
SHEET 9
10 2670 BRN 3 GND 2520 BLK E
SHEET 4
2 4670 LGN SIG 7.8 OHM 12V
GWY CTRLR 2 C411
E
C422 C
7
3 GND A
2680 BRN
4680 LGN SIG
2
WIRING SCHEMATIC B
C412
A HORN
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
7210761 (C)
764 of 1234
LIGHTS
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
C434-1
C408 WORK LIGHT
CAB-MFR HARN CONN 1
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRONT
WORK C103
C603
GND 85 86 C602
2045 BLK
SHEET 4
6330 PNK 1 SIG
Dealer Copy -- Not for Resale 2640 BLK 2 GND
LEFT REAR
TAIL LIGHT
SHEET 4
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4
RIGHT REAR

+12V LIGHT
1320 RED/WHT
LEFT REAR
2055 BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 11 of 15
765 of 1234
HVAC
CAB DISPLAY
CAB
PAGE 8
PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 (NOT IN STD CAB HARN 7210557)
HVAC PAGE 12
#
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS PAGE 13
C610
* 2 GND
HVAC DUCT
1 SIG FAN
C483
2560 BLK * C BLK
SWITCH)
C635
* D SIG
B
E
C438
(DK GRAY)
Dealer Copy -- Not for Resale F
*BLOWER
SW10

PWR 30 OFF
1140 RED/WHT
1
2016 BLK GND 85 86 4
SHEET 4
1790 RNG/WHT
7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
2745 BLK 8 2745 BLK 2580 BLK 4
SHEET 4
J1A
GWY CTRLR
2570 BLK
* C630
2 THERMOSTAT
11 7021 WHT 7020 WHT 9 7020 WHT 1
3
AC EVAPORATOR C350
SWITCH B
A
7023 WHT WIRING SCHEMATIC
7024 WHT
C355
SW11
*
AC SWITCH
(ACS / SJC MACHINE)
FUEL HARN # C486
7015 WHT 1 C 7400 WHT
A 7024 WHT 7025 WHT 1
2 MAGNET CLUTCH
(COMPRESSOR)
2100 BLK
3 S550 (S/N A3NL11631 - A3NL12191)
2290 BLK 2280 BLK
SHEET 13
D4 (S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 12 of 15
7210761 (C)
Printed In U.S.A.
766 of 1234
OPTIONS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
OPTIONS
C428
PAGE 13
# C607 C355 (LT GRAY)
FUEL HARN CAB-MFR HARN CONN 2
PWR BOB CLOSE
1 4470 LGN E 4470 LGN 8 4470 LGN
#
2 2470 BLK
2290 BLK
2770 BLK B 2770 BLK
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480 BLK SWITCH 6
1 4480 LGN F 4480 LGN 7
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
(BLINKER/FLASHER)
C
SHEET 8
3400 LBL *BEACON
SW2
6570 PNK
5 PIN
E
A 6515 PNK SHEET 3
2725 BLK 6
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
3 2
(PINS 3 & 6
TAILGATE HARN (DK GRAY) 2850 BLK
INSULATED) 6
C670
(SEE ADDITIONAL
E 6410 PNK
CAB-MFR HARN CONN 3
SHEET 8
3500 LBL
D1
* E
D 6510 PNK 6500 PNK 3 6500 PNK 6530 PNK 2420 BLK D
OPTIONS SHEET)
EXTERIOR HARNESS
6540 PNK 6540 PNK B
(SEE ADDITIONAL
C423 C
3 OPTIONS SHEET)
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6 A

2780 BLK 1 2780 BLK
SHEET 4
C408 * C676
RADIO
* C277
(BLACK) 2 1
SHEET 9 2885 BLK
CAB-MFR HARN CONN 1 C126 1 2
1885 RNG/WHT
SHEET 4 SHEET 9 3
C412 2785 BLK B
C279
LEFT HANDLE
(HORN)
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A HORN *
2210 BLK
4
5
PWR
GND
AIR RIDE
2 PIN SPEAKER 6
-
C278
5 7200 WHT
C497
C SJC
RIGHT
*
- 2 7810 WHT 6
SPEAKER +
6520 PNK B (SEE ADDITIONAL
J2A 3
OPTIONS SHEET) Printable Version Click Here
AUX CTRLR
C415
26 2460 BRN
4460 LGN
B
A
GND
SIG
HIGH FLOW
SOLENOID WIRING SCHEMATIC
7.5 OHM 12 V
J2B 26 (ACS / SJC MACHINE)

AUX CTRLR
C441 S550 (S/N A3NL11631 - A3NL12191)
J1A 26 2 GND
2350 BRN TWO SPEED
GWY CTRLR
5.1 OHM 12V
(S/N AZN811061 - AZN811162)
J1B
GWY CTRLR
26 (S/N AZN911113 - AZN911229)
Sheet 13 of 15
767 of 1234
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
H 2280 BLK
2280 BLK
2240 BLK
1170 RED/WHT C409 C466
C492 C493 K A
4275 LGN
4220 LGN 5 4 2240 BLK G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
8 J C467 E DETENT
2260 BLK
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 LIFT TWO SPD
G 4260 LGN 4280 LGN 1 C
B 1740 RNG/WHT 6 SOLENOID
2 D
A 5970 YEL PWM
13 OHM B
G 2250 BRN 12V
C468
FOR PEDAL LOCK C410
2
3 K
2500 BLK TILT
1 D
4270 LGN SOLENOID FLOAT
C
B SKI CTRL
C472
2650 BRN B B GND
G
SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
3990 LBL 2 SIG
5750 YEL
5650 YEL 5980 YEL
5970 YEL 5990 YEL

H 3980 LBL
E 3990 LBL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
(S/N AZN811061 - AZN811162)
(S/N AZN911113 - AZN911229)
Sheet 14 of 15
768 of 1234
SJC A
B
C
D
E
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
A
B
C
D
E
FLOAT-SPARE
A
B
C
D
E
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
2
3
4
5
6
TWO SPEED SWITCH
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
CONTROLS
12 CAN HIGH
C429 ACTUATOR
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4 19 L JOYSTICK Y
29 2890 BRN 2880 BRN 3 7
GND 21 L FWD DRIVE
5880 YEL 1 +5V PWR 5980 YEL 3 +5V PWR
LEFT SPEED 22 CAN LOW
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL C453 4 25 TWO SPEED 1
5970 YEL
5870 YEL 1 +5V PWR 3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870 BRN 3 GND 6
SIG 2990 BRN 1 GND
SENSOR 28 GROUND
24 3875 LBL 4 SIG 4640 LGN 5
7 29 SENSOR GROUND
C536
30 SENSOR SUPPLY . 2 +5V
2970 BRN
5810 YEL 2 C543 A22 PUMP HARNESS 4650 LGN 8
2810 BRN 4 2810 BRN 1 GND
31 L REV DRIVE ..
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
SWASHPLATE E 35 SAFETY OUT
5860 YEL 2 C542
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
C547
Dealer Copy -- Not for Resale 42 R FWD RETURN
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1 D
9140 PUR/WHT 47 UNSWITCHED BATTERY
41 2680/BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
2280 BLK H 49 SPARE PWN COIL 6
C544 C
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A 1 1
C474 1830 RNG/WHT +12V PWR
D 2 2070 BLK 2
26 4210 LGN A GND
J3-ACS
F 4 9660 PUR 4 CAN LO
RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
Printable Version Click Here SUSP SEAT JOYSTICK HARNESS

27 2470 BLK C493
28 2490 BLK 2235 BLK 3
47
48
1250 RED/WHT
1260 RED/WHT
1235 RED/WHT
1170 RED/WHT
2
1
WIRING SCHEMATIC
2240 BLK 4
(ACS / SJC MACHINE)
S550 (S/N A3NL11631 - A3NL12191)
1760 RNG/WHT
2280 BLK (S/N AZN811061 - AZN811162)
2270 BLK
2260 BLK (S/N AZN911113 - AZN911229)
1180 RED/WHT
1190 RED/WHT Sheet 15 of 15
HARNESS)
769 of 1234
PINS PINS PINS
C212 POWER SOCKET 2 9 C483 TEMP CONTROL SWITCH 3 12 T20 BACKUP ALARM (GND) 10
C252 WASHER ADAPTER INTMD 2 9 C486 AC COMPRESSOR 2 12
C253 WASHER PUMP 2 9 C489 MFR ACCESSORY 2 3,4 T37 DOMELIGHT (+) 9
C277 AIR RIDE SEAT 6 13 C492 ACS/SJC HARNESS 8 3,5,9 T38 DOMELIGHT (-) 9
C278 RIGHT SPEAKER 2 13 C493 ACS/SJC HARNESS 4 3,4
C279 LEFT SPEAKER 2 13 C497 SJC HORN/BLINKER 3 13 SW1 BRAKE SWITCH 8
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8 SW2 BEACON SWITCH 13
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8 SW3 HAZARD SWITCH 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8 SW4 HAND/FOOT, H/ISO SWITCH 9
C404 BACKUP ALARM 2 3,10 C602 LEFT REAR TAIL LIGHT 2 11 SW5 POWER BOBTACH SWITCH 13
C405 AIR FILTER SWITCH 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 SW6 BUCKET POSITION SWITCH 13
C406 FUEL SENDER 2 6 C606 POWER BOBTACH OPEN 2 13 SW9 TRAVEL CONTROL SWITCH 8
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C607 POWER BOBTACH CLOSE 2 13 SW10 BLOWER SWITCH 12
C409 RIGHT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 SW11 AC SWITCH 12
C410 LEFT HANDLE 10 10 C611 BLOWER MOTOR 4 12
C411 LEFT HANDLE 5 WAY (FLSHR) 5 10,13 C630 THERMOSTAT 3 12
C412 LEFT HANDLE 2 WAY (HORN) 2 10,13 C635 HEATER VALVE 6 12
C415 HIGH FLOW SOLENOID 2 13 C667 DOORDealer Copy -- 6Not for Resale
9
C418 FRONT ROD 2 7 C670 EXTERIOR BEACON 6 13
C419 FRONT BASE 2 7 C676 RADIO 6 13
J1A GATEWAY COTROLLER 34 3,6,7,10,11
C420 HYD LOCK 2 7
12,13
C421 TILT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26 3,4,5,6,9,
10,13
C422 LIFT SPOOL LOCK 3 10 J2A AUX CONTROLLER 34 7,10,13
C423 BUCKET POSITION 2 13 J2B AUX CONTROLLER 26 3,4,5,7,10,
13

BATT FEED, GENERAL
BATT FEED, FUSED
1000 THROUGH 1499
1000 THROUGH 1499
RED
RED/WHITE
RED
RED/WHT
POWER
GROUND
PAGE 3
PAGE 4
WIRING SCHEMATIC
CAN BUS PAGE 5
BATTERY GROUND
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE PAGE 6 (ACS / SJC MACHINE)
HYDRAULICS PAGE 7
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
S550 (S/N A3NL12192 - A3NL12725)
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 (S/N AZN811163 - AZN811512)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 (S/N AZN911230 - AZN911254)
Sheet 1 of 15

Printed In U.S.A.
7254448 (A)
770 of 1234
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 B-10
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER
A-25 ENGINE OIL PRESS B-25 A-25 B-25 BUCKET POSITION (SPARE)
A-26 TWO SPEED B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27
A-29 A-29
A-30 FUEL PULL RELAY FDBK Dealer
A-30Copy -- Not for Resale
RH LEFT UP
LEGEND
PARTIAL CONNECTOR HARNESS PART NUMBER
MFR CTRL 7210555
STD CAB 7210557
FUEL SWITCH
DLX CAB 7253409
TRACTION
STARTER
PULL PULL POWER CONNECTOR DLX FUEL 7240781
STD FUEL 7149219 Printable Version Click Here
ENG 2403 7181036
GLOW
PLUG
REAR
LIGHT
FRONT
LIGHT
HVAC
WIRE BREAK
(TWO WIRE BREAKS
ENG 2607
TAILGATE DOM
7181037
7217484 WIRING SCHEMATIC
JOIN ONE WIRE)
SHEET # (ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 2 of 15
Printed In U.S.A.
7254448 (A)
771 of 1234
FUSE 1
25 A
POWER 1240/RED/WHT SHEET 8
1300/RED 1140/RED/WHT C503 RH DLX PANEL
SHEET 12
FRC1 HVAC RELAY 1150/RED/WHT 3 J2B C408
1400/RED/WHT
BATTERY MEGAFUSE
FUSE 4
1180/RED/WHT 2 AUX CTRLR (BLACK)
CAB-MFR HARN CONN 1
SHEET 9
C667 DOOR HARNESS
100.0 Amps
BATT_CABLE/RED 25 A
1025/RED 1160/RED/WHT 1450/RED/WHT 6 1450/RED/WHT 1420/RED/WHT SHEET 8
1110/RED/WHT
J1B
1 C493 1130/RED/WHT 3 GWY CTRLR 1440/RED/WHT
FUSE 12 1170/RED/WHT SHEET 8
ACS / SJC HARNESS
SHEET 6 1270/RED 1120/RED/WHT 1235/RED/WHT (4 PIN)
STARTER
1460/RED/WHT
SHEET 13
1010/RED
1040/RED 25 A 1410/RED/WHT
1490/RED/WHT
SHEET 13
FUSE 11 1165/RED/WHT
15 A SHEET 5
1290/RED 1370/RED/WHT C426 REMOTE RUN, ACD
SHEET 9
FUSE 9
1620/RNG/WHT
30 A 1360/RED/WHT SHEET 8
1050/RED FRC1 TRACTION LOCK RELAY
FUSE 10
1030/RED 30 A 1350/RED/WHT SHEET 8
1060/RED FUSE 2 FRC1 FUEL SHUTOFF RELAY
FRC1 GLOW PLUG RELAY 20 A 1330/RED/WHT SHEET 8
1340/RED C499 RH PANEL PTOL
SHEET 11
FUSE 3 1775/RNG/WHT
(LT GRAY)
15 A SHEET 8
1320/RED/WHT CAB-MFR HARN CONN 2 SW1 BRAKE SWITCH
SHEET 11
1660/RNG/WHT 2 1660/RNG/WHT 1590/RNG/WHT
SHEET 8
1520/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
FUSE 6
5A C409 RIGHT HANDLE 1950/RNG/WHT
1570/RNG/WHT 1530/RNG/WHT SHEET 10 SHEET 8
1560/RNG/WHT 22 J2B
FUSE 8 AUX CTRLR 1785/RNG/WHT
SHEET 9
25 A 1730/RNG/WHT SHEET 5 SW4 H/ISO SWITCH
1780/RNG/WHT A 1960/RNG/WHT
25 A
1760/RNG/WHT 1750/RNG/WHT 1815/RNG/WHT SHEET 6
C110 ALT EXCITATION
C404
1720/RNG/WHT B BACKUP ALARM HARN
1850/RNG/WHT
SWITCHED SHEET 9 Printable Version Click Here
1790/RNG/WHT C408 CAB-MFR CONN (FR WIPER)
+12V POWER SHEET 12
1050/RED
PWR
30
87
FRC1 HVAC RELAY 1580/RNG/WHT SHEET 9
WIRING SCHEMATIC
SHEET 4
2030/BLK GND 85 86
1740/RNG/WHT 6 C492
ACS/SJC HARNESS
(ACS / SJC MACHINE)
(8 PIN)
3380/LBL 4 J1A
S550 (S/N A3NL12192 - A3NL12725)
GWY CTRLR
(S/N AZN811163 - AZN811512)
C428
(LT GRAY)
CAB-MFR HARN CONN 2
(S/N AZN911230 - AZN911254)
C449 LH JOYSTICK
1920/RNG/WHT 6 1920/RNG/WHT
Sheet 3 of 15
C450 RH JOYSTICK
Printed In U.S.A.
7254448 (A)
772 of 1234
GROUND
2080/BLK
SHEET 5
C449 LH JOYSTICK
2070/BLK
SHEET 5 C408
C450 RH JOYSTICK C493 3 2235/BLK
(BLACK)
2920/BLK CAB-MFR HARN CONN 1 ACS / SJC HARNESS 4
SHEET 8 2240/BLK
(4 PIN)
C479 LH PANEL
2940/BLK 2950/BLK 10 2950/BLK
SHEET 8
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8
16 2540/BLK
C428 J2B
2930/BLK (LT GRAY) 15 2550/BLK 2090/BLK
SHEET 8 AUX CTRLR
CAB-MFR HARN CONN 2
SW1 BRAKE SWITCH
2765/BLK
2830/BLK 2900/BLK 1 2900/BLK SHEET 11
2700/BLK SHEET 5 2710/BLK 2745/BLK
SHEET 8 C426 REMOTE RUN, ACD 2300/BLK SHEET 12
SW9 TRAVEL CONTROL SWITCH C408 CAB-MFR CONN (HVAC)
SHEET 13 2455/BLK
2785/BLK 2790/BLK T8
SHEET 13 C421 BKT POSITION SOLENOID SHEET 9
C126 HORN BATT GND
2620/BLK C489
SHEET 11 B 2720/BLK 2780/BLK
2630/BLK C103 2770/BLK
SHEET 11 SHEET 13
T18 LH REAR LIGHT TAILGATE HARN C355 FUEL HARN (PWR BOB, AC) T1 2730/BLK
BATT GND SHEET 9
2650/BLK 2600/BLK B 2600/BLK C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 10
T20 BU ALARM 2390/BLK
SHEET 6 2810/BLK
2640/BLK 2005/BLK
SHEET 11 SHEET 6 C113 ENG-MFR (FUEL SHUTOFF)
C602 LH REAR LIGHT FRC1 STARTER RELAY Dealer Copy
2200/BLK -- Not for Resale
SHEET 6 2035/BLK SHEET 7
2610/BLK C425 BRAKE
SHEET 11 FRC1 FUEL PULL RELAY
C603 RH REAR LIGHT SHEET 11 2045/BLK
2055/BLK SHEET 10 2530/BLK
SHEET 11
2115/BLK 2105/BLK 2000/BLK
SHEET 6
2320/BRN 2016/BLK 2520/BLK
SHEET 7 SHEET 12 SHEET 10
C112 HYD OIL FILTER SWITCH FRC1 HVAC RELAY C410 LEFT HANDLE
2030/BLK
2145/BRN SHEET 3
SHEET 6 FRC1 SWITCHED PWR RELAY
C113 ENGINE HARN (ENG SPEED, ENG OIL PRESS) 2025/BLK
SHEET 7
2370/BRN FRC1 TRACTION LOCK RELAY
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) Printable Version Click Here
2220/BRN
SHEET 7
C108 HYD TEMP SENDER 2230/BRN 17
J1B
GWY CTRLR WIRING SCHEMATIC
2190/BRN
SHEET 7
C105 HYD CHG PRESSURE SENDER (ACS / SJC MACHINE)
2180/BRN
SHEET 6
C355 FUEL HARN (FUEL SENDER) S550 (S/N A3NL12192 - A3NL12725)
SHEET 6
2170/BRN
(S/N AZN811163 - AZN811512)
SHEET 6
2150/BRN (S/N AZN911230 - AZN911254)
Sheet 4 of 15
773 of 1234
CAN BUS
C408
J1B (BLACK)
8 9200/PUR 9270/PUR 9210/PUR 9280/PUR 9230/PUR 4 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4
CAN LO C479
9 9100/PUR/WHT 9170/PUR/WHT 9110/PUR/WHT 9180/PUR/WHT 9130/PUR/WHT 3 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426
Remote Start Tool, ACD C492 9160/PUR/WHT 2 C503
14 9500/PUR/WHT A ACS/SJC HARNESS 9260/PUR 4 RIGHT DELUXE PANEL
CAN HI (8 PIN)
20 9600/PUR B
CAN LO
21 3090/LBL D 1
REMOTE RUN KEY 9240/PUR
1730/RNG/WHT
C
E
9140/PUR/WHT 4 ACS CTRLR
1830/RNG/WHT * C450
1
SHEET 3 SWITCHED POWER SHEET 3
1165/RED/WHT F 2070/BLK 2
SHEET 3 UNSWITCHED POWER 9290/PUR 7 SHEET 4 RIGHT JOYSTICK
2710/BLK G 9560/PUR/WHT 3 (SJC ONLY)
SHEET 4 GROUND 9190/PUR/WHT 8 DRIVE CTRLR
9660/PUR 4
9220/PUR
8 SHEET 3
1840/RNG/WHT * C449
1
J2B 2080/BLK 2
9120/PUR/WHT 9 SHEET 4 LEFT JOYSTICK
AUX CTRLR
9540/PUR/WHT 3 (SJC ONLY)
9640/PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 5 of 15
Printed In U.S.A.
7254448 (A)
774 of 1234
FUEL
C113
MFR-ENG HARN
ENGINE C101
FUEL SHUTOFF
SOLENOID
+12V PULL
8120/TAN 8120/TAN 8 8120/TAN 8100/TAN B PULL 0.33 OHM
PWR
1350/RED/WHT 30
SHEET 3 87 3410/LBL D5
2810/BLK 10 2810/BLK 2800/BLK C GND
SHEET 4
GND 85 86 8110/TAN
SHEET 4 2035/BLK A
8800/TAN 9 8800/TAN HOLD
24.5 OHM

1030/RED PWR 30
SHEET 3 8200/TAN 1 8200/TAN B SHEET 3
87 8200/TAN S M
3560/LBL 2 3560/LBL R 1015/RED
GND 85 86 8210/TAN
2005/BLK C110
SHEET 4 B
ALTERNATOR S 1020/RED
G
2015/BLK L 1815/RNG/WHT
GLOW T14
PLUG 1815/RNG/WHT 7 1815/RNG/WHT EXCITATION
1060/RED PWR 30 8500/TAN
SHEET 3 87 3420/LBL
2115/BLK GND 85 86 8510/TAN

SHEET 4
6 8510/TAN
14 3420/LBL
7 8210/TAN
3 8110/TAN
J1A 30 3410/LBL Dealer Copy -- Not for Resale
GWY CTRLR
22 3560/LBL C106
15 3160/LBL 3160/LBL 3 3160/LBL A SIG
2160/BRN B GND ENGINE SPEED SENSOR
C405 163 OHM
16 3150/LBL A SIG 2145/BRN 4 2145/BRN
SHEET 4
2150/BRN B AIR FILTER C107
GND
SHEET 4 SWITCH (NC) 2140/BRN A GND
25 3140/LBL 3140/LBL 6 3140/LBL C SIG ENGINE OIL PRESSURE
5140/YEL 5 5140/YEL B +5V PWR SENDER (0.5 ~ 4.5V)
SHEET 9
4 8800/TAN
C355
FUEL HARN
J1B C406
GWY CTRLR 12 3180/LBL C 3180/LBL A SIG
FUEL SENDER Printable Version Click Here
2180/BRN D 2180/BRN B GND
SHEET 4 (30-270 OHM)
C104 WIRING SCHEMATIC

2170/BRN B GND
SHEET 4
18 3170/LBL A SIG ENGINE COOLANT
SENSOR (500-3000 OHM) (ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 6 of 15
775 of 1234
7254448 (A)
TRACTION
HYDRAULICS
C425
+12V LOCK
PWR 30 4100/LGN B C308
1360/RED/WHT BRAKE
SHEET 3 87 3430/LBL 4200/LGN A 4200/RED A SOLENOID
2200/BLK C 2200/BLK B 9.8 OHM
GND 85 86 SHEET 4
2025/BLK 4110/LGN 12 V
SHEET 4
C425 WHEEL MACHINES

B PULL 0.3 OHM
8 A HOLD 10.9 OHM
C
13
TRACTION LOCK
C108 HYDRAULIC
2220/BRN B TEMPERATURE
SHEET 4
32 3220/LBL A SENDER
500 - 3000 OHM
C112
34 3320/LBL A
J1A
HYDRAULIC
2320/BRN B
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYD LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12V
C105
HYDRAULIC
2190/BRN B GND CHARGE
3190/LBL C SIG PRESSURE
5190/YEL A +8V PWR 0.5-7.5V
19 13 1 23 6
J1B +8V
GWY CTRLR
J2A 18 2330/BRN
C418
2 GND FRONT ROD
WIRING SCHEMATIC
AUX CTRLR 4330/LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM (ACS / SJC MACHINE)
C419
1 2340/BRN
4340/LGN
2
1
GND
SIG
FRONT BASE S550 (S/N A3NL12192 - A3NL12725)
SOLENOID (FEMALE)
3.3 OHM PWM
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
19 13
Sheet 7 of 15
J2B Printable Version Click Here
AUX CTRLR
776 of 1234
CAB
DISPLAY
T13
SHEET 3
1940/RNG/WHT
BUZZER (+)
C499
BUZZER (-) PTOL
C408 1930/RNG/WHT 1
2940/BLK 3
20 3030/LBL 1 3030/LBL 2
C479 PTOL OUTPUT
LEFT PANEL (BLACK) 19 2380/BRN 12 2380/BRN 4 PTOL LED
7040/WHT 10 J1A
2920/BLK 2 RIGHT H KEY SWITCH PANEL
SHEET 4 GROUND
1440/RED/WHT 1 24 8130/TAN 2 8130/TAN 2
1960/RNG/WHT SHEET 3 BATTERY (+) START
SHEET 3
*
SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5
11
SWITCHED POWER
SWITCH (OPTIONAL) SHEET 13 3400/LBL LEFT BLINKER INPUT J1B 22 3040/LBL 14 3040/LBL 4
5 6 3500/LBL 8 RIGHT BLINKER INPUT
SHEET 13
4
2700/BLK 2 3 3650/LBL 7 Dealer Copy -- Not for Resale
TRAVEL CONTROL INPUT SHEET 3 1950/RNG/WHT 5 SWITCHED POWER
SHEET 4 1 1420/RED/WHT 1
3600/LBL 9 SHEET 3 BATTERY (+)
PARK BREAK INPUT 2960/BLK 3
SW1 SHEET 4 GROUND
6
3 2 BRAKE SWITCH
1 C480
3610/LBL 4 5 LEFT PANEL (GRAY) C503
1775/RNG/WHT RIGHT DELUXE PANEL
SHEET 3 6 3630/LBL 12
2930/BLK SHEET 9 DOOR SIGNAL
SHEET 4 11 1590/RNG/WHT 5
10
1240/RED/WHT 1
3610/LBL 2 PARK BREAK OUTPUT 2250/BLK 3
SHEET 4 GROUND
8
7
6
5
4
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
777 of 1234
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
CAB
1785/RNG/WHT 2
SWITCH
1
SHEET 3
SHEET 9
2060/BLK 5
3
6 (NOT IN STD CAB HARN 7210557)
4
C438
SHEET 10 4230/LGN (DK GRAY)
CAB-MFR HARN CONN 3
SHEET 10 4240/LGN
5 4220/LGN 4235/LGN 4 4235/LGN
C492
ACS/SJC HARNESS 3 4275/LGN 5 4275/LGN
(8 PIN) 2 4550/LGN 6 4550/LGN * C212
POWER
SOCKET
2795/BLK 1
GND
1375/RED/WHT 2
C408 +12V PWR
(BLACK)
CAB-MFR HARN CONN 1

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010/BLK LIGHT
CAB ACCESSORY
T38
1210/RED/WHT A
SHEET 3 1580/RNG/WHT 5 1580/RNG/WHT 1865/RNG/WHT B
+12V BATT PWR
+12V SW PWR
* DOME LIGHT (-)
2820/BLK C
GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT
SHEET 13
2730/BLK 11 2730/BLK 2210/BLK
SHEET 4 SHEET 13
2885/BLK SHEET 13
C428 2060/BLK SHEET 9
(LT GRAY)
CAB-MFR HARN CONN 2
Dealer Copy -- Not for Resale *
C667
DOOR HARN
(SEE ADDITIONAL
2790/BLK 11 2790/BLK OPTIONS DWG)
SHEET 4
3630/LBL 4 DOOR SIGNAL
SHEET 8
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
2840/BLK 2
WIPER MOTOR GROUND
1850/RNG/WHT 13 1850/RNG/WHT 1850/RNG/WHT 1

7310/WHT 3
C482 SEATBAR
J1B SENSOR
2370/BRN 4 2370/BRN A GND
GWY CTRLR SHEET 4
11 3370/LBL 5 3370/LBL B SIG
+5V
24 5100/YEL
5140/YEL
5370/YEL 3 5370/YEL C +5V PWR
HARNESS WASHER PUMP
WIRING SCHEMATIC
SHEET 6
7253378
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
* C252
A 7310/WHT
C253
1
PWR
WASHER (S/N AZN811163 - AZN811512)
MOTOR
2845/BLK B 2845/BLK 2 GND (S/N AZN911230 - AZN911254)
Sheet 9 of 15

Printed In U.S.A.
7254448 (A)
778 of 1234
MANUAL SHEET 4
SHEET 9
SHEET 3
2530/BLK
4230/LGN
1520/RNG/WHT
C409
K
G
A
RIGHT HANDLE
CONTROLS
4940/LGN H
4930/LGN J SKI CTRL
21 4920/LGN E DETENT FLOW
4910/LGN F
TWO SPD
J2B 17 4310/LGN C -
AUX CTRLR 18 4320/LGN D
PWM
23 4300/LGN B +
30
31 C410
C404 C103 13 K
T19 TERMINAL (+) J2A 20 4640/LGN D
(SEE ADDITIONAL A 7100/WHT C 7100/WHT AUX CTRLR 28 4840/LGN C
OPTIONS SHEET) BACK UP 22 4830/LGN B SKI CTRL
2650/BLK ALARM 12 4820/LGN G
SHEET 4
T20 TERMINAL (-) 11 4810/LGN F SIDE SHIFT
1530/RNG/WHT A
SHEET 3
J
C421 4240/LGN H
SHEET 9
10 2670/BRN 3 GND 2520/BLK E
SHEET 4
1 TILT SPOOL LOCK
J1A 2 4670/LGN SIG 7.8 OHM 12V
GWY CTRLR 2 C411
E
C422 C
7
3 GND A
2680/BRN
4680/LGN SIG
2
C412
B
A HORN
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
7254448 (A)
779 of 1234
LIGHTS
C434-1
2735/BLK B GND LEFT FRONT
C408 WORK LIGHT
(BLACK) 6100/PNK A SIG 37.00 Watts
CAB-MFR HARN CONN 1
C434-2
2765/BLK 9 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 4
6110/PNK A SIG WORK LIGHT
50.00 Watts
C435-1
6000/PNK 8 6000/PNK 6120/PNK A SIG RIGHT FRONT
2760/BLK B WORK LIGHT
GND 37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
2705/BLK B GND WORK LIGHT
50.00 Watts
FRONT
WORK C103
+12V LIGHTS C603
TAILGATE HARN SHEET 4
PWR 30 2610/BLK 2 GND
1330/RED/WHT 6310/PNK RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6320/PNK 1 SIG TAIL LIGHT
GND 85 86 C602
2045/BLK
SHEET 4
6330/PNK 1 SIG LEFT REAR
2640/BLK 2 GND TAIL LIGHT
SHEET 4
5 6320/PNK
31 3460/LBL
J1A 17
GWY CTRLR
6210/PNK
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 4
RIGHT REAR
Dealer Copy -- Not for Resale 6210/PNK SIG WORK LIGHT

+12V LIGHT
1320/RED/WHT
SHEET 3 87 6200/PNK H 6200/PNK 6220/PNK SIG
LEFT REAR
GND 85 86 2630/BLK GND WORK LIGHT
2055/BLK SHEET 4
SHEET 4
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
780 of 1234
HVAC
*
C610
2
1
GND
SIG
HVAC DUCT
FAN
*
C483
(NOT IN STD CAB HARN 7210557) 2560/BLK

7420/WHT
C
A
BLK
DBL POTENTIOMETER
7425/WHT B WHT (TEMP CONTROL
#
DLX FUEL HARN 7240781 ONLY SWITCH)
*
C635
(NOT IN STD FUEL HARN 7149219) 2130/BLK
D
C
SIG
GND HEATER
7430/WHT A +12V PWR VALVE
B
E
C438
(DK GRAY)
F
*BLOWER
SW10

PWR 30 OFF
1140/RED/WHT
SHEET 3 87 1500/RNG/WHT 7 1500/RNG/WHT 5 2
1
2016/BLK GND 85 86 4
SHEET 4
1790/RNG/WHT
7410/WHT 6
3 7530/WHT * C611
1 14.00 Amps High
SHEET 3 7520/WHT 2 7.50 Amps Med BLOWER
21 3450/LBL 7510/WHT 3 5.00 Amps Low MOTOR
2745/BLK 8 Dealer
2745/BLK Copy -- Not for Resale 2580/BLK 4
SHEET 4
J1A
GWY CTRLR
2570/BLK
* C630
2 THERMOSTAT
11 7021/WHT 7020/WHT 9 7020/WHT 1
3
AC EVAPORATOR C350
SWITCH B 7023/WHT
A 7024/WHT
C355
SW11
*
AC SWITCH
FUEL HARN # C486
A 7024/WHT 7025/WHT 1
MAGNET CLUTCH
7015/WHT
2100/BLK
1 C 7400/WHT
3
WIRING SCHEMATIC
2
(COMPRESSOR)
SHEET 13
2290/BLK
D4
2280/BLK
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Sheet 12 of 15
7254448 (A)
Printed In U.S.A.
781 of 1234
OPTIONS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11

COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
C428 (NOT IN STD CAB HARN 7210557)

# C607
C355 (LT GRAY)
FUEL HARN
PWR BOB CLOSE CAB-MFR HARN CONN 2 #
1 4470/LGN E 4470/LGN 8 4470/LGN
2 2470/BLK
2290/BLK
2770/BLK B 2770/BLK
SHEET 4 4480/LGN (NOT IN STD FUEL HARN 7149219)
SHEET 12
# C606 *POWER
SW5 2 1
3
5 4
2 2480/BLK SWITCH 6
1 4480/LGN F 4480/LGN 7
1380/RED/WHT
SHEET 3
C411
B 6010/PNK 10
1430/RED/WHT
6010/PNK
X
L
* T3
FLASHER CONN
LEFT HANDLE D 6415/PNK 6400/PNK 14 D2 6430/PNK

6400/PNK
(BLINKER/FLASHER)
5 PIN
C
SHEET 8
3400/LBL *BEACON
SW2
6570/PNK
E
1550/RNG/WHT 9 1550/RNG/WHT SWITCH
A 6515/PNK SHEET 3
2725/BLK 6
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
3 2
(PINS 3 & 6
TAILGATE HARN (DK GRAY) INSULATED)
2850/BLK
6
(SEE ADDITIONAL
E 6410/PNK
CAB-MFR HARN CONN 3
SHEET 8
3500/LBL
D1
* C670
E
D 6510/PNK 6500/PNK 3 6500/PNK 6530/PNK 2420/BLK D
OPTIONS DWG) Dealer Copy -- Not for Resale
6440/PNK F BEACON/FLASHER
6540/PNK 6540/PNK B EXTERIOR HARNESS
(SEE ADDITIONAL
C423 C
OPTIONS DWG)
BUCKET
POSITION
SIG A 4450/LGN D3 4455/LGN 2 4455/LGN
3
1
4
2 *BUCKET
SW6 A
SOLENOID 2830/BLK 5 POSITION

GND B 2450/BLK 2455/BLK SWITCH
2780/BLK 1 2780/BLK
SHEET 4
C408 * C676
RADIO
* C277
(BLACK) 2 1
SHEET 9 2885/BLK
CAB-MFR HARN CONN 1 1 2
C126 1885/RNG/WHT
SHEET 4 SHEET 9 3
C412 2785/BLK B
LEFT HANDLE
(HORN)
B
A 1460/RED/WHT
7210/WHT 13 7210/WHT A HORN *C279
+ 1 7820/WHT 3 SHEET 9 1510/RNG/WHT
2210/BLK
4
5
PWR
GND
AIR RIDE
SHEET 3 LEFT 2 7830/WHT 4 SHEET 9 SEAT
2 PIN SPEAKER 6
-
5 7200/WHT
C497
C SJC RIGHT
*-
C278
2 7810/WHT 6
4 6420/PNK A HORN/BLINKER 1 7800/WHT 5
SPEAKER +
3 6520/PNK B (SEE ADDITIONAL
J2A OPTIONS DWG) Printable Version Click Here
AUX CTRLR
C415
26 2460/BRN
4460/LGN
B
A
GND
SIG
HIGH FLOW
SOLENOID WIRING SCHEMATIC
7.5 OHM 12 V
J2B 26 (ACS / SJC MACHINE)

AUX CTRLR
J1A
C441 S550 (S/N A3NL12192 - A3NL12725)
26 2350/BRN 2 GND TWO SPEED
GWY CTRLR
4350/LGN 1 SIG SOLENOID
5.1 OHM 12V
(S/N AZN811163 - AZN811512)
J1B
GWY CTRLR
26 (S/N AZN911230 - AZN911254)
Sheet 13 of 15
782 of 1234
ACS
ACS CONTROLLER
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
J1-ACS HARNESS PART NUMBER

CONTROLLER ACS 7164144 EXMF, LF
H 2280/BLK ACS 7190593 MF
SEE MANUAL CONTROL
2280/BLK
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A PWM
+5V
5970/YEL 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER 2650/BRN B B GND
G
SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A HALL SENSOR 2980/BRN 1 GND
+5V PWR
3980/LBL 2 SIG
C471
2 C428 TILT ACTUATOR
2660/BRN GND
J 3 SIG K 4645/LGN 8
4660/LGN LIFT PEDAL
1 HALL SENSOR 7
5660/YEL +5V PWR
2980/BRN
6
2990/BRN
C470 A 4640/LGN 5
2760/BRN 2 4
GND
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 3990/LBL 2 SIG
5750/YEL
B 5650/YEL 5980/YEL
C 5970/YEL 5990/YEL
D
H 3980/LBL
E 3990/LBL WIRING SCHEMATIC
(ACS / SJC MACHINE)
S550 (S/N A3NL12192 - A3NL12725)
(S/N AZN811163 - AZN811512)
(S/N AZN911230 - AZN911254)
Printed In U.S.A. Sheet 14 of 15
7254448 (A)
783 of 1234
ACS CONTROLLER
SJC
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS J5 DRIVE CONTROLLER
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 1 SAFETY IN
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 2 TWO SPEED SWITCH
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
CONTROLS
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 4 H PAT SWITCH
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 5 ISO PAT SWITCH
F F LIFT HANDLE F LIFT MOTOR 1 6 ISO LITE
G GROUND G TILT HANDLE G PEDAL ENABLE 7 L SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 8 R SWASH PLATE ANGLE
# J LIFT PEDAL J GROUND 9 SPARE ANALOG 4
HARNESSES 7159325, 7159458 ONLY K TILT PEDAL K TILT MOTOR 2 10 SPARE ANALOG 5
11 L FWD RETURN
HARNESS PART NUMBER 12 CAN HIGH
LIFT 13 LF ANGLE
SJC WHEEL 7210503 EXMF, LF C429 ACTUATOR
SJC TRACK 7210504 EXMF, LF 4600/LGN 5 14 RF ANGLE
J5 - DRIVE SJC WHEEL 7159325 EXMF, LF
4610/LGN
6
8
15
16
LR ANGLE
H PAT LITE
SJC TRACK 7159458 EXMF, LF
CONTROLLER SJC WHL,TRK 7210505 MF
2980/BRN 1
4
GND 17 RR ANGLE
A22 PUMP 7188448 MF, EXMF, LF 18 L JOYSTICK X
# C454 3980/LBL 2 SIG
SUSP JSTK 7163706 MF, EXMF, LF 7 19 L JOYSTICK Y
29 2890/BRN 2880/BRN 3 GND
5980/YEL 3 +5V PWR 20 R JOYSTICK X
5880/YEL 1 +5V PWR
LEFT SPEED
33 3880/LBL 2 SIG
21 L FWD DRIVE
SENSOR
34 3885/LBL 4 SIG C428 TILT ACTUATOR 22 CAN LOW
5990/YEL 3 +5V PWR 23 R QUAD A DRIVE
40 5890/YEL # C453 4
+5V 24 R QUAD B DRIVE
5970/YEL
5870/YEL 1 +5V PWR 3990/LBL 2 SIG
2870/BRN 3 GND 25 TWO SPEED 1
6
23 3870/LBL 2 RIGHT SPEED 26 BRAKE LIGHT OUTPUT
SIG 2990/BRN 1 GND
SENSOR
24 3875/LBL 4 SIG 4640/LGN 5 27 GROUND
C536
7 28 GROUND
4650/LGN 8
2970/BRN
5810/YEL 2 C543 A22 PUMP HARNESS 29 SENSOR GROUND
2810/BRN 4 2810/BRN 1 GND 30 SENSOR SUPPLY 2 +5V
8 3810/LBL 3 3810/LBL 3 SIG RIGHT 31 L REV DRIVE
1710/RNG/WHT 1 1710/RNG/WHT 2 SWASHPLATE K
+12V PWR 32 CAN SHIELD
J
33 L QUAD A DRIVE
J2-ACS
C537
E
5860/YEL 2 C542 34 L QUAD B DRIVE
H
2860/BRN 4 2860/BRN 1 GND
LEFT F 35 SAFETY OUT
7 3860/LBL 3 3860/LBL 3 SIG SWASHPLATE G 36 BACKUP ALARM
1770/RNG/WHT 1 1770/RNG/WHT 2 +12V PWR
C 37 R JOYSTICK Y
C501 C546 D
38 SPARE ANALOG 1
43 4260/LGN 1 4260/LGN 1 B
RIGHT FORWARD DRIVE 39 SPARE PWM COIL 7
42 2660/BRN 2 2660/BRN 2 A
ACS CONTROLLER
40 SENSOR SUPPLY 1 +5V
41 L REV RETURN
44 4250/LGN 3 4250/LGN
C547
1
Dealer Copy -- Not for Resale A 42 R FWD RETURN
RIGHT REVERSE DRIVE +5V
45 2650/BRN 4 2650/BRN 2 G 43 R FWD DRIVE
J1-ACS
F 44 R REV DRIVE
C545 9240/PUR E 45 R REV RETURN
31 4280/LGN 5 4280/LGN 1 9140/PUR/WHT D
41 2680/BRN 6 2680/BRN 2 LEFT REVERSE DRIVE 46 TWO SPEED 2
1760/RNG/WHT B
H
47 UNSWITCHED BATTERY
2280/BLK
C544 C 48 UNSWITCHED BATTERY
21 4270/LGN 7 4270/LGN 1 49 SPARE PWN COIL 6
11 2670/BRN 8 2670/BRN 2 LEFT FORWARD DRIVE
50 SWITCHED BATTERY
K
A
C474
D
26 4210/LGN A C460
J3-ACS
F
1 1830/RNG/WHT 1 +12V PWR
2270/BLK H
C450 2 2070/BLK 2 GND
2260/BLK J RIGHT JOYSTICK RIGHT
C492 4 9660/PUR 4 CAN LO
1180/RED/WHT C (TO DLX CAB HARNESS) JOYSTICK
12 9190/PUR/WHT 8
1190/RED/WHT B
22 9290/PUR 7 3 9560/PUR/WHT 3 CAN HI
E
4 4550/LGN 2
G
6 4220/LGN 5 C459
16 4275/LGN 3 1 1840/RNG/WHT 1 +12V PWR
9140/PUR/WHT 4
C449 2 2080/BLK 2 GND
9240/PUR 1
50 1750/RNG/WHT 1740/RNG/WHT 6
MAINFRAME LEFT JOYSTICK LEFT
(TO DLX CAB HARNESS) 4 9640/PUR 4 CAN LO
HARNESS JOYSTICK
27 2470/BLK C493 3 9540/PUR/WHT 3 CAN HI
28 2490/BLK 2235/BLK 3 SUSP SEAT JOYSTICK HARNESS
47 1250/RED/WHT 1235/RED/WHT 2
48 1260/RED/WHT 1170/RED/WHT 1 Printable Version Click Here
2240/BLK 4
WIRING SCHEMATIC
1760/RNG/WHT (ACS / SJC MACHINE)
2280/BLK
2270/BLK
2260/BLK
S550 (S/N A3NL12192 - A3NL12725)
1180/RED/WHT
1190/RED/WHT
(S/N AZN811163 - AZN811512)
36 7100/WHT
C404
A (CONNECTS TO BACKUP (S/N AZN911230 - AZN911254)
B ALARM C404 ON MFR
HARNESS)
Sheet 15 of 15
PrintedInInU.S.A.
Printed U.S.A.
7254448 (A)
784 of 1234
Index Diagram
1
2
SH01 - INDEX
4 SH04 - GROUND
6 SH06 - ENGINE LEGEND
7 SH07 - HYDRAULICS
8 SH08 - CAB DISPLAY CONNECTOR
9 SH09 - CAB
10 SH10 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1 1
11 SH11 - LIGHTS
12 SH12 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
13 SH13 - OPTIONS 1 PARTIAL CONNECTOR
14 SH14 - OPTIONS 2 CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
1 1
HARNESS PART NUMBER MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
MFR CTRL 7307214 LGN 1 1
STD CAB 7210557
CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX CAB 7304511
WIRE BREAK
STD FUEL 7149219 SHT1/F2 SHT1/F2
ENG 2403 7181036 SHT1/F2
WIRE BREAK
SHT1/F2
ENG 2607 7181037 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT

7165061
TRK BRAKE ADP
SUSP JSTK 7163706 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
ACS/AWS/SJC
COMPUTER ATTACHMENT
UNSWITCHED
TRACTION FUEL SWITCHED
STARTER
PULL PULL POWER
POWER PLUG REAR LIGHT ALT & KITS
FUEL PULL FRONT LIGHT SWITCHED
GLOW REAR FRONT

HVAC
PLUG LIGHT LIGHT
TRACTION HVAC UNSWITCHED

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

ACS / SJC Machine S/N AZN811513
B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM
Printable Version Click Here MF CTRL
Click Here For Interactive PDF S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 1 of 16
0
REV DESCRIPTION
102711 MSE
SHT 1 / 14
7307213
785 of 1234
UNSWITCHED
BATT POWER
FUSE RELAY CENTER
1300 RED
1A 1B SHT12/F8
AUX CTRLR
1180 RED/WHT
2
1150 RED/WHT
3
J2B 1240 RED/WHT
4A 4B 6 6 1420 RED/WHT
T4 SP7 SHT8/E3
T5
1440 RED/WHT
GWY CTRLR SHT8/G8
1110 RED/WHT
2
1130 RED/WHT
3
J1B
C493
SHT6/G1 ACS/SJC/AWS CONN 2
1270 RED
FUSE 12 25 A 1120 RED/WHT SP25 1170 RED/WHT

12A 12B 1 1
1010 RED
1235 RED/WHT
2 2
1460 RED/WHT
SHT13/B7
1040 RED
5A 5B SHT13/G7
SP24 1165 RED/WHT
SHT5/C8
BUS BAR
9A 9B SHT7/H8
SP26 1290 RED

11A 11B SHT9/F8
BUS BAR
10A 10B SHT6/D1
1340 RED
2A 2B SHT11/D8
BUS BAR
3A 3B SHT11/B8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/E8
1060 RED
SHT6/E1

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213

Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 2 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 2 / 14
7307213
786 of 1234
SWITCHED
POWER
1560 RNG/WHT
22 AUX CTRLR
J2B
1520 RNG/WHT
SHT10/G3
SHT10/D3
1620 RNG/WHT
SHT8/G8
FUSE 6 5 A
1940 RNG/WHT
6A 6B C428 SHT8/H8
SHT8/H3
2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
BUS BAR
SHT8/E8
1565 RNG/WHT
SHT14/E4
1815 RNG/WHT

SHT6/G5
FRC1 1550 RNG/WHT
SWITCHED SHT13/F7
C489
POWER
MFR ACCESSORY
RELAY - A 1780 RNG/WHT
A A
C404
1050 RED 30 BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)
SHT2/C1 F4 87 1765 RNG/WHT
FUSE 7 25 A 1750 RNG/WHT SP52 1720 RNG/WHT
F1 7A 7B B B
2030 BLK 86 85
SHT4/B8 F5 F2 1850 RNG/WHT
SHT9/D8
BUS BAR
FRC1 FRC1 1580 RNG/WHT
SHT9/F8
1575 RNG/WHT

8A 8B SHT5/C8
3380 LBL
FRC1 FRC1
1920 RNG/WHT
1790 RNG/WHT
SHT12/E8
1740 RNG/WHT
GWY CTRLR
3450 LBL
J1A
C428
1920 RNG/WHT SP37 SHT5/E3
6 6 1840 RNG/WHT
SHT5/E3
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
6 6

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213

Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 3 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 3 / 14
7307213
787 of 1234
GROUND
C493 2150 BRN

ACS/SJC/AWS CONN 2 SHT6/G7
2235 BLK 2145 BRN
2080 BLK 3 3 SHT6/F5 GWY CTRLR
SHT5/D3
2170 BRN
2240 BLK SHT6/B7
2070 BLK 4 4 2180 BRN SP12 2230 BRN
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK

2700 BLK 1 1 SHT13/D8
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/C8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

2650 BLK
SHT10/F8 C103
2600 BLK SP6 2390 BLK 1 T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2810 BLK
SHT6/C7 2185 BRN
SHT10/D3 SHT10/G3
2005 BLK J2B
SHT6/G8
2016 BLK
SHT12/E8
2025 BLK
SHT7/H5
2055 BLK
SHT11/B8 SP1 2105 BLK SP5 2000 BLK
2035 BLK
SHT6/D1
2045 BLK
SHT11/D8
2030 BLK
SHT3/D8
2115 BLK
SHT6/E1
2505 BLK
SHT14/G4
2530 BLK
SHT10/F3
2155 BLK
SHT14/F4

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 4 / 14
7307213
788 of 1234
CAN BUS
RE016 RE019 C479

C408
GWY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP19 SP18 R1-1 (BLACK)
TP-09 9200 PUR TP-09 TP-10 9270 PUR TP-10 SP31 TP-12 TP-12 SP79 TP-14 9280 PUR TP-14 TP-16 9230 PUR TP-16 TP-01 9230 PUR TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 TP-08 9630 PUR TP-08
9210 PUR 9240 PUR 9250 PUR 9650 PUR
SP30 SP80 SP17 SP38 SP34

9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
R3-2 TP-11 TP-13 SP20 TP-15 R1-2
TP-02 TP-04 TP-06
C479
C492
9240 PUR TP-15
1 1 CAN LO C503
RH DLX PANEL
9140 PUR/WHT
4 4 CAN HI 9260 PUR TP-06
4 CAN LO
9290 PUR TP-13
7 7 CAN LO
9160 PUR/WHT
2 CAN HI
9190 PUR/WHT
8 8 CAN HI
C503
AUX CTRLR C450 C460

TP-11 1830 RNG/WHT
9220 PUR 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/C1 1 1 1 1

9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
C426
TP-17 9500 PUR/WHT TP-17
9600 PUR SHT3/C1 1 1 1 1
SHT4/H8 2 2 2 2
9540 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
3090 LBL SP93 3085 LBL

J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/D1 E E SWITCHED POWER
1165 RED/WHT
2710 BLK
SHT4/E8 G G GROUND

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213

Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 5 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 5 / 14
7307213
789 of 1234
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C113
MFR-ENG HARN T21 S
1030 RED
SHT2/C1 J4 87 8200 TAN 8220 TAN
30 J1 1 1
8210 TAN 85 3560 LBL
J2 J5 2 2 T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
GWY CTRLR
C110 ALTERNATOR
1015 RED 1020 RED
3560 LBL SHT3/E1 7 7 L
2015 BLK 1
SHT4/H3 B T11
AIR FILTER
T12
C405
3160 LBL 3160 LBL
ENGINE SPEED
B
2145 BRN 2145 BRN SP99 C106
SHT4/H3 4 4
2140 BRN
SENDER (0.5-4.5V)
3140 LBL 3140 LBL
5140 YEL 5140 YEL

SHT9/B8 5 5 B
C107

FRC1 GLOW PLUG
RELAY - F
1 8500 TAN
1060 RED
T14 3420 LBL B1 SHT2/C1
8510 TAN 2115 BLK
FRC1 FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL G4 SHT2/D1
8110 TAN 2035 BLK
J1A FRC1 FRC1

C113 C101
8 8 B B 0.33 OHM
D1
SHT4/C8 10 10 C C

C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213

Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 6 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 6 / 14
7307213
790 of 1234
FRC1
C425 HYDRAULICS
4100 LGN
1360 RED/WHT B B
SHT2/E1 H4 87 4200 LGN C308
30 H1 A A A
BRAKE
H2 H5 SHT4/C8 2200 BLK 2200 BLK
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
RELAY FEEDBACK PULL
B B 0.3 OHMS
2220 BRN GND
SHT4/G3 B 10.9 OHMS
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1

C446
2410 BRN GND

HYD LOCK VALVE 1 2
SOL GROUND HYDRAULIC LOCK SOLENOID
1
J1A
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
6
HYD CHARGE PRESS
SENDER SIGNAL
HYD LOCK
SOLENOID SIGNAL
HYD CHARGE PRESS

SENDER POWER
TRACTION
SOLENOID OUTPUT
HYDRAULIC FAN
SIGNAL
4330 LGN GND

AUX CTRLR 1
FRONT ROD SIG 3.3 OHM PWM
2330 BRN
C418
4340 LGN GND
GWY CTRLR 1
2340 BRN SIG 3.3 OHM PWM
FRONT BASE 1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
AUX CTRLR SOLENOID SIGNAL

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 7 / 14
7307213
791 of 1234
1940 RNG/WHT
SHT3/F1 1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
SHT2/F1 1 PTOL LED 19 12 12 4
SHT3/G1 5 C499
C500
SHT13/F5 11
J1A
SW9

SHT3/F1 5
6
1
5 4 SHT2/F1 1

SW9 SW9 9
SHT3/F1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4 SHT2/F1 1
3
SW1 SHT4/G8 3
SHT3/F1
6
SHT9/D3 12
C503 SHT5/F1

2
C480

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM
Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 8 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 8 / 14
7307213
792 of 1234
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/F1 2 1
SHT9/E3 5
4230 LGN 4
SHT10/F3
4240 LGN SW4 3
SHT10/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
HAND CONTROL LIGHT 5 5 4 4
4275 LGN 4275 LGN
FOOT CONTROL LIGHT 3 3 5 5

4550 LGN
6 6
4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
2
C212
C408
SHT2/D1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
SHT3/D1 5 5 B B +12V SW PWR
* T38
2820 BLK

C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
2885 BLK
C428
SHT13/B3
* C667
MFR HARN CONN 2 (LT GRAY) DOOR HARNESS
2790 BLK 2790 BLK
OPTIONS DWG)
3630 LBL
1400 RED/WHT
2840 BLK
6 6
2370 BRN 2370 BRN 7310 WHT
SENSOR
GWY CTRLR GND

A
11 5 5 B
SIGNAL
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/E5 A A PWR 1
WASHER
2845 BLK 2845 BLK
MOTOR
B B GND 2

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM
Printable Version Click Here MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 9 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 9 / 14
7307213
793 of 1234
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/G1 A
RIGHT HANDLE LEFT
ROCKER DOWN 4930 LGN
31 J
30 H LEFT POSITION SWITCH
ROCKER UP 2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
13 F
ADDITIONAL OPTION DWG) ROCKER UP
TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B8 K
SHT4/D8 4230 LGN
T20 SHT9/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GWY CTRLR

10 3
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR LIFT (ACS/AHC ONLY)
4670 LGN SIG
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT9/G8 H
LIFT SPOOL LOCK 2680 BRN GND 2520 BLK
2 3 SHT4/C8 E
SOLENOID GROUND
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/G1 A
LEFT HANDLE RIGHT
C422 4830 LGN
ROCKER DOWN 22 B RIGHT POSTION SWITCH
ROCKER UP
28 C
LEFT HANDLE 4810 LGN
11 F PADDLE
J1B
PADDEL RIGHT
4820 LGN
7

C410
LIFT SPOOL LOCK
SOLENOID SIGNAL
TILT SPOOL LOCK
SOLENOID SIGNAL
TRIGGER
GWY CTRLR

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 10 / 14
7307213
794 of 1234
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2

FRC1
SHT4/D8 2
LIGHTS RELAY - B
C103 RIGHT REAR
TAIL LIGHT
D4 A A 1
2045 BLK
C603
SHT4/C8 D2 D5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
GWY CTRLR TAIL LIGHT
6320 PNK SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK 31
REAR LIGHT 6210 PNK

2620 BLK
3440 LBL SHT4/E8
GND 1
REAR LIGHT 28
RELAY FEEDBACK RIGHT REAR
FRC1 WORK LIGHT
J1A

30 C4 H H SIG 1
86
SHT4/D8
T18 TERMINAL (-)

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 11 / 14
7307213
795 of 1234
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
1 DLX FUEL HARN 7266824 ONLY
C610
*(NOT IN STD FUEL HARN 7149219)
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
MED
30 E4 7 7 5 1 2
4 7510 WHT
LOW

2016 BLK 85 SW10 3
86 3
FRC1 FRC1 M
SW10
SHT3/D1 4
3450 LBL
SHT3/C6 C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
A A A 1
D4
C350 MAGNET CLUTCH

2
C486

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 12 / 14
7307213
796 of 1234
C428
# C355
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP332770
2 GND SW5
C607
B B SHT4/E8
# 4480 LGN 4480 LGN
2
3
1 SIG F F 7 7
POWER BOB SW5 (NOT IN STD CAB HARN 7210557)
SW5
OPEN 2480 BLK
2 GND
C606 10 10
SHT14/D6
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
SHT3/E1
1550 RNG/WHT
9 9
1550 RNG/WHT * SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
D 6500 PNK 3

6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
EURO TAIL LIGHTS
(SEE ADDITIONAL
2850 BLK
SP46 2725 BLK
SIG 4450 LGN 4455 LGN 4455 LGN 6570 PNK 6700 PNK
BUCKET A 2 2 1
POSITION 2
D3
2905 BLK
SOLENOID 3 SHT14/F6

SHT4/E8
2830 BLK
4 SHT14/F4
2970 BLK
2810 BLK
*
C423 SHT4/E8 6 5 SHT14/D4 E E
2420 BLK C670
SW6 SW6 D D
6440 PNK
LEFT HANDLE AUX CTRLR F F (SEE ADDITIONAL
C C
LEFT HANDLE (HORN) 2 WAY C497
(SEE ADDITIONAL OPTIONS DWG) 7200 WHT A A
HORN SIGNAL 5 C C C676
SJC HORN/BLINKER LEFT SPEAKER
* RADIO CONN *
RIGHT BLINKER
SIGNAL 4
6420 PNK
A A (SEE ADDITIONAL
OPTIONS DWG)
* 7820 WHT
1
LEFT
LEFT BLINKER 6520 PNK 1 3 SPEAKER (+)
2
SIGNAL 3 B B L010
7830 WHT LEFT 3 AIR RIDE SEAT
HIGH FLOW 2460 BRN 2 4 SPEAKER (-) 1510 RNG/WHT PWR
FLOAT (ACS/AHC ONLY) SOLENOID GROUND 26 SHT9/E3 4 PWR
C279
J2A GND RIGHT SPEAKER
B
RIGHT POSTION SWITCH
HIGH FLOW
SOLENOID
* 7810 WHT RIGHT SHT9/E3
2210 BLK GND
5
GND
SIG 7.5 OHM 12 V 2 6 SPEAKER (-)

A 6
PADDLE
C415 GWY CTRLR 7800 WHT RIGHT
C277
HIGH FLOW 4460 LGN 1 5 SPEAKER (+)
SOLENOID SIGNAL
26
C278 1885 RNG/WHT
J2B SHT9/E3 1
TWO SPEED GROUND 26
LEFT POSITION SWITCH 2885 BLK
C408 J1A SHT9/D3 2
MFR HARN CONN 1 C126 C676
1460 RED/WHT
TRIGGER
7210 WHT 7210 WHT SIG 2350 BRN GND
B 13 13 A A _ 2
TWO SPEED TRACK 2 SPEED
HORN
4350 LGN OPTIONS DWG)
+ TWO SPEED SIGNAL 26 SIG
1 5.1 OHM 12 V
2785 BLK GND
SHT4/E8 B B
J1B C441

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 13 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711
CHG NOTICE DWN
MSE
SHEET
SHT 13 / 14
7307213
797 of 1234
* SW7
AUX CTRLR C438
RIDE CONTROL OPTIONS 2
3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8 * DLX CAB HARN 7304511 ONLY
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIGNAL 7
RIDE CONTROL
RELAY - RC1
1575 RNG/WHT
3415 LBL SP9 3425 LBL 30
RIDE CONTROL COIL SIGNAL 21 87
3435 LBL 3445 LBL 2505 BLK
1 1 85 86 SHT4/B8
RIDE CONTROL RIDE CONTROL RC1 RC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/B8
C438
*SW13
REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIGNAL 16 12 12 3
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/F1

C443 4
2175 BRN
REVERSING FAN RETURN SIGNAL 27 2 SW13 SW13
J2A REVERSING
FAN COIL
3485 LBL
REVERSING FAN SIGNAL 25 1
2185 BRN
SHT4/C3 A
RIDE CONTROL PRESSURE 3455 LBL RIDE CONTROL
SENSOR SIGNAL 10 C
PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR +5V PWR 24 B
J2B C442
SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133
A3NL12726 through
& Above
AboveA3NL12899
csf

B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
SCHEM MF CTRL
S/NCOPYRIGHT
AZN911255 & Above C
X ± 13 MAT
Sheet 14 of 16
0
REV
SEE SHEET 1
DESCRIPTION
102711 MSE
SHT 14 / 14
7307213
798 of 1234
ACS CONTROLLER
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
HARNESS PART NUMBER

J1-ACS
CONTROLLER
ACS 7164144 EXMF, LF
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 FLOW

H 2270/BLK 2510/BLK 3 F
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL
Wiring Schematic S510 S/N A3NL12726

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133 through
& Above
AboveA3NL12899 Printed On November 2017
B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
S/N AZN911255 & Above Printable Version Click Here
Sheet 15 of 16
799 of 1234
Wiring Schematic S510 S/N A3NL12726

S530
S550 A3NJ12676 &
AZN411662
A7TV13681
AZN611133 through
& Above
AboveA3NL12899 Printed On November 2017
B42411048 && Above
AZN511949
B42811122
AZN713110 Above 7307213
S/N AZN911255 & Above Sheet 16 of 16
800 of 1234
Index Diagram
1
2
SH01 - INDEX
4 SH04 - GROUND
6 SH06 - ENGINE LEGEND
7 SH07 - HYDRAULICS
8 SH08 - CAB DISPLAY CONNECTOR
9 SH09 - CAB
10 SH10 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1 1
11 SH11 - LIGHTS
12 SH12 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
13 SH13 - OPTIONS 1 PARTIAL CONNECTOR
14 SH14 - OPTIONS 2 CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
1 1
HARNESS PART NUMBER MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
MFR CTRL 7322224 LGN 1 1
STD CAB 7210557
CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX CAB 7304511
WIRE BREAK
STD FUEL 7149219 SHT1/F2 SHT1/F2
ENG 2403 7181036 SHT1/F2
WIRE BREAK
SHT1/F2
ENG 2607 7181037 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT

7165061
TRK BRAKE ADP
SUSP JSTK 7163706 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR

csf

ACS / SJC Machine 7322223
SCHEM ELEC MF CTRL
Sheet 1 of 16
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Printable Version Click Here
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
0
REV DESCRIPTION
108481 MMM
SHT 1 / 14
7322223
801 of 1234
UNSWITCHED
BATT POWER
FUSE RELAY CENTER
1300 RED
1A 1B SHT12/F8
AUX CTRLR
1180 RED/WHT
2
1150 RED/WHT
3
J2B 1240 RED/WHT
4A 4B 6 6 1420 RED/WHT
T4 SP7 SHT8/E3
T5
1440 RED/WHT
GWY CTRLR SHT8/G8
1110 RED/WHT
2
1130 RED/WHT
3
J1B
C493
SHT6/G1 ACS/SJC/AWS CONN 2
1270 RED
FUSE 12 25 A 1120 RED/WHT SP25 1170 RED/WHT

12A 12B 1 1
1010 RED
1235 RED/WHT
2 2
1460 RED/WHT
SHT13/B7
1040 RED
5A 5B SHT13/G7
SP24 1165 RED/WHT
SHT5/C8
BUS BAR
9A 9B SHT7/H8
SP26 1290 RED

11A 11B SHT9/F8
BUS BAR
10A 10B SHT6/D1
1340 RED
2A 2B SHT11/D8
BUS BAR
3A 3B SHT11/B8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/D8
1060 RED
SHT6/E1
1205 RED
SHT3/G8

csf

SCHEM ELEC MF CTRL
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 2 / 14
7322223
802 of 1234
SWITCHED
POWER
SWITCHED POWER
RELAY RC1
1205 RED FUSE 25A

SHT2/C1 30 87 1585 RNG/WHT 1580 RNG/WHT
A B SHT9/F8
3385 LBL
C171 C171 2065 BLK
86 85 SHT4/B8
RC1 RC1
1560 RNG/WHT
22 AUX CTRLR
J2B
1520 RNG/WHT
SHT10/G3
SHT10/D3
1620 RNG/WHT
SHT8/G8
FUSE 6 5 A
1940 RNG/WHT
6A 6B C428 SHT8/H8
SHT8/H3
2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT

SHT9/H6
1960 RNG/WHT
BUS BAR
SHT8/E8
1565 RNG/WHT
SHT14/E4
1815 RNG/WHT
SHT6/G5
1550 RNG/WHT
SHT13/F7
C489
MFR ACCESSORY
SWITCHED POWER 1780 RNG/WHT
A A
RELAY RC2
C404
1050 RED
FUSE 7 25 A BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)
SHT2/C1 30 1770 RNG/WHT SP101 1765 RNG/WHT 1750 RNG/WHT SP52 1720 RNG/WHT
87 7A 7B B B
SP100
3390 LBL 2030 BLK
86 85 SHT4/B8 1850 RNG/WHT
SHT9/D8
BUS BAR
RC2 RC2
1575 RNG/WHT
SHT14/G4
FUSE 8 25 A
1730 RNG/WHT
8A 8B SHT5/C8
FRC1 FRC1
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
3380 LBL
J1A
C428
1920 RNG/WHT 1920 RNG/WHT SP37 SHT5/E3
6 6 1840 RNG/WHT
SHT5/E3
C492
1740 RNG/WHT
6 6

csf


Here ELEC MF CTRL
Sheet 3 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 3 / 14
7322223
803 of 1234
GROUND
C493 2150 BRN

ACS/SJC/AWS CONN 2 SHT6/G7
2235 BLK 2145 BRN
2080 BLK 3 3 SHT6/F5 GWY CTRLR
SHT5/D3
2170 BRN
2240 BLK SHT6/B7
2070 BLK 4 4 2180 BRN SP12 2230 BRN
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK

2700 BLK 1 1 SHT13/D8
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/C8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

2650 BLK
SHT10/F8 C103
2600 BLK SP6 2390 BLK 1 T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2810 BLK
SHT6/C7 2185 BRN
SHT10/D3 SHT10/G3
2005 BLK J2B
SHT6/G8
2016 BLK
SHT12/E8
2025 BLK
SHT7/H5
2055 BLK
SHT11/B8 SP55 2105 BLK SP5 2000 BLK
2035 BLK
SHT6/D1
2045 BLK
SHT11/D8
2030 BLK
SHT3/D6
2115 BLK
SHT6/E1
2505 BLK
SHT14/G4
2065 BLK
SHT3/G1
2530 BLK
SHT10/F3
2155 BLK
SHT14/F4

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Sheet 4 of 16
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE Printable Version Click Here
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 4 / 14
7322223
804 of 1234
CAN BUS
C479
GWY CTRLR C408 LEFT PANEL
Z3 Z1
MFR HARN CONN 1 (BLACK) (BLACK)
120 OHM 0.5 W RESISTOR SP19 SP18 120 OHM 0.5 W RESISTOR
SP31 SP79 SP39 SP35
9200 PUR 9270 PUR 9210 PUR 9280 PUR 9230 PUR 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR
SP30 SP80 SP17 SP38 SP34

9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
SP20
C479
C492
9240 PUR C503
1 1 CAN LO
RH DLX PANEL
9140 PUR/WHT
4 4 CAN HI 9260 PUR
4 CAN LO
9290 PUR
7 7 CAN LO
9160 PUR/WHT
2 CAN HI
9190 PUR/WHT
8 8 CAN HI
C503
AUX CTRLR C450 C460

9220 PUR 1830 RNG/WHT 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/B1 1 1 1 1

9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT 9560 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
C426
9500 PUR/WHT
9600 PUR SHT3/B1 1 1 1 1
SHT4/H8 2 2 2 2
9540 PUR/WHT 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
3090 LBL SP93 3085 LBL

J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/C1 E E SWITCHED POWER
1165 RED/WHT
2710 BLK
SHT4/E8 G G GROUND

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Here ELEC MF CTRL
Sheet 5 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 5 / 14
7322223
805 of 1234
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C113
MFR-ENG HARN T21 S
1030 RED
SHT2/C1 J4 87 8200 TAN 8220 TAN
30 J1 1 1
8210 TAN 85 3560 LBL
J2 J5 2 2 T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
GWY CTRLR
C110 ALTERNATOR
1015 RED 1020 RED
3560 LBL SHT3/E1 7 7 L
2015 BLK 1
SHT4/H3 B T11
AIR FILTER
T12
C405
3160 LBL 3160 LBL
ENGINE SPEED
B
2145 BRN 2145 BRN SP99 C106
SHT4/H3 4 4
2140 BRN
SENDER (0.5-4.5V)
3140 LBL 3140 LBL
5140 YEL 5140 YEL

SHT9/B8 5 5 B
C107

FRC1 GLOW PLUG
RELAY - F
1 8500 TAN
1060 RED
T14 3420 LBL B1 SHT2/C1
8510 TAN 2115 BLK
FRC1 FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL G4 SHT2/D1
8110 TAN 2035 BLK
J1A FRC1 FRC1

C113 C101
8 8 B B 0.33 OHM
D1
SHT4/C8 10 10 C C

C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

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Printable Version Click SCHEM ELEC MF CTRL

Sheet 6 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 6 / 14
7322223
806 of 1234
FRC1
C425 HYDRAULICS
4100 LGN
1360 RED/WHT B B
SHT2/E1 H4 87 4200 LGN C308
30 H1 A A A
BRAKE
H2 H5 SHT4/C8 2200 BLK 2200 BLK
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
RELAY FEEDBACK PULL
B B 0.3 OHMS
2220 BRN GND
SHT4/G3 B 10.9 OHMS
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1

C446
2410 BRN GND

HYD LOCK VALVE 1 2
SOL GROUND HYDRAULIC LOCK SOLENOID
1
J1A
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT9/B8 B
C105
4200 LGN
J1B
19
13
6
HYD CHARGE PRESS
SENDER SIGNAL
HYD LOCK
SOLENOID SIGNAL
TRACTION
SOLENOID OUTPUT
HYDRAULIC FAN
SIGNAL
4330 LGN GND

AUX CTRLR 1
FRONT ROD SIG 3.3 OHM PWM
2330 BRN
C418
4340 LGN GND
GWY CTRLR 1
2340 BRN SIG 3.3 OHM PWM
FRONT BASE 1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
AUX CTRLR SOLENOID SIGNAL

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Here ELEC MF CTRL
Sheet 7 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 7 / 14
7322223
807 of 1234
1940 RNG/WHT
SHT3/F1 1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
SHT2/F1 1 PTOL LED 19 12 12 4
SHT3/F1 5 C499
C500
SHT13/F5 11
J1A
SW9

SHT3/E1 5
6
1
5 4 SHT2/F1 1

SW9 SW9 9
SHT3/E1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4 SHT2/F1 1
3
SW1 SHT4/G8 3
SHT3/F1
6
SHT9/D3 12
C503 SHT5/F1

2
C480

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Sheet 8 of 16
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 8 / 14
7322223
808 of 1234
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
SHT9/E3 5
4230 LGN 4
SHT10/F3
4240 LGN SW4 3
SHT10/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
HAND CONTROL LIGHT 5 5 4 4
4275 LGN 4275 LGN
FOOT CONTROL LIGHT 3 3 5 5

4550 LGN
6 6
4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
2
C212
C408
SHT2/D1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
SHT3/G1 5 5 B B +12V SW PWR
* T38
2820 BLK

C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
2885 BLK
C428
SHT13/B3
* C667
MFR HARN CONN 2 (LT GRAY) DOOR HARNESS
2790 BLK 2790 BLK
OPTIONS DWG)
3630 LBL
1400 RED/WHT
2840 BLK
6 6
2370 BRN 2370 BRN 7310 WHT
SENSOR
GWY CTRLR GND

A
11 5 5 B
SIGNAL
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/E5 A A PWR 1
WASHER
5190 YEL
SHT7/D7 2845 BLK 2845 BLK
MOTOR
B B GND 2

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SCHEM ELEC MF CTRL
Sheet 9 of 16
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT Printable Version Click Here
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 9 / 14
7322223
809 of 1234
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/F1 A
RIGHT HANDLE LEFT
ROCKER DOWN 4930 LGN
31 J
30 H LEFT POSITION SWITCH
ROCKER UP 2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
13 F
ADDITIONAL OPTION DWG) ROCKER UP
TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B8 K
SHT4/D8 4230 LGN
T20 SHT9/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GWY CTRLR

10 3
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR LIFT (ACS/AHC ONLY)
4670 LGN SIG
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT9/G8 H
LIFT SPOOL LOCK 2680 BRN GND 2520 BLK
2 3 SHT4/C8 E
SOLENOID GROUND
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/F1 A
LEFT HANDLE RIGHT
C422 4830 LGN
ROCKER DOWN 22 B RIGHT POSTION SWITCH
ROCKER UP
28 C
LEFT HANDLE 4810 LGN
11 F PADDLE
J1B
PADDEL RIGHT
4820 LGN
7

C410
LIFT SPOOL LOCK
SOLENOID SIGNAL
TILT SPOOL LOCK
SOLENOID SIGNAL
TRIGGER
GWY CTRLR

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Sheet 10 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 10 / 14
7322223
810 of 1234
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2

FRC1
SHT4/D8 2
LIGHTS RELAY - B
C103 RIGHT REAR
TAIL LIGHT
D4 A A 1
2045 BLK
C603
SHT4/C8 D2 D5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
GWY CTRLR TAIL LIGHT
6320 PNK SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK 31
REAR LIGHT 6210 PNK

2620 BLK
3440 LBL SHT4/E8
GND 1
REAR LIGHT 28
RELAY FEEDBACK RIGHT REAR
FRC1 WORK LIGHT
J1A

30 C4 H H SIG 1
86
SHT4/D8
T18 TERMINAL (-)

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Sheet 11 of 16
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Printable Version Click Here
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 11 / 14
7322223
811 of 1234
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
1 DLX FUEL HARN 7266824 ONLY
C610
*(NOT IN STD FUEL HARN 7149219)
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
MED
30 E4 7 7 5 1 2
4 7510 WHT
LOW

2016 BLK 85 SW10 3
86 3
FRC1 FRC1 M
SW10
SHT3/C1 4
3450 LBL C611

SHT3/C6
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
AC SIGNAL MO

s550 6989494 Enus SM Bob Cat s550

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Service Manual

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 NA1204 NA1193

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1200 NA1191 B-6589

1-1 S550 Service Manual

1-2 S550 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 1234 1-3 S550 Service Manual

6 of 1234 1-4 S550 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 1234 1-5 S550 Service Manual

8 of 1234 1-6 S550 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach® attachment

Dealer Copy -- Not for Resale

6. Machine signs (decals) must 14. Check all machine fluid

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 1234 1-7 S550 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 1234 1-8 S550 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

11 of 1234 1-9 S550 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

12 of 1234 1-10 S550 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

13 of 1234 1-11 S550 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as