S530 Service Manual

Dealer Copy -- Not for Resale
Service Manual
Skid-Steer Loader
S/N ALR811001 & Above
S/N B42T11001 & Above
6990673enUS (04-19) (G)
1 of 1148
Printed in U.S.A.
©2019 Bobcat Company. All rights reserved.
T4-B S4B
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Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
WARNING
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
W-2003-0807
instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT
P-90216
Never service the Bobcat SkidSteer Loader without instructions.
NA1694
Use the correct procedure to lift or
lower operator cab.
WRONG
WRONG
NA1695
Disconnecting or loosening any
hydraulic tubeline, hose, fitting,
component or a part failure can
cause lift arms to drop. Do not go
under lift arms when raised
unless
supported
by
an
approved lift arm support device.
Replace it if damaged.
NA1680
Never work on loader with lift
arms up unless lift arms are held
by an approved lift arm support
device. Replace if damaged.
Never modify equipment or add
attachments not approved by
Bobcat Company.
WRONG
WRONG
WRONG
NA1683
NA1682
Stop, cool and clean engine of
flammable
materials
before
checking fluids.
Never service or adjust loader
with the engine running unless
instructed to do so in the
manual.
Avoid contact with leaking
hydraulic fluid or diesel fuel
under pressure. It can penetrate
the skin or eyes.
Never fill fuel tank with engine
running, while smoking or when
near open flame.
NA1693
Cleaning and maintenance are
required daily.
WRONG
NA1674
Have good ventilation when
welding or grinding painted
parts.
Wear dust mask when grinding
painted parts. Toxic dust and gas
can be produced.
Avoid exhaust fume leaks which
can kill without warning. Exhaust
system must be tightly sealed.
CORRECT
Keep body, jewelry and clothing
away
from
moving
parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep rear door closed except for
service. Close and latch door
before operating the loader.
B-6589
Lead-acid
batteries
produce
flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW39-0609
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CORRECT
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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 AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING AND VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
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SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
Dealer Copy -- Not for Resale
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FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-11
1-11
1-11
1-11
1-11
1-11
1-11
1-11
1-12
1-12
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
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SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
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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:
9. The parking brake
function correctly.
must
2. Check that ROPS mounting
hardware is tightened and is
Bobcat approved.
10. Enclosure door latches must
open and close freely.
3. The seat belt must be
correctly installed, functional
and in good condition.
11. Bob-Tach®
attachment
mounting system wedges and
linkages
must
function
correctly and be in good
condition.
4. The seat bar must be
correctly adjusted, clean and
lubricated.
12. Safety treads must be in good
condition.
SERVICE
5. Check lift arm support device,
replace if damaged.
13. Check for correct function of
indicator lamps.
6. Machine signs (decals) must
be legible and in the correct
location.
14. Check
levels.
7. Steering levers, hand controls
and foot pedals must return to
neutral (as applicable).
15. Inspect for fuel,
hydraulic fluid leaks.
8. Check for correct function of
the work lights.
16. Lubricate the loader.
all
machine
oil
fluid
or
FW SSL-0119 SM
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1. Check that the ROPS/FOPS
(Including side screens) is in
good condition and is not
modified.
23. Operate the machine and
check all functions.
18. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.
24. Check for correct function of
the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging
system.
25. Check for proper function of
front horn and back-up alarm
(if equipped).
20. Check tires for wear and
pressure. Check tracks for
wear and tension. Use only
approved tires or tracks.
26. Check function or condition of
all equipped options and
accessories (examples: fire
extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken
parts or connections.
27. Recommend to the owner
that all necessary corrections
be made before the machine
is returned to service.
Dealer Copy -- Not for Resale
17. Check the condition of the
battery and cables.
22. Check
for
any
field
modification not completed.
FW SSL-0119 SM
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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
instructions have been given to the new owner and
that the machine is in safe operating condition.
•
The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
•
Machine signs (decals) instruct on the safe operation
and care of your Bobcat machine or attachment. The
signs and their locations are shown in the Operation
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
•
An Operator’s Handbook fastened to the operator
cab. It’s brief instructions are convenient to the
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
•
The AEM Safety Manual delivered with the machine
gives general safety information.
This notice identifies procedures which must be
followed to avoid damage to the machine.
•
The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shoptype service and repair work.
•
The Skid-Steer Loader Operator Training Course is
available through your local dealer or at Bobcat.com/
training or Bobcat.com. This course is intended to
provide rules and practices of correct operation of the
skid-steer loader. The course is available in English
and Spanish versions.
•
Service Safety Training Courses are available from
your Bobcat dealer or at Bobcat.com/training or
Bobcat.com. They provide information for safe and
correct service procedures.
•
The Skid-Steer Loader Safety Video is available from
your Bobcat dealer or at Bobcat.com/training or
Bobcat.com.
This symbol with a warning statement means:
“Warning, be alert! Your safety is involved!”
Carefully read the message that follows.
WARNING
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
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
I-2019-0284
DANGER
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
D-1002-1107
WARNING
The signal word WARNING on the machine and in the
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1016 SM
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SAFETY INSTRUCTIONS
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
Dealer Copy -- Not for Resale
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
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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
solvents.
The machine and some attachments have components
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
Fueling
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating.
Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
higher Sulfur content. Avoid death or serious injury from
fire or explosion. Consult with your fuel or fuel system
supplier to ensure the delivery system is in compliance
with fueling standards for proper grounding and bonding
practices.
All fuels, most lubricants and some coolants mixtures are
flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material,
explosive dust or gases.
Do not use ether or starting fluids on any engine that has
glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
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
system, but the muffler and the exhaust gases are still
hot.
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrester muffler (if equipped).
Battery gas can explode and cause serious injury. Use
the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-1016 SM
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Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
sparks. Fill the fuel tank outdoors.
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.
Dealer Copy -- Not for Resale
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
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SERIAL NUMBER LOCATIONS
Engine Serial Number
Always use the serial number of the loader when
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.
Figure 3
Loader Serial Number
1
Figure 1
1
P109660
Dealer Copy -- Not for Resale
The engine serial number (Item 1) [Figure 3] is located
on the side of the engine next to the oil fill cap.
P107305D
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.
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DELIVERY REPORT
Figure 4
NA3106
Dealer Copy -- Not for Resale
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.
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LOADER IDENTIFICATION
20
2
1
11
3
19
12
4
18
5
13
10
14
6
9
7
8
15
17
NA5775
NA5776
ITEM
DESCRIPTION
ITEM
DESCRIPTION
1
Operation & Maintenance Manual and Operator’s
Handbook
11
Lift Cylinder (Both Sides)
2
Front Lights
12
Rear Grille
3
Grab Handles
13
Back-up Alarm
4
Operator Seat with Seat Belt and Seat Bar
14
Rear Work Lights and Taillights
5
Tilt Cylinders
15
Rear Door
16
Rear Tie-down (Both Sides) Front Tie-down located
behind Bucket
Bucket [A]
6
7
Bucket Steps
17
Tires [C]
8
Step
18
Lift Arm Support Device
9
Alternate Front Tie-down (Both Sides)
19
Lift Arm
10
Front Auxiliary Quick Couplers
20
Operator Cab (ROPS and FOPS) [B]
[A] Bucket – Several different buckets and other attachments are available for the Bobcat loader.
[B] ROPS – Roll-Over Protective Structure per ISO 3471 and FOPS – Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
[C] Tires – Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.
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SAFETY AND MAINTENANCE
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-20-1
10-20-1
10-20-2
10-20-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . .
Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . .
10-30-1
10-30-1
10-30-1
10-30-2
10-30-3
10-30-4
10-30-4
10-30-5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-60-1
10-60-1
10-60-3
10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-61-1
10-61-1
10-61-2
10-61-3
10-61-4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10-90-1
10-90-1
10-90-1
10-90-3
10-90-4
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Dealer Copy -- Not for Resale
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
10-100-1
10-100-1
10-100-1
10-100-2
10-100-3
10-100-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-110-1
10-110-1
10-110-1
10-110-2
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . .
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-120-1
10-120-1
10-120-1
10-120-2
10-120-4
10-120-5
10-120-7
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-160-1
10-160-1
10-160-1
10-160-2
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
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FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . .
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-200-1
10-200-1
10-200-1
10-200-1
10-200-2
10-200-2
10-200-3
Dealer Copy -- Not for Resale
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
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10-04
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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
notched area of the frame [Figure 10-10-2].
B-7023A
WARNING
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
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
P-85985
W-2003-0807
Read the Removal And Installation, Disassembly And
Assembly, etc. completely to become familiar with the
procedure before beginning [Figure 10-10-1].
Lift the front of the loader and install jackstands under the
axle tubes [Figure 10-10-3].
NOTE: Make sure the jackstands do not touch the
tires. Make sure the tires clear the floor or any
obstacles.
Always park the loader on a level surface.
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
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Dealer Copy -- Not for Resale
Figure 10-10-3
Dealer Copy -- Not for Resale
24 of 1148
10-10-2
S530 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
Dealer Copy -- Not for Resale
Figure 10-20-1
1
2
P107248A
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.)
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S530 Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D)
Figure 10-20-3
Installing
DANGER
P-90567D
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Have a second person install the lift arm support device
over the rod of one of the lift cylinders [Figure 10-20-3].
The lift arm support device must be tight against the
cylinder rod.
Figure 10-20-4
Remove attachment from the loader.
Figure 10-20-2
P107250A
1
P107307
P107247A
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
of the lift arm support device must go past the end of the
cylinder (Inset) [Figure 10-20-4].
P107248
Put jackstands under the rear corners of the loader frame
(Inset) [Figure 10-20-2].
Remove the lift arm support device (Item 1) [Figure 1020-2] from the storage position.
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
26 of 1148
10-20-2
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Dealer Copy -- Not for Resale
•
LIFT ARM SUPPORT DEVICE (CONT’D)
Figure 10-20-5
Removing
DANGER
P-90567D
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Have a second person remove the lift arm support device
[Figure 10-20-5] after the lift arms are all the way up.
Lower the lift arms all the way and stop the engine.
Figure 10-20-6
Dealer Copy -- Not for Resale
•
D-1009-0409
The operator must be in the operator’s seat, with the seat
belt fastened and seat bar lowered, until the lift arm
support device is removed, and the lift arms are lowered
all the way.
NOTE: The lift arm support device should remain
resting on the cylinder barrel when the lift
arms are raised. Service or replace the lift arm
support device if the lift arm support raises
with the cylinder rod.
Start the engine and raise the lift arms all the way up.
P107248
Return the lift arm support device to the storage position
and secure with clamping knobs [Figure 10-20-6].
Remove the jackstands.
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28 of 1148
10-20-4
S530 Service Manual
OPERATOR CAB
Cab Door Sensor
Description
This machine may be equipped with a Cab Door Sensor.
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.
Figure 10-30-1
Inspect the cab, mounting, and hardware for damage.
Never modify the cab. Replace the cab and hardware if
damaged.
ROPS - Roll-Over Protective Structure per ISO 3471 and
FOPS - Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
1
Level I
Level II
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
forestry.
P-68116B
The cab door has a sensor (Item 1) [Figure 10-30-1]
installed that deactivates the lift and tilt valves when the
door is open.
Figure 10-30-2
2
WARNING
1
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
NA3275
The LIFT AND TILT VALVE light (Item 1) [Figure 10-302] is OFF when the door is closed, the key switch is
turned to RUN, the seat bar is lowered, and the PRESS
TO OPERATE LOADER button is pressed.
The LIFT AND TILT VALVE light (Item 1) [Figure 10-302] is ON 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.
[DOOR] will appear in the data display (Item 2) [Figure
10-30-2] 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.
29 of 1148
10-30-1
S530 Service Manual
Dealer Copy -- Not for Resale
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.
OPERATOR CAB (CONT’D)
WARNING
Raising
Always stop the engine before raising or lowering the
operator cab.
Stop the loader on a level surface. Lower the lift arms. If
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
Figure 10-30-3
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.
P107247
Install jackstands under the rear of the loader frame
[Figure 10-30-3].
P-90564C
Figure 10-30-4
Hardware Installed
Hardware Removed
P100235A
P100236A
Lift on the grab handles and bottom of the operator cab
[Figure 10-30-5] slowly until the operator cab is all the
way up and the latching mechanism engages.
Remove the nuts and washers [Figure 10-30-4] (both
sides) at the front corners of the operator cab.
30 of 1148
10-30-2
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 10-30-5
OPERATOR CAB (CONT’D)
Lowering
Always stop the engine before raising or lowering the
operator cab.
Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-6]. Remove your hand
from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
all the way down.
NOTE: Always use the grab handles to lower the
operator cab.
WARNING
Figure 10-30-6
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-7
P100953
Hardware Installed
P-90565A
Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-6].
NOTE: The weight of the operator cab increases
when equipped with options and accessories
such as: cab door and heater. In these cases,
the operator cab may need to be raised
slightly from the latch to be able to release the
latch.
P100236A
P100235A
Install the washers and nuts (both sides) [Figure 10-307].
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.
31 of 1148
10-30-3
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Dealer Copy -- Not for Resale
Hardware Removed
OPERATOR CAB (CONT’D)
Special Applications Kit Inspection And Maintenance
Special Applications Kit
•
•
•
•
•
Inspect for cracks or damage. Replace if required.
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.
10-30-4
S530 Service Manual
WARNING
•
AVOID INJURY OR DEATH
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
Dealer Copy -- Not for Resale
Figure 10-30-8
NA1026
Available for special applications to restrict material from
entering cab openings. Kit includes 12,7 mm (0.50 in)
thick polycarbonate front door and polycarbonate rear
window [Figure 10-30-8].
Polycarbonate top window (standard item) must be
installed for special applications to restrict material from
entering cab openings.
32 of 1148
OPERATOR CAB (CONT’D)
Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
•
•
Figure 10-30-9
•
•
•
•
•
•
Inspect for cracks or damage. Replace if required.
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
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,
polycarbonate side windows, and polycarbonate rear
window [Figure 10-30-9].
1
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
•
33 of 1148
•
Inspect both emergency exit levers (Item 1) [Figure
10-30-10], linkages, and hardware for loose or
damaged parts.
Repair or replace if necessary.
10-30-5
S530 Service Manual
Dealer Copy -- Not for Resale
NA1819
Dealer Copy -- Not for Resale
34 of 1148
10-30-6
S530 Service Manual
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
break and cause personal injury.
P107245A
P107253A
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-90561G
Alternate Rear Tie-Down
Alternate Front Tie-Down
P107246A
P-85599C
1
P-90560G
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 1040-1].
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up.
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
during sudden stops, or when going up or down slopes
[Figure 10-40-2].
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.
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NOTE: Always disengage the auto idle feature when
loading or unloading the loader on a trailer.
(See Left Panel on Page 60-50-1.)
Dealer Copy -- Not for Resale
36 of 1148
10-40-2
S530 Service Manual
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.
Dealer Copy -- Not for Resale
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC10-2.)
37 of 1148
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Dealer Copy -- Not for Resale
38 of 1148
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S530 Service Manual
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
MEL1566 - Service Tool Harness
(Computer Interface)
3
Communicator
1
Figure 10-60-1
1
P16117
P16114
The Remote Start Tool (Item 1) [Figure 10-60-1] is
required when the service technician is testing the
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics.
39 of 1148
The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] 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
the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.
10-60-1
S530 Service Manual
Dealer Copy -- Not for Resale
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.
Figure 10-60-5
REMOTE START TOOL - MEL1563 (CONT’D)
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
1
2
2
1
P114629
Remove the Service Tool Harness (Item 1) from the
cover (Item 2) [Figure 10-60-3].
Connect the Service Tool Harness to the ACD connector
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.
1
P-85729
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.
40 of 1148
10-60-2
S530 Service Manual
Dealer Copy -- Not for Resale
Loaders equipped with an attachment harness (Item 1)
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
P16114
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
required to connect the 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.
41 of 1148
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P16115
REMOTE START TOOL - MEL1563 (CONT’D)
Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
P114630
1
Figure 10-60-11
P-85729
2
1
1
P114631
Connect the Remote Start Tool to the engine harness
connector (Item 1) [Figure 10-60-10].
P114629
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the Remote Start Tool to the engine harness
connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
OR
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped).
42 of 1148
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.
10-60-4
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 10-60-9
Figure 10-60-13
REMOTE START TOOL KIT - MEL1563 (CONT’D)
Remote Start Procedure (Cont'd)
WARNING
2
3
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
W-2457-1110
P16118
The traction lock switch (Item 1) [Figure
used to turn traction lock ON or OFF. Push
the OVERRIDE position. The switch will
indicate traction lock OVERRIDE. in this
wheels are able to turn.
10-60-13] is
the switch to
illuminate to
position, the
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.
Figure 10-60-12
NOTE: With the engine running, pushing and holding
the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
1
WARNING
P16116
•
The Remote Start Tool (Item 1) [Figure 10-60-12] has
three rocker switches.
•
•
•
•
AVOID INJURY OR DEATH
Use traction lock override switch for service work
with seat bar raised.
Traction lock is engaged when light is OFF.
Lift and block the loader. Check that wheels are
clear.
Traction lock is disengaged when light is ON.
See Service Manual for more instruction.
W-2785-0209
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Dealer Copy -- Not for Resale
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
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area.
1
REMOTE START TOOL KIT - MEL1563 (CONT’D)
Remote Start Procedure (Cont'd)
Figure 10-60-14
P166657
44 of 1148
10-60-6
Dealer Copy -- Not for Resale
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].
S530 Service Manual
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.
Dealer Copy -- Not for Resale
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.
45 of 1148
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S530 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Figure 10-61-2
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps
are:
5
3
Order from Bobcat Parts P/N: 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 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
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678
The Remote Start Tool (Item 1) [Figure 10-61-1] is
required when the service technician is testing the
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics.
46 of 1148
The TRACTION LOCK button (Item 5) [Figure 10-61-2]
is used to turn traction lock ON or OFF. Push the button
and the button will illuminate indicating the traction lock is
disabled in which the wheels or tracks are able to turn.
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.
10-61-2
S530 Service Manual
Dealer Copy -- Not for Resale
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-2] has five buttons.
Figure 10-61-5
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Loader Service Tool Harness - 6689747
2
Figure 10-61-3
1
1
P114629
2
P-76678
The Loader Service Tool Harness is used to connect the
Remote Start Tool (Service Tool) (Item 2) [Figure 10-613] to the electrical system on the loader.
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-4] or
reconnect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
1
P-85729
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).
47 of 1148
10-61-3
S530 Service Manual
Dealer Copy -- Not for Resale
Loaders with an attachment control harness (7 pin or 14
pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
10-61-5].
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Computer Service Tool Harness - 6689746
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
1
3
2
2
1
P-76450
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 Computer Service Tool Harness is required to
connect Remote Start Tool (Service Tool) to the Service
PC (Item 2) [Figure 10-61-7].
Dealer Copy -- Not for Resale
P114632
The second connector (Item 3) [Figure 10-616] 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
•
•
•
•
AVOID INJURY OR DEATH
Lift and block the machine.
Check that wheels or tracks are clear.
Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
See machine Service Manual for more
instructions.
W-2792-0409
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10-61-4
S530 Service Manual
Figure 10-61-9
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Remote Start Procedure
1
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
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area.
P-85729
Loaders without an attachment control harness, remove
the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
The tool listed will be needed to do the following
procedure:
7217666: Remote Start Tool (Service Tool) Kit
NOTE: When using a Remote Start Tool (Service tool)
harness on loaders not equipped with an
attachment control device, the Remote Start
Tool (Service Tool) harness attachment
control device connector must be capped.
Figure 10-61-10
Figure 10-61-8
1
1
2
P114629
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-8] is required when the operator cab is in the
raised position for service and the service technician
needs to turn on the loader or start the engine. Example:
adjusting 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.
Loaders with an attachment control harness (7 pin or 14
pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
10-61-10].
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
harness.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.
49 of 1148
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Dealer Copy -- Not for Resale
W-2457-1110
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Figure 10-61-12
2
Remote Start Procedure (Cont'd)
Figure 10-61-11
5
3
6
4
3
1
2
P-76439
1
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-12] has five buttons.
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-11] is always used for
connection to the loader harness.
The second connector (Item 3) [Figure 10-6111] 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 10-61-11].
NOTE: The key switch must be in the OFF position or
the Remote Start Tool (Service Tool) will not
operate.
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
The RUN button (Item 3) [Figure 10-61-12] is used to
turn the Remote Start Tool (Service Tool) on and
activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
The START button (Item 4) [Figure 10-61-12] is used to
start the loader engine.
The TRACTION LOCK button (Item 5) [Figure 10-61-12]
is used to turn traction lock ON or OFF. Push the button
and the button will illuminate indicating the traction lock is
disabled in which the wheels or tracks are able to turn.
The AUXILIARY button (Item 6) [Figure 10-61-12] 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.
WARNING
•
•
•
•
AVOID INJURY OR DEATH
Lift and block the machine.
Check that wheels or tracks are clear.
Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
See machine Service Manual for more
instructions.
W-2792-0409
50 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
P114632
REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT’D)
Figure 10-61-14
Remote Start Procedure (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
auxiliary pressure [Figure 10-61-14].
P-76441
Dealer Copy -- Not for Resale
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.
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52 of 1148
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S530 Service Manual
SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early
failures.
The service schedule is a guide for correct maintenance
of the Bobcat loader.
WARNING
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
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
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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 hydraulic fluid cooler and radiator assembly, fuel cooler, air conditioning
condenser (if equipped), and rear grille. Check coolant level COLD and add premixed coolant as needed.
Fuel Filter – Check the display panel. Remove the trapped water when required.
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 SF MF EXMF T4-B-0118
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Every 10 Hours (Before Starting The Loader)
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
•
•
Battery – Check cables and connections.
Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and 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.
Every 500 Hours or Every 12 Months
•
•
•
•
Fuel Filter – Replace filter element.
Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap – Replace the charge filter and the reservoir breather
cap.
Engine Oil and Filter – Replace oil and filter.
Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.
Every 1000 Hours or Every 12 Months
•
•
•
•
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 1500 Hours or Every 24 Months
•
Coolant – Replace the coolant.
SS SSL SF MF EXMF T4-B-0118
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Every 250 Hours or Every 12 Months
ENGINE AIR CLEANER
Figure 10-80-3
Replacing Filters
Figure 10-80-1
2
1
1
P109625
3
Replace the air filters only when necessary. The service
indicator (Item 1) will FLASH. Press the Information
button (Item 3) until the display screen shows the service
codes. Service code [M0117] (Air Filter Plugged) will
show in the display screen (Item 2) [Figure 10-80-1]
when air filter replacement is necessary.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
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 outer filter. Push in until the filter contacts the
base of the housing.
Install the cover and secure four latches [Figure 10-802].
Install the rear grille and close the rear door.
Outer Filter
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
Figure 10-80-2
2
1
P109624
Open four latches (Item 1) and move the cover (Item 2)
[Figure 10-80-2] out of the way. (One latch is not visible
in the photo.)
55 of 1148
10-80-1
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the outer filter (Item 1) [Figure 10-80-3] and
discard.
NA3271
ENGINE AIR CLEANER (CONT’D)
Figure 10-80-5
Replacing Filters (Cont’d)
Inner Filter
Replace the inner filter only under the following
conditions:
•
Replace the inner filter every second 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.
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
Remove the cover [Figure 10-80-2] and the outer filter
[Figure 10-80-3].
2
1
P109624
Install the cover (Item 2) and secure the latches (Item 1)
[Figure 10-80-5]. (One latch is not visible in the photo).
Install the rear grille and close the rear door.
Dealer Copy -- Not for Resale
Figure 10-80-4
1
P109626
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].
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S530 Service Manual
ENGINE COOLING SYSTEM
Figure 10-90-2
Check the cooling system every day to prevent overheating, loss of performance, or engine damage.
Maintenance Platform
1
Figure 10-90-1
P109632
Use low air pressure or water pressure to clean the top of
the fuel cooler (Item 1) [Figure 10-90-2].
Figure 10-90-3
1
A maintenance platform [Figure 10-90-1] is available to
facilitate access when cleaning the engine cooling
system.
Cleaning
See the SERVICE SCHEDULE for the correct service
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.)
P107641
WARNING
Use low air pressure or water pressure to clean the top of
the hydraulic fluid cooler and radiator assembly (Item 1)
[Figure 10-90-3].
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
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P107266
ENGINE COOLING SYSTEM (CONT’D)
Cleaning (Cont’d)
Figure 10-90-4
1
2
P109633
Dealer Copy -- Not for Resale
The area between the fuel cooler and the hydraulic fluid
cooler and radiator assembly will require occasional
cleaning. Remove the bolt (Item 2) and lift the fuel cooler
up while sliding out of the bracket (Item 1) [Figure 10-904].
NOTE: Be careful when removing and installing the
fuel cooler so that the fuel cooler does not fall
on the hydraulic fluid cooler and radiator
assembly and damage the fins.
Install the fuel cooler into the bracket. Install and tighten
the bolt (Item 2) [Figure 10-90-4].
Check the cooling system for leaks.
Install the rear grille and close the rear door.
58 of 1148
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S530 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
IMPORTANT
Checking And Adding Coolant
Check the engine coolant level every day before starting
the engine for the work shift.
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
Figure 10-90-5
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
1
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
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 10-90-5].
Install the coolant fill cap [Figure 10-90-5].
P109634B
Coolant must be between the top and bottom level
markers (Item 2) [Figure 10-90-5] when the engine is
cold.
NOTE: The coolant fill cap must be tightened until the
cap clicks.
Install the rear grille and close the rear door.
NOTE: The loader is factory filled with propylene
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 10-90-5] 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.
59 of 1148
10-90-3
S530 Service Manual
Dealer Copy -- Not for Resale
2
ENGINE COOLING SYSTEM (CONT’D)
Figure 10-90-7
Removing And Replacing Coolant
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
1
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine
is hot. You can be seriously burned.
NOTE: This procedure requires the use of a spare
0.75 in coolant hose approximately 600 mm
(24 in) long.
Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
[Figure 10-90-7] or similar tool.
Install the coolant fill cap (Item 1) [Figure 10-90-6].
Dealer Copy -- Not for Resale
W-2607-0804
P109814
Figure 10-90-8
Figure 10-90-6
1
1
2
P109813
P109634B
Remove the coolant fill cap (Item 1) [Figure 10-90-6].
3
Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-8].
Quickly install the spare 0.75 in coolant hose onto the
engine oil cooler fitting.
Drain the coolant into a container.
60 of 1148
10-90-4
S530 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
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.
Removing And Replacing Coolant (Cont’d)
Figure 10-90-9
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
2
P109634B
Remove the coolant fill cap (Item 1) [Figure 10-90-9] to
drain the coolant faster.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Remove the spare 0.75 in coolant hose from the engine
oil cooler fitting when the coolant has drained.
Figure 10-90-10
Add premixed coolant, 47% water and 53% propylene
glycol, to the coolant tank until the coolant level reaches
the lower level marker on the tank (Item 2) [Figure 10-909].
Install the coolant fill cap (Item 1) [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.
1
2
Operate the engine until coolant reaches normal
operating temperature. Stop the engine.
Check the coolant level when cool. Add coolant as
needed. (See Checking And Adding Coolant on Page 1090-3.)
P109635
Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-10].
Remove the tool used to pinch off the coolant hose.
Recycle or dispose of used coolant in an environmentally
safe manner.
Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-5.)
61 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Dealer Copy -- Not for Resale
62 of 1148
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S530 Service Manual
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.
•
Biodiesel blend fuel is an excellent medium for
microbial growth and contamination that can cause
corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel must be used in this machine.
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur
maximum.
•
Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as: plugged
fuel filters and deteriorated fuel lines.
The following is one suggested blending guideline that
should prevent fuel gelling during cold temperatures:
•
Shorter maintenance intervals may be required, such
as: cleaning the fuel system and replacing fuel filters
and fuel lines.
•
Using biodiesel blended fuels containing more than
5% biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
pump, and seals.
U.S. Standard (ASTM D975)
Use only clean, high quality diesel fuel, Grade Number
2-D or Grade Number 1-D.
GRADE 2-D GRADE 1-D
Above -9°C (+15°F)
100%
0%
Down to -21°C (-5°F)
50%
50%
Below -21°C (-5°F)
0%
100%
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain
no more than 5% biodiesel mixed with ultra
low sulfur petroleum based diesel. This
biodiesel blend fuel is commonly marketed as
B5 blended diesel fuel. B5 blended diesel fuel
must meet ASTM specifications.
E.U. Standard (EN590)
Use only clean, high quality diesel fuel that meets the
EN590 specifications listed below:
•
•
Ultra low sulfur diesel fuel defined as 10 mg/kg (10
ppm) sulfur maximum.
Apply the following guidelines if biodiesel blend fuel is
used:
•
Ensure the fuel tank is as full as possible at all times
to prevent moisture from collecting in the fuel tank.
•
Ensure that the fuel tank cap is securely tightened.
•
Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
•
Drain all water from the fuel filter daily before
operating the machine.
•
Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
•
Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer, and
operate the engine for at least 30 minutes.
Diesel fuel with cetane number of 51.0 and above.
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain
no more than 7% biodiesel mixed with ultra
low sulfur petroleum based diesel. This
biodiesel blend fuel is commonly marketed as
B7 blended diesel fuel. B7 blended diesel fuel
must meet EN590 specifications.
63 of 1148
NOTE: Biodiesel blend fuel does not have long-term
stability and should not be stored for more
than three months.
10-100-1
S530 Service Manual
Dealer Copy -- Not for Resale
TEMPERATURE
FUEL SYSTEM (CONT’D)
Figure 10-100-2
WRONG
Filling The Fuel Tank
WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Stop the engine and open the rear door.
NA1684
Figure 10-100-1
Install and tighten the fuel cap (Item 1) [Figure 10-1001].
1
NOTE: The fuel fill cap must be tightened until the
cap clicks.
Close the rear door.
WARNING
P121905
Remove the fill cap (Item 1) [Figure 10-100-1].
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
64 of 1148
10-100-2
S530 Service Manual
Dealer Copy -- Not for Resale
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].
FUEL SYSTEM (CONT’D)
Replacing Element
Fuel Filter
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Removing Water
Stop the engine and open the rear door.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Figure 10-100-4
Stop the engine and open the rear door.
3
Figure 10-100-3
1
4
2
1
Disconnect the electrical connector (Item 2) [Figure 10100-4].
P121906
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter to remove trapped water from the filter.
Loosen the fuel filter head (Item 3) from the fuel filter
element (Item 1) [Figure 10-100-4]. Do NOT remove the
hoses from the fuel filter head.
Securely tighten the drain.
Loosen the clamps (Item 4) [Figure 10-100-4].
Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-100-4].
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Close the rear door.
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
Put clean oil on the two new fuel filter element O-rings,
install the element, and tighten to 13,5 N•m (10 ft-lb)
torque.
Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector [Figure 10-100-4].
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.)
65 of 1148
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P121907
FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System
Fuel Filter (Cont’d)
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.
Replacing Element (Cont’d)
WARNING
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Close the rear door.
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Start the engine and allow to operate for one minute.
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
1
2
W-2072-0807
Stop the engine and check for leaks at the filter.
P121908
Open the air vent plug (Item 1) [Figure 10-100-5] on the
fuel assembly three full turns.
Squeeze the hand pump (priming bulb) (Item 2)
[Figure 10-100-5] until fuel flows from the vent with no
air bubbles.
Close the vent (Item 1) [Figure 10-100-5].
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
66 of 1148
10-100-4
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 10-100-5
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 for the work shift.
ENGINE CRANKCASE OIL
Recommended SAE Viscosity Number
1
Refer to temperature range anticipated before next
oil change
Must use API Category CJ-4 or better, or ACEA E9 or
better
Do not use API Category FA-4 engine oil
[1] SAE 10W-30
[2] SAE 15W-40
[3] Bobcat Synthetic Oil – SAE 5W-40
2
P109631
Park the loader on a level surface. Stop the engine. Open
the rear door and remove the dipstick (Item 1) [Figure
10-110-1].
Keep the oil level between the marks on the dipstick. Do
not overfill.
Bobcat engine oils are recommended for use in this
machine. If Bobcat engine oil is not available, use a good
quality engine oil that meets API Service Category of
CJ-4 or better, or ACEA E9 or better [Figure 10-110-2].
Remove the oil fill cap (Item 2) [Figure 10-110-1] to add
engine oil.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
IMPORTANT
AVOID ENGINE DAMAGE
Use of API Service Category FA-4 engine oil is not
approved and may cause irreversible damage to the
engine.
I-2384-0916
W-2103-0508
Close the rear door.
67 of 1148
10-110-1
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 10-110-1
ENGINE LUBRICATION SYSTEM (CONT’D)
Figure 10-110-5
Removing And Replacing Oil And Filter
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
1
Operate the engine until coolant reaches normal
operating temperature. Stop the engine.
Figure 10-110-3
1
P107265
2
Install and tighten the oil drain cap [Figure 10-110-5].
P107954A
Return the oil drain hose to the storage location on top of
the fuel tank [Figure 10-110-4].
P107264
The oil drain hose is located behind a cover (Item 1)
under the rear of the loader (Inset) [Figure 10-110-3].
Install the cover and the cover mounting bolts [Figure 10110-3]. Tighten both bolts.
Loosen one cover mounting bolt and remove the other
bolt (Item 2) [Figure 10-110-3] to allow the cover to
swing open.
Open the rear door.
Figure 10-110-4
1
P109631
The oil drain hose (Item 1) [Figure 10-110-4] storage
location is on top of the fuel tank.
68 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the oil drain cap (Item 1) [Figure 10-110-5] from
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
ENGINE LUBRICATION SYSTEM (CONT’D)
WARNING
Removing and Replacing Oil And Filter (Cont’d)
Figure 10-110-6
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
3
1
W-2072-0807
2
Stop the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-6] and
check the oil level.
P109631
Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filters only.
Remove the oil fill cap (Item 2) [Figure 10-110-6].
Put oil into the engine and replace the oil fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Start the engine and allow to operate for several minutes.
69 of 1148
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
10-110-3
W-2103-0508
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the oil filter (Item 3) [Figure 10-110-6] and clean
the filter base.
Add oil as needed if oil level is not at the top mark on the
dipstick. Install the dipstick and close the rear door.
Dealer Copy -- Not for Resale
70 of 1148
10-110-4
S530 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM
Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid
Figure 10-120-3
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) AND
VISCOSITY INDEX (VI)
Check the hydraulic / hydrostatic fluid level every day
before starting the work shift.
Park the loader on a level surface, lower the lift arms, and
put the attachment flat on the ground or tilt the BobTach® fully back if no attachment is installed.
Stop the engine.
TEMPERATURE RANGE ANTICIPATED DURING
MACHINE USE
[1] BOBCAT All-Season Fluid
[2] BOBCAT Synthetic Fluid
[3] 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 temperatures.)
[4] VG 100; Minimum VI 130
[5] VG 46; Minimum VI 150
1
P107282
Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1]. Keep the fluid level within the operating range.
Open the rear door and remove the rear grille. (See
REAR GRILLE on Page 50-60-1.)
Bobcat hydraulic fluids are recommended for use in this
machine. If Bobcat hydraulic fluid is not available, use a
good quality hydraulic fluid meeting the viscosity grade
and viscosity index shown in the chart [Figure 10-120-3].
(See Hydraulic System on Page SPEC-10-4.)
Figure 10-120-2
WARNING
1
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
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.
71 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 10-120-1
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Figure 10-120-5
Removing And Replacing Hydraulic Fluid
1
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
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 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.)
P107955A
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
NOTE: The hose used to drain the hydraulic reservoir
is located under the fan motor on earlier
models and on the right side of the fan motor
on later models.
1
Figure 10-120-6
Earlier Model
Later Model
1
P109638
1
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4].
2
2
P109760A
P115527A
Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-120-6] 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.
72 of 1148
10-120-2
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the right side access cover bolts (Item 1)
[Figure 10-120-5] and remove the access cover. (Lift
arms shown raised for visual clarity.)
Figure 10-120-4
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Fluid (Cont’d)
Recycle or dispose of used fluid in an environmentally
safe manner.
Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range
of the sight gauge. (See Capacities on Page SPEC-105.) and (See Checking And Adding Fluid on Page 10120-1.)
Install the hydraulic fill cap [Figure 10-120-4].
Install the rear grille and close the rear door.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Start the engine and operate the loader hydraulic
controls.
WARNING
Install the side access cover and bolts [Figure 10-120-5].
Figure 10-120-7
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
1
P109639
Remove and clean the hydraulic fill screen (Item 1)
[Figure 10-120-7]. Use low air pressure to dry the
screen.
73 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
W-2103-0508
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Install new filter ensuring that filter is fully seated in the
housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter
Remove the filter cap O-rings (Item 3) [Figure 10-120-9]
and discard.
See the SERVICE SCHEDULE for the correct service
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.)
Install new filter cap O-rings and lubricate with clean oil.
NOTE: The filter cap O-rings are not the same size.
Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and rotate clockwise to engage the
bolts [Figure 10-120-8]. Alternate tightening the bolts to
draw the cap down evenly. Tighten the bolts to 27 - 41
N•m (20 - 30 ft-lb) torque.
Figure 10-120-8
1
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
2
W-2103-0508
P109640
Install the rear grille and close the rear door.
Loosen the bolts (Item 1) and rotate the filter cap (Item 2)
[Figure 10-120-8] 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.
WARNING
Figure 10-120-9
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
1
2
W-2072-0807
3
Stop the engine and check for leaks at the filter.
P109072A
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
P109073B
Remove the filter (Item 2) [Figure 10-120-9] and discard.
Lubricate the O-ring (Item 1) [Figure 10-120-9] on new
filter with clean oil.
74 of 1148
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S530 Service Manual
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WARNING
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Earlier Models
Removing And Replacing Hydraulic Charge Filter
Figure 10-120-12
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine.
Figure 10-120-10
1
1
P109622
Put a suitable container below the filter housing and
remove the filter housing (Item 1) [Figure 10-120-12].
Dealer Copy -- Not for Resale
Figure 10-120-13
P109069A
Remove the left side access cover bolts (Item 1) [Figure
10-120-10] and remove the access cover. (Lift arms
shown raised for visual clarity.)
NOTE: Identification of the hydraulic charge filter
used on your machine is necessary to
perform the correct replacement procedure.
Figure 10-120-11
1
Earlier Model
Later Model
P109622A
Remove the filter (Item 1) [Figure 10-120-13] and
discard.
Clean the surface of the filter housing and the filter base
where they contact the filter seal.
P109622B
Put clean oil on the seal of the new filter. Install the filter
on the filter base [Figure 10-120-13].
P115441A
Earlier models use a separate filter housing and filter
element. Later models use a spin-on filter [Figure 10120-11].
75 of 1148
Install and tighten the filter housing to 65 - 70 N•m (48 52 ft-lb) torque [Figure 10-120-12].
10-120-5
S530 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
All Models
Removing And Replacing Hydraulic Charge Filter
(Cont’d)
Recycle or dispose of used fluid in an environmentally
safe manner.
Later Models
WARNING
Figure 10-120-14
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
1
Install the side access cover and bolts [Figure 10-12010].
Start the engine and operate the loader hydraulic
controls.
WARNING
Put a suitable container below the filter, remove the filter
(Item 1) [Figure 10-120-14], 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.
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Stop the engine and check for leaks at the filter.
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
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P115526
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Replacing Reservoir Breather Cap
See the SERVICE SCHEDULE for the correct
replacement 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.)
Figure 10-120-15
Dealer Copy -- Not for Resale
1
P109638
Remove the breather cap (Item 1) [Figure 10-120-15]
and discard.
Install new breather cap.
Install the rear grille and close the rear door.
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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.)
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
The chaincase contains the final drive sprockets and
chains, and uses the same type fluid as the hydraulic /
hydrostatic system. (See Hydraulic / Hydrostatic Fluid
Chart on Page 10-120-1.)
Park the loader on a level surface and stop the engine.
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
Figure 10-130-2
Park the loader on a level surface and stop the engine.
Figure 10-130-1
P107281A
Pump the fluid out of the chaincase [Figure 10-130-2].
(Lift arms shown raised for visual clarity.)
P107956
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing. (Lift arms shown
raised for visual clarity.)
If fluid can be reached with the tip of your finger through
the hole, the fluid level is correct.
Recycle or dispose of used fluid in an environmentally
safe manner.
Add fluid through the check plug hole until fluid flows from
the hole. (See Capacities on Page SPEC-10-5.)
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.
WARNING
Install and tighten the plug [Figure 10-130-1].
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
W-2103-0508
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1
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BOB-TACH (HAND LEVER)
The spring loaded wedges (Item 1) must contact the
lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-140-2].
Inspection And Maintenance
Figure 10-140-1
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.
Figure 10-140-3
P-85513A
Dealer Copy -- Not for Resale
Move the Bob-Tach levers down to engage the wedges
[Figure 10-140-1].
The levers and wedges must move freely.
WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Figure 10-140-2
Inspect the mounting frame on the attachment and BobTach, linkages, and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
1
2
Inspect for cracked welds.
Both
wedges
must
contact lower edge of
holes in the attachment
mounting frame.
P-31233A
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
NA3098
The wedges (Item 1) [Figure 10-140-2] must extend
through the holes in the attachment mounting frame.
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BOB-TACH (POWER)
The wedges (Item 1) [Figure 10-141-2] must extend
through the holes in the attachment mounting frame.
This machine may be equipped with a Power Bob-Tach.
The spring loaded wedges (Item 1) must contact the
lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-141-2].
Inspection And Maintenance
Figure 10-141-1
If the wedges do not contact the lower edge of the holes
[Figure 10-141-2], the attachment will be loose and can
come off the Bob-Tach.
1
Figure 10-141-3
2
NA3234
Dealer Copy -- Not for Resale
Push and hold the BOB-TACH WEDGES “UP” switch
(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH WEDGES “DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down.
The levers and wedges must move freely.
WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-141-2
NA13065S
1
Inspect the mounting frame on the attachment and BobTach, 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.
2
Inspect for cracked welds.
Both
wedges
must
contact lower edge of
holes in the attachment
mounting frame.
P-31233A
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Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
NA3098
10-141-1
S530 Service Manual
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10-141-2
S530 Service Manual
LUBRICATING THE LOADER
Lubricate the following:
Lubrication Locations
Figure 10-150-2
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
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.
P107286
Figure 10-150-1
1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-2].
Figure 10-150-3
4
8
Dealer Copy -- Not for Resale
2
1
2
9 10
11
5
3
6
7
P107957B
The grease fitting locations [Figure 10-150-1] are shown
in more detail in the following figures.
P107287
2. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-3].
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S530 Service Manual
LUBRICATING THE LOADER (CONT’D)
Figure 10-150-6
Lubrication Locations (Cont’d)
Figure 10-150-4
5
3
P107291
5. Rear Control Link (Both Sides) (2) [Figure 10-150-6].
P107285
Figure 10-150-7
Figure 10-150-5
4
6
P107292
6. Front Control Link (Both Sides) (2) [Figure 10-150-7].
P107284
4. Rod End Lift Cylinder (Both Sides) (2) [Figure 10150-5].
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S530 Service Manual
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3. Base End Lift Cylinder (Both Sides) (2) [Figure 10150-4].
LUBRICATING THE LOADER (CONT’D)
Figure 10-150-10
Lubrication Locations (Cont’d)
Figure 10-150-8
9
7
P107960
9. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10150-10].
P-31308A
Figure 10-150-11
Figure 10-150-9
8
10
P107961
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-15011].
P107288
8. Base End Tilt Cylinder (Both Sides) (2) [Figure 10150-9].
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7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8].
LUBRICATING THE LOADER (CONT’D)
Lubrication Locations (Cont’d)
If Equipped With Power Bob-Tach
Figure 10-150-12
11
Dealer Copy -- Not for Resale
P107959
11. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10150-12].
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TIRE MAINTENANCE
Rotating
Wheel Nuts
Check the tires regularly for wear, damage, and pressure.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Figure 10-160-2
Figure 10-160-1
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].
P107283
Follow the torques specified below for the wheel nuts
[Figure 10-160-1]:
When installing wheel nuts, tighten to 217 N•m (160
ft-lb) torque.
When checking wheel nut torque, set the torque
wrench to 190 N•m (140 ft-lb) to prevent
overtightening.
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The same size tires must be used on each side of the
loader. If different sizes are used, each tire will turn at a
different rate and cause excessive wear. The tread bars
of all the tires must face the same direction.
Recommended tire pressure must be maintained to avoid
excessive tire wear, loss of stability, and loss of handling
capability. Check for correct pressure before operating
the loader. (See Tires on Page SPEC-10-6.)
10-160-1
S530 Service Manual
Dealer Copy -- Not for Resale
NA1023A
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.
Dealer Copy -- Not for Resale
WARNING
AVOID INJURY OR DEATH
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010
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PIVOT PINS
Inspection And Maintenance
Figure 10-170-1
1
P107293A
Dealer Copy -- Not for Resale
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-170-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 40 ft-lb) torque.
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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
for storage:
•
Check the engine and hydraulic fluid levels; check
coolant level.
•
Thoroughly clean the loader including the engine
compartment.
•
Install a fully charged battery.
•
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.
•
•
Put fuel stabilizer into the fuel tank and operate the
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors.
Start the engine and let run for a few minutes while
observing the instrument panels and systems for
correct operation.
•
Operate machine, check for correct function.
•
Stop the engine and check for leaks. Repair as
needed.
10-180-1
S530 Service Manual
•
If biodiesel blend fuel has been used, perform the
following:
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 it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
•
Cover the exhaust pipe opening.
•
Tag the machine to indicate that it is in storage
condition.
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LOADER STORAGE AND RETURN TO SERVICE
Dealer Copy -- Not for Resale
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STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
Stop the loader on level ground.
Fully lower the lift arms and put the attachment flat on the
ground.
Figure 10-190-1
(Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
personnel.
NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Deluxe
Instrumentation
Panel
allows
operation of the loader without using a
password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
P107184
P-85737A
Set the engine speed control to the LOW IDLE position
[Figure 10-190-1].
P-85735A
Exit the loader using grab handles, safety tread, and
steps (maintaining a three-point contact) [Figure 10-1903].
Engage the parking brake.
Figure 10-190-2
WARNING
1
1
P-90688A
AVOID INJURY OR DEATH
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
position to make sure the lift, tilt and traction
drive functions are deactivated.
P-90214C
Turn the key switch to the STOP position (Item 1) [Figure
10-190-2].
NOTE: If the loader lights are ON, they will remain ON
for approximately 90 seconds after turning
the loader OFF.
The seat bar system must deactivate these functions
when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
W-2463-1110
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
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Figure 10-190-3
Dealer Copy -- Not for Resale
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S530 Service Manual
EMERGENCY EXIT
The front opening on the operator cab and rear window
provide exits.
There are two different procedures for removing the rear
window from your machine:
Rear Window Identification
1. This window is equipped with latches [Figure 10-2001].
Figure 10-200-1
Latches
2. This window is equipped with a rubber cord and tag
[Figure 10-200-1].
Rubber Cord
NOTE: Use these procedures to remove the rear
window only under emergency conditions.
Damage to machine may occur.
2
1
P-85309B
P-64994G
Rear Window Removal (Latches)
Rear Window Removal (Rubber Cord)
Figure 10-200-2
Figure 10-200-4
1
P-85309A
P-64994F
Turn both latches (Item 1) [Figure 10-200-2] in until they
disengage from the window frame.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-200-4].
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 10-200-3
Figure 10-200-5
P-90676
P-90676
Exit through the rear of the operator cab [Figure 10-2003].
97 of 1148
Exit through the rear of the operator cab [Figure 10-2005].
10-200-1
S530 Service Manual
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—————————————————————————————————————————————————————
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 10-200-6
Figure 10-200-8
1
1
P-90669A
The rear window can be removed from outside the loader
using a T40 TORX® Drive tool. Turn both screws (Item 1)
[Figure 10-200-6] counterclockwise until the latches
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
Pull both handles (Item 1) [Figure 10-200-8] up and out
to remove the rear window.
OR
Figure 10-200-7
1
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 10-200-7]
counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.
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P13982
EMERGENCY EXIT (CONT’D)
NOTE: Later models route the washer fluid hose
differently and will not require this step.
Front Door
Figure 10-200-11
NOTE: Use this procedure to remove the front door
only under emergency conditions. Damage to
machine may occur.
2
Figure 10-200-9
3
1
1
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 10-200-11].
P-90725
Remove the door hinges from the loader.
Turn both latches (Item 1) [Figure 10-200-9] down until
they disengage from the door frame.
Figure 10-200-12
Push the door out of the operator cab door frame and exit
through the opening.
2
Front Door Reassembly
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
1
Figure 10-200-10
1
P-90685
Orient the latches as shown (Item 1) and install the door
hinges (Item 2) [Figure 10-200-12] on the door. (Bottom
hinge shown.)
2
P-85781A
Disconnect electrical connector (Item 2) and washer fluid
hose (if equipped) (Item 1) [Figure 10-200-10].
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P-85588A
EMERGENCY EXIT (CONT’D)
Front Door (Cont’d)
Front Door Reassembly (Cont’d)
Figure 10-200-13
1
2
Dealer Copy -- Not for Resale
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 10-200-13]
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 10-200-11].
Connect electrical connector and washer fluid hose (if
equipped) [Figure 10-200-10].
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S530 Service Manual
SEAT BELT
Figure 10-210-1
Inspection And Maintenance
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.
4
2
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 10-210-1].
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.
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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.
Dealer Copy -- Not for Resale
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HYDRAULIC SYSTEM
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1
20-20-1
20-20-2
20-20-6
20-20-7
20-20-9
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-21-1
20-21-1
20-21-2
20-21-3
20-21-4
20-21-5
20-21-7
CYLINDER (LIFT) (B42T11022 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-22-1
20-22-1
20-22-2
20-22-6
20-22-7
20-22-9
CYLINDER (TILT) (B42T11022 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-23-1
20-23-1
20-23-2
20-23-3
20-23-4
20-23-5
20-23-7
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-24-1
20-24-1
20-24-2
20-24-3
20-24-4
20-24-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30-1
20-30-1
20-30-2
20-30-4
20-30-5
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HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-13
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-15
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-15
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
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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
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-50-1
20-50-1
20-50-1
20-50-2
20-50-3
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
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-12
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-80-1
20-80-1
20-80-1
20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-100-1
20-100-1
20-100-1
20-100-3
20-100-3
20-100-5
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-110-1
20-110-1
20-110-1
20-110-2
20-110-3
BOB-TACH (POWER) BLOCK (S/N ALR811001 - ALR813067) . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-120-1
20-120-1
20-120-1
20-120-3
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HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
20-121-1
20-121-1
20-121-2
20-121-4
20-121-6
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly (FFI/FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly (FFH/FH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-130-1
20-130-1
20-130-2
20-130-2
20-130-4
AUTOMATIC RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking The Pressure In The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Nitrogen To The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-140-1
20-140-1
20-140-2
20-140-5
20-140-7
Dealer Copy -- Not for Resale
BOB-TACH (POWER) BLOCK (S/N ALR813068 & ABOVE) . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH NO OPTIONS
S530 (S/N ALR811001 AND ABOVE)
(S/N B42T11001 AND ABOVE)
(PRINTED MARCH 2016)
V-1523legend
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal)
2
SIGHT GUAGE
3
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
4
FILTER - HYDRAULIC (CANISTER)
5
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
6
DIAGNOSTIC COUPLER
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
26 SENSOR – CHARGE PRESSURE
9
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
28 SENSOR – HYD. TEMPERATURE
10
29 FLUSHING RELIEF VALVE
11
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
13
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
15
16
Printed in U.S.A.
107 of 1148
NOT USED FOR THIS MODEL
36
CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
37
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
22 PROPORTIONAL RELIEF VALVE –
40 RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa
2827 kPa (28,3 bar) (410 psi) at High
(108 - 123 bar) (1566 - 1784 psi)
Engine Idle With 60 ° C (140 ° F) Fluid
23 SPRING LOADED FILTER BY-PASS VALVE:
41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
With
345 kPa (3,45 bar) (50 psi) Spring
Dealer Copy -- Not for
Resale
24 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
25 FILTER - HYDRAULIC (CANISTER)
6A
14
35
30
DRIVE MOTOR SHUTTLE VALVE
31 NOT USED FOR THIS MODEL
32
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
33 NOT USED FOR THIS MODEL
34 NOT USED FOR THIS MODEL
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1523legend (3-21-16)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B
A
Male
A
B
DRIVE MOTOR
B
P
B
A
A
A
B
1
A
27
29
30
B
B
B
A
Male
A
A
A
A
B
A
P
0
B
A
Female
2
A
B
B
A
OUT
A
B
HYDRAULIC CONTROL VALVE
32
B
A
B
9
A
B
A
A
A
A
A
B
A
A
B
B
A
9
A
B
10
A
A
B
10
BA
A
6A
CA
Auxiliary Spool
A
B
T
T
B
B
A
A
A
P
A
A
A
B
A
B
B
T1
HYDROSTATIC PUMP
38
A
R
A
A
P
P
A
B
A
B
B
A
B
A
T2
B
A
A
A
T
11
A
A
A
8
B
B
A
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
A
B
B
TILT CYLINDERS
8
A
39
A
A
1
A
M4
B
B
2
3
Tilt Spool
4
13
A
A
C
12
M3
C
B
D
A
B
B
0
6
A
C
5
A
11
B
B
A
A
B
A
A
40
A
B
B
B
A
A
A
B
A
B
A
B
LIFT CYLINDERS
A
B
A
C
P
A
C
M2
A
A
B
B
14
8
A
B
Dealer Copy -- Not for Resale
A
A
B
P
B
B
1
B
M1
2
A
B
A
A
Lift Spool
3
B
A
A
T
B
0
5
A
A
A
B
4
P
B
A
A
B
B
39
A
B
20
11
A
B
15
A
A
B
B
17
B
A
A
B
18
B
IN
7
6
17
A
A
2
A
A
A
16
B
A
T
A
38
B
B
A
A
A
1
A
PA
B
41
Oil Cooler
A
A
37
19
B
B
A
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
B
36
HYDRAULIC RESERVOIR
(VENTED)
4
5
HYDRAULIC
FILTER
2
A
A
B
1
A
A
A
3
A
B
25
B
B
23
26
A
B
A
C
2
A
B
B
A
WORKING CIRCUIT
A
A
24
A
21
1
CHARGE
PRESSURE
B
A
A
P
A
DR
22
DRAIN / RETURN
A
A
A
DRAIN/RETURN MANIFOLD
32
28
Printable Version Click Here
A
A
2
0
A
A
B
1
30
A
29
DRIVE MOTOR
108 of 1148
Printed In U.S.A.
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH NO OPTIONS
S530 (S/N ALR811001 AND ABOVE)
(S/N B42T11001 AND ABOVE)
(PRINTED MARCH 2016)
7204247 (C)
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR811001 – ALR813067)
(PRINTED OCTOBER 2013)
V-1524legend
Printable Version Click Here
LEGEND
1
2
3
4
5
6
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal)
SIGHT GUAGE
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
9
10
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
11
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
13
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
14
15
16
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
63
RELIEF VALVE - CHARGE INLET:
2827 kPa (28,3 bar) (410 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
41
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
19
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
31 HIGH PRESSURE SHUTTLE
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
34 NOT USED FOR THIS MODEL
35
37
109 of 1148
65 FLOW DIVIDER ADJUSTMENT VALVE
42
NOT USED ON THIS MODEL
22 PROPORTIONAL RELIEF VALVE –
43 NOT USED ON THIS MODEL
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
44 NOT USED ON THIS MODEL
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
25 FILTER - HYDRAULIC (CANISTER)
FILTER
- BOB-TACH VALVE
47
26 SENSOR – CHARGE PRESSURE
48 RESTRICTION - 2,03 mm (0.08 in)
27 FRONT AUXILIARY MANUAL PRESSURE
49 SOLENOID ACTIVATED DIRECTIONAL
BLEED-OFF VALVE
CONTROL VALVE (TWO COIL)
28 SENSOR – HYD. TEMPERATURE
50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
29 FLUSHING RELIEF VALVE
51 CHECK VALVE - With 552 kPa) (5,5 bar)
(80 psi) Spring
30 DRIVE MOTOR SHUTTLE VALVE
52 SHUTTLE VALVE
36
Printed in U.S.A.
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
53
RELIEF VALVE - 13790 kPa (137 bar) (2000 psi)
54
CHECK VALVE - With 2068 kPa (20,7 bar) (300
psi) Spring And With 0,33 mm (0.013 in) Orifice
55
RESTRICTION - 0,51 mm (0.020 in)
56
RESTRICTION - 0,51 mm (0.020 in)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
57
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
58
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
66
68 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
69
NOT USED ON THIS MODEL
70
NOT USED ON THIS MODEL
71
NOT USED ON THIS MODEL
72
NOT USED ON THIS MODEL
73 RIDE CONTROL VALVE
74 HIGH PRESSURE CHAMBER
75 LOW PRESSURE CHAMBER
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1524legend (10-16-13)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B
A
Male
A
B
DRIVE MOTOR
B
P
B
A
A
A
B
1
A
27
29
30
B
B
B
A
Male
A
A
A
A
B
A
P
0
B
A
Female
2
A
B
B
A
31
OUT
A
A
32
B
HYDRAULIC CONTROL VALVE
C
B
B
A
LIFT CYLINDERS
RIDE CONTROL
(FIELD INSTALLED OPTION)
B
9
A
B
REAR AUXILIARY VALVE
(OPTIONAL)
A
A
2
A3
A0
A
A B
FEMALE
A
A
A
MALE
A
A
A
A
B
B
B
A
B
B
75
9
A
A
B
A
B
33
B
B
A
A
B
A
B
A
REAR QUICK COUPLERS
1
A
A
10
A
A
B
74
1
73
B
0
61
P
A
A
PB
B
A
A
B
B
10
A
A
A
6A
B
A
B
A
A
38
Auxiliary Spool
T
B
HYDROSTATIC PUMP
CA
A
T
B
A
A
B
A
P
A
A
A
B
A
B
B
T1
A
A
P
A
B
B
B
A
T2
BUCKET POSITIONING
VALVE (OPTIONAL)
A
T
B
11
A
60
A
A
A
A
B
B
A
P
A
B
59
A
R
A
BA
A
63
B
C
62
P
A
T
A
C
B
B
8
A
B
B
A
A
B
A
A
P
A
B
58
A
B
B
B
65
P
A
8
A
A2
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
B
B
A
A1
E3
A
B
A
A
E2
E1
A
B
B
39
P
A
A
1
57
A
A
66
A T
P
67
B
2
3
Tilt Spool
4
A
13
B
A
A
B
P
T
D2
B
A
M4
2-SPEED VALVE
(OPTIONAL)
B
B
A
P in
P out
B
C
T
A
A
A
12
M3
C
B
D
A
B
6
A
5
A
11
B
B
A1
A
A
A
T
A
A
B
A
B
POWER BOBTACH CYLINDER
(OPTIONAL)
A
B
B
A
B A
A
B BA A
P
BB A
B
B
BA
B
B
A
A
P
A
B
B
C
B
B
A
B
1
B
M1
2
A
51
A
B
A
A
T
54
0
5
A
A
A
B
4
P
B
A
A
B
B
39
A
B
C
A
1
A
A
A
B
49
2
B
20
11
A
B
A
B
B
17
15
A
B
B
A
A
B
18
B
53
0
IN
3
B
7
B
B
A
B
A
B
A
48
D
B
A
T
A
38
6
56
B
17
A
2
A
A
16
A
A
55
A
B
A
B
A
A
P
A
A
A
A
1
A
47
41
46
A
PA
B
Oil Cooler
A
A
19
B
B
A
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
B
36
HYDRAULIC RESERVOIR
(VENTED)
4
5
HYDRAULIC
FILTER
2
A
A
B
1
A
A
A
3
A
B
25
B
B
23
26
A
B
A
C
2
A
B
33
B
A
WORKING CIRCUIT
A
A
24
1
A
21
1
CHARGE
PRESSURE
B
A
A
A
2
A3
A0
P
A
DR
22
DRAIN / RETURN
A
A
A
DRAIN/RETURN MANIFOLD
32
28
B
C
A
A
A
Printable Version Click Here
31
B
2
0
A
A
B
1
30
A
29
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR811001 - ALR813067)
DRIVE MOTOR
110 of 1148
Printed In U.S.A.
C2
D1
A
B
52
A
B
Lift Spool
3
A
37
A
B
B
C
35
50
A
14
P
A
A
B
A
68
C1
C
A
A
B
POWER BOBTACH
VALVE (OPTIONAL)
A
M2
A
A
A
B
A
8
A
B
B
Dealer Copy -- Not for Resale
B
A
A
B
A
A
A
40
A
B
B
0
C
(PRINTED AUGUST 2015)
7204247 (C)
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR813068 AND ABOVE)
(S/N B42T11001 - B42T11009)
(PRINTED OCTOBER 2017)
V-1524legend
Printable Version Click Here
LEGEND
1
2
3
4
5
6
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal)
SIGHT GUAGE
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
9
10
11
12
13
14
15
16
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 35000 kPa (350 bar) (5075 psi)
63
RELIEF VALVE - CHARGE INLET:
2827 kPa (28,3 bar) (410 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
41
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
19
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
29 FLUSHING RELIEF VALVE
30
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
34 NOT USED FOR THIS MODEL
35
37
111 of 1148
42
NOT USED ON THIS MODEL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
66
68 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
69
NOT USED ON THIS MODEL
70
NOT USED ON THIS MODEL
71
NOT USED ON THIS MODEL
72
NOT USED ON THIS MODEL
73 RIDE CONTROL VALVE
50
RELIEF VALVE - 24100 kPa (241 bar) (3500 psi)
74 HIGH PRESSURE CHAMBER
51
NOT USED ON THIS MODEL
75 LOW PRESSURE CHAMBER
52
NOT USED ON THIS MODEL
53
RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
54
CHECK VALVE
55
RESTRICTION - 0,25 mm (0.10 in)
56
NOT USED ON THIS MODEL
57
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
DRIVE MOTOR SHUTTLE VALVE
31 HIGH PRESSURE SHUTTLE
36
Printed in U.S.A.
65 FLOW DIVIDER ADJUSTMENT VALVE
22 PROPORTIONAL RELIEF VALVE –
43 NOT USED ON THIS MODEL
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
44 NOT USED ON THIS MODEL
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
25 FILTER - HYDRAULIC (CANISTER)
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
47 FILTER - BOB-TACH VALVE
26 SENSOR – CHARGE PRESSURE
48 RESTRICTION - 1,17 mm (0.046 in)
27 FRONT AUXILIARY MANUAL PRESSURE
49 SOLENOID ACTIVATED DIRECTIONAL
BLEED-OFF VALVE
CONTROL VALVE (TWO COIL)
28 SENSOR – HYD. TEMPERATURE
ANTICAVITATION VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
58
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1524legend (9-27-17)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B
A
Male
A
B
DRIVE MOTOR
B
P
B
A
A
A
B
1
A
27
29
30
B
B
B
A
Male
A
A
A
A
B
A
P
0
B
A
Female
2
A
B
B
A
31
OUT
A
A
32
B
HYDRAULIC CONTROL VALVE
C
B
B
A
LIFT CYLINDERS
RIDE CONTROL
(FIELD INSTALLED OPTION)
B
9
A
B
REAR AUXILIARY VALVE
(OPTIONAL)
A
A
2
A3
A0
A
A B
FEMALE
A
A
A
MALE
A
A
A
A
B
B
B
A
B
B
75
9
A
A
B
A
B
33
B
B
A
A
B
A
B
A
REAR QUICK COUPLERS
1
A
A
10
A
A
B
74
1
73
B
0
61
P
A
A
B
10
PB
B
A
A
B
A
A
A
6A
B
A
B
A
A
38
Auxiliary Spool
T
B
HYDROSTATIC PUMP
CA
A
T
B
A
A
B
A
P
A
A
A
B
A
B
B
T1
A
A
P
A
T
B
B
B
A
T2
BUCKET POSITIONING
VALVE (OPTIONAL)
A
B
11
A
60
A
A
A
A
B
B
A
P
A
B
59
A
R
A
BA
A
63
B
C
62
P
A
T
A
C
B
B
8
A
B
B
A
A
A
B
A
B
58
A
B
B
B
65
P
A
8
A
A2
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
A
A
P
A1
E3
A
B
A
B
B
A
E2
E1
A
B
B
39
P
A
A
1
A
A
57
66
A T
P
67
B
2
3
Tilt Spool
4
A
13
B
A
A
B
P
T
D2
B
A
M4
2-SPEED VALVE
(OPTIONAL)
B
B
A
P in
P out
B
C
T
A
A
A
12
M3
C
B
D
A
B
6
A
5
A
11
B
B
A1
A
A
B
A
B
POWER BOBTACH CYLINDER
(OPTIONAL)
A
B
B
A
B A
A
B BA A
P
BB A
B
B
BA
B
B
B
A
A
P
A
C
P
A
A
A
B
B
A
C1
C
M2
A
A
M1
1
B
53
54
A
B
C2
14
POWER BOBTACH
VALVE (OPTIONAL)
A
A
B
68
8
A
B
A
A
B
A
B
A
A
B
B
B
A
A
40
A
A
A
Dealer Copy -- Not for Resale
A
A
T
A
B
B
0
C
2
A
B
A
D1
A
Lift Spool
3
B
35
A
T
B
0
5
A
A
A
B
4
P
B
A
A
B
B
39
A
49
55
2
5
B
20
11
A
B
15
A
A
B
B
17
B
A
A
B
18
B
1
4
IN
3
B
D
A
7
A
6
17
A
T
A
38
2
A
16
47
B
A
A
A
48
B
A
B
A
A
A
1
A
46
41
A
A
37
PA
B
Oil Cooler
19
B
B
A
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
B
36
HYDRAULIC RESERVOIR
(VENTED)
4
5
HYDRAULIC
FILTER
2
A
A
B
1
A
A
A
3
A
B
25
B
B
23
26
A
B
A
C
2
A
B
33
B
A
WORKING CIRCUIT
A
A
24
1
A
21
1
CHARGE
PRESSURE
B
A
A
A
2
A3
A0
P
A
DR
22
DRAIN / RETURN
A
A
A
DRAIN/RETURN MANIFOLD
32
Printable Version Click Here
28
B
C
A
A
A
31
B
2
0
A
A
B
1
30
A
29
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR813068 AND ABOVE)
(S/N B42T11001 - B42T11009)
DRIVE MOTOR
112 of 1148
Printed In U.S.A.
(PRINTED OCTOBER 2017)
7204247 (C)
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N B42T11010 AND ABOVE)
(PRINTED OCTOBER 2017)
V-1652legend
Printable Version Click Here
LEGEND
1
2
3
4
5
6
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
SIGHT GUAGE
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
9
10
11
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
63
RELIEF VALVE - CHARGE INLET:
2827 kPa (28,3 bar) (410 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
19
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
22 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
65 FLOW DIVIDER ADJUSTMENT VALVE
41
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
42
NOT USED ON THIS MODEL
43
NOT USED ON THIS MODEL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
44
NOT USED ON THIS MODEL
68
66
69
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
NOT USED ON THIS MODEL
70 NOT USED ON THIS MODEL
71 NOT USED ON THIS MODEL
47
FILTER - BOB-TACH VALVE
48
RESTRICTION - 1,17 mm (0.46 in)
49
50
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
NOT USED ON THIS MODEL
51
NOT USED ON THIS MODEL
52
NOT USED ON THIS MODEL
31 HIGH PRESSURE SHUTTLE
53
RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
75 ORIFICE WITH CHECK VALVE:
2,54 mm (0.10 in)
76 ORIFICE: 1,60 mm (0.063 in)
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
54
CHECK VALVE
77 FAN REVERSING VALVE (OPTIONAL)
55
RESTRICTION - 0,25 mm (0.10 in)
56
NOT USED ON THIS MODEL
57
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
29 FLUSHING RELIEF VALVE
30
DRIVE MOTOR SHUTTLE VALVE
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
34 NOT USED FOR THIS MODEL
35
36
37
Printed in U.S.A.
40
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
With Build-up Valve 275 kPa (2,75 bar) (40 psi)
25 FILTER - HYDRAULIC (CANISTER)
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
28 SENSOR – HYD. TEMPERATURE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
113 of 1148
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
13
16
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
26 SENSOR – CHARGE PRESSURE
ANTICAVITATION VALVE
15
38
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
12
14
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
58
72 NOT USED ON THIS MODEL
73 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Ride Control (OPTIONAL)
74 ACCUMULATOR – Ride Control (OPTIONAL)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1652legend (9-27-17)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B
A
Male
A
B
DRIVE MOTOR
B
P
B
A
A
A
B
1
A
27
29
30
B
B
B
A
Male
A
A
A
A
B
A
P
0
B
A
Female
2
A
B
B
A
74
B
RIDE CONTROL (OPTION)
31
OUT
A
A
HYDRAULIC CONTROL VALVE
C
T2
B
ACC
A
B
75
B
T
B
32
NOTE: Cushioned Lift Cylinder
Pistons On Later Models Only.
B
B
A
LIFT CYLINDERS
A
76
A
A
P
P
B
9
A
B
A
P
REAR AUXILIARY VALVE
(OPTIONAL)
A
A
A
A
73
A
2
A3
A0
A
A B
FEMALE
A
MALE
A
A
B
A
A
REAR QUICK COUPLERS
B
B
9
A
CR
CR2
1
A
A
B
33
B
B
B
A
A
A
B
B
B
A
A
B
61
B
A
A
P
B
PB
A
A
B
A
A
A
A
B
6A
Auxiliary Spool
B
T
B
A
B
A
A
38
CA
A
T
B
A
HYDROSTATIC PUMP
BA
A
63
B
C
B
10
62
A
A
P
A
A
A
B
A
B
B
59
A
B
T1
A
A
T
P
B
B
A
B
A
T2
BUCKET POSITIONING
VALVE (OPTIONAL)
A
B
A
60
A
A
A
A B
B
A
P
A
B
R
A
CB
10
A
B
P
A
T
A
11
C
B
8
A
B
B
A
A
A
B
A
58
A
B
65
B
B
B
P
A
8
A
A2
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
A
A
P
A1
E3
A
A
B
B
B
A
E2
E1
A
B
B
39
66
P A T
A
A
1
A
57
A
P
67
B
2
3
Tilt Spool
4
A
A
13
B
A
B
P
T
D2
B
A
M4
2-SPEED VALVE
(OPTIONAL)
B
B
A
P in
P out
B
T
A
A
C
A
M3
C
D
B
A
12
B
6
A
5
A
11
B
B
A1
A
A
A
T
A
A
POWER BOBTACH CYLINDER
(OPTIONAL)
A
B
B
B
A
B
A
B
P
BB B
A
A
BA A
B
BA
B
B
B
A
B
A
A
B
A
68
P
A
A
B
C2
14
8
A
A
A
A
B
B
C1
POWER BOBTACH
VALVE (OPTIONAL)
A
A
B
B
Dealer Copy -- Not for Resale
B
A
A
A
A
40
A
B
B
0
C
D1
B
A
A
P
A
C
A
C
M2
A
A
B
B
M1
1
B
53
54
A
2
B
A
A
Lift Spool
3
B
A
35
A
T
B
A
0
5
A
A
B
4
P
B
39
B
49
11
A
55
2
20
A
B
5
B
B
A
B
17
15
A
A
A
B
B
A
B
A
B
1
4
3
18
IN
B
D
A
7
A
6
17
A
T
2
A
16
47
B
A
A
A
48
B
A
B
A
38
A
A
A
1
A
46
41
A
A
PA
B
Oil Cooler
19
B
B
37
A
4
VARIABLE SPEED
HYDRAULIC FAN MOTOR W/
INTEGRATED FILTER (Show n
With OPTIONAL Reversing
Valve)
B
36
HYDRAULIC RESERVOIR
(VENTED)
5
HYDRAULIC
FILTER
A
1
A
A
A
A
2
A
B
3
B
25
23
B
B
26
A
B
A
C
33
B
1
4
3
2
T
2
B
A
A
B
P
A
A
WORKING CIRCUIT
A
1
A
24
A
A3
CHARGE
PRESSURE
1
B
77
A
2
21
A
A0
22
A
DR
DRAIN / RETURN
P
A
A
A
DRAIN/RETURN MANIFOLD
32
Printable Version Click Here
28
B
C
A
A
A
31
B
2
0
A
A
B
1
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N B42T11010 AND ABOVE)
A
30
29
DRIVE MOTOR
114 of 1148
Printed In U.S.A.
(PRINTED OCTOBER 2017)
7204247 (E)
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
S530 (S/N ALR811001 AND ABOVE)
(S/N B42T11001 AND ABOVE)
(PRINTED MARCH 2016)
V-1525legend
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 31,8 L (8.4 U.S. gal)
2
SIGHT GUAGE
3
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
4
FILTER - HYDRAULIC (CANISTER)
5
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
6
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
9
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
10
11
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
13
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
14
15
16
Printed in U.S.A.
115 of 1148
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
35
NOT USED FOR THIS MODEL
36
CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
37
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
22 PROPORTIONAL RELIEF VALVE –
40 RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa
2861 kPa (28,6 bar) (415 psi) at High
(108 - 123 bar) (1566 - 1784 psi)
Engine Idle With 60 ° C (140 ° F) Fluid
23 SPRING LOADED FILTER BY-PASS VALVE:
41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
With
345 kPa (3,45 bar) (50 psi) Spring
Dealer Copy -- Not for
Resale
24 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
42 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
25 FILTER - HYDRAULIC (CANISTER)
43 FILTER
26 SENSOR – CHARGE PRESSURE
44 SERVO PISTON – Swash Plate
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
28 SENSOR – HYD. TEMPERATURE
29
FLUSHING RELIEF VALVE
30
DRIVE MOTOR SHUTTLE VALVE
31 NOT USED FOR THIS MODEL
32
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
33 NOT USED FOR THIS MODEL
34 NOT USED FOR THIS MODEL
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1525legend (3-21-16)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR
27
29
Male
30
Female
OUT
HYDRAULIC CONTROL VALVE
32
9
9
A
10
B
10
Auxiliary Spool
6A
HYDROSTATIC PUMP
R
38
T
11
42
8
43
X1
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
TILT CYLINDERS
8
X2
39
Tilt Spool
MA
MB
43
B
A
13
12
11
MG
Dealer Copy -- Not for Resale
40
LIFT CYLINDERS
14
8
G
B
A
MB
Lift Spool
43
MA
20
39
11
X2
17
15
44
18
IN
7
X1
6
17
43
2
16
42
T
38
1
R
41
Oil Cooler
19
37
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
36
HYDRAULIC RESERVOIR
(VENTED)
4
2
5
HYDRAULIC
FILTER
1
3
25
23
26
B
A
WORKING CIRCUIT
24
21
P
DR
CHARGE
PRESSURE
22
DRAIN / RETURN
DRAIN/RETURN MANIFOLD
32
28
30
29
DRIVE MOTOR
116 of 1148
Printed In U.S.A.
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
S530 (S/N ALR811001 AND ABOVE)
(S/N B42T11001 AND ABOVE)
(PRINTED MARCH 2016)
7204248 (C)
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR811001 – ALR813067)
(PRINTED AUGUST 2015)
V-1526legend
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal)
2
SIGHT GUAGE
3
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
4
FILTER - HYDRAULIC (CANISTER)
5
6
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
9
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
10
11
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
13
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
63
RELIEF VALVE - CHARGE INLET:
2861 kPa (28,6 bar) (415 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
41
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
22 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
15
16
29 FLUSHING RELIEF VALVE
30
DRIVE MOTOR SHUTTLE VALVE
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
34 NOT USED FOR THIS MODEL
117 of 1148
43
FILTER
44
SERVO PISTON – Swash Plate
50
RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
51
52
CHECK VALVE - With 552 kPa) (5,5 bar)
(80 psi) Spring
SHUTTLE VALVE
53
RELIEF VALVE - 13790 kPa (137 bar) (2000 psi)
54
CHECK VALVE - With 2068 kPa (20,7 bar) (300
psi) Spring And With 0,33 mm (0.013 in) Orifice
55
RESTRICTION - 0,51 mm (0.020 in)
56
RESTRICTION - 0,51 mm (0.020 in)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
57
35 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
CHARGE
PUMP 36
49,2 L/min (13.0 U.S. gpm) at High Engine Idle
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
37
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-- Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
25 FILTER - HYDRAULIC (CANISTER)
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
47 FILTER - BOB-TACH VALVE
26 SENSOR – CHARGE PRESSURE
48 RESTRICTION - 2,03 mm (0.08 in)
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
49 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
28 SENSOR – HYD. TEMPERATURE
31 HIGH PRESSURE SHUTTLE
14
42
58
65 FLOW DIVIDER ADJUSTMENT VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
66
68 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
69
NOT USED ON THIS MODEL
70
NOT USED ON THIS MODEL
71
NOT USED ON THIS MODEL
72
NOT USED ON THIS MODEL
73 RIDE CONTROL VALVE
74 HIGH PRESSURE CHAMBER
75 LOW PRESSURE CHAMBER
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1526legend (8-11-15)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR
27
29
Male
30
Female
31
OUT
HYDRAULIC CONTROL VALVE
32
LIFT CYLINDERS
RIDE CONTROL
(FIELD INSTALLED OPTION)
9
REAR AUXILIARY VALVE
(OPTIONAL)
FEMALE
MALE
10
B
33
74
75
9
REAR QUICK COUPLERS
A
73
61
10
Auxiliary Spool
63
6A
62
59
HYDROSTATIC PUMP
BUCKET POSITIONING
VALVE (OPTIONAL)
R
38
T
11
60
42
8
43
X1
E2
E1
A1
A2
E3
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
65
B
TILT CYLINDERS
8
58
X2
66
39
57
MA
2-SPEED VALVE
(OPTIONAL)
MB
P in
43
P out
11
Dealer Copy -- Not for Resale
T
40
LIFT CYLINDERS
POWER BOBTACH CYLINDER
(OPTIONAL)
P
C2
C1
POWER BOBTACH
VALVE (OPTIONAL)
B
A
68
14
8
G
A
D2
12
MG
A1
13
T
B
A
67
Tilt Spool
D1
MB
Lift Spool
43
MA
51
35
52
50
54
20
39
X2
11
49
17
15
44
7
X1
56
43
42
18
IN
53
6
17
2
16
55
48
D
T
38
1
R
47
41
46
Oil Cooler
19
37
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
36
HYDRAULIC RESERVOIR
(VENTED)
4
2
5
HYDRAULIC
FILTER
1
3
25
23
26
33
B
A
WORKING CIRCUIT
24
21
P
DR
CHARGE
PRESSURE
22
DRAIN / RETURN
DRAIN/RETURN MANIFOLD
32
28
Printable Version Click Here
31
30
29
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
S530 (S/N ALR811001 - ALR813067)
DRIVE MOTOR
118 of 1148
Printed In U.S.A.
(PRINTED AUGUST 2015)
7204248 (C)
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N ALR813068 AND ABOVE)
(S/N B42T11001 - B42T11009)
(PRINTED OCTOBER 2017)
V-1526legend
Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal)
2
SIGHT GUAGE
3
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
4
FILTER - HYDRAULIC (CANISTER)
5
6
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
9
10
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
11
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 35000 kPa (350 bar) (5075 psi)
63
RELIEF VALVE - CHARGE INLET:
2861 kPa (28,6 bar) (415 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
41
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
22 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
14
15
16
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
26 SENSOR – CHARGE PRESSURE
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
119 of 1148
43
FILTER
44
SERVO PISTON – Swash Plate
29 FLUSHING RELIEF VALVE
30
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
34 NOT USED FOR THIS MODEL
68 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
69
NOT USED ON THIS MODEL
70
NOT USED ON THIS MODEL
71
NOT USED ON THIS MODEL
72
NOT USED ON THIS MODEL
FILTER - BOB-TACH VALVE
48
RESTRICTION - 1,17 mm (0.046 in)
49
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
73 RIDE CONTROL VALVE
50
RELIEF VALVE - 24100 kPa (241 bar) (3500 psi)
74 HIGH PRESSURE CHAMBER
51
75 LOW PRESSURE CHAMBER
52
CHECK VALVE - With 552 kPa) (5,5 bar)
(80 psi) Spring
RESTRICTION - 3,18 mm (0.125 in)
53
NOT USED ON THIS MODEL
54
NOT USED ON THIS MODEL
55
NOT USED ON THIS MODEL
56
NOT USED ON THIS MODEL
57
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
DRIVE MOTOR SHUTTLE VALVE
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
66
47
28 SENSOR – HYD. TEMPERATURE
35 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
CHARGE
PUMP 36
49,2 L/min (13.0 U.S. gpm) at High Engine Idle
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
37
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-- Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
25 FILTER - HYDRAULIC (CANISTER)
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
31 HIGH PRESSURE SHUTTLE
13
42
65 FLOW DIVIDER ADJUSTMENT VALVE
58
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1526legend (3-21-16)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR
27
29
Male
30
Female
31
OUT
HYDRAULIC CONTROL VALVE
32
LIFT CYLINDERS
RIDE CONTROL
(FIELD INSTALLED OPTION)
9
REAR AUXILIARY VALVE
(OPTIONAL)
FEMALE
MALE
10
B
33
74
75
9
REAR QUICK COUPLERS
A
73
61
10
Auxiliary Spool
63
6A
62
59
HYDROSTATIC PUMP
BUCKET POSITIONING
VALVE (OPTIONAL)
R
38
T
42
11
60
8
43
X1
E2
E1
A1
A2
E3
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
65
B
TILT CYLINDERS
8
58
X2
66
39
57
MA
2-SPEED VALVE
(OPTIONAL)
MB
P in
43
P out
11
40
POWER BOBTACH CYLINDER
(OPTIONAL)
G
A
Dealer Copy -- Not for Resale
T
P
LIFT CYLINDERS
68
C2
14
8
POWER BOBTACH
VALVE (OPTIONAL)
B
A
D2
12
MG
A1
13
T
B
A
67
Tilt Spool
C1
D1
MB
51
43
MA
Lift Spool
50
35
20
49
39
52
X2
11
17
15
44
18
IN
D
X1
7
48
43
42
6
17
2
16
47
T
38
R
1
46
41
Oil Cooler
19
37
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
36
HYDRAULIC RESERVOIR
(VENTED)
4
2
5
HYDRAULIC
FILTER
1
3
25
23
26
33
B
A
WORKING CIRCUIT
24
21
P
DR
CHARGE
PRESSURE
22
DRAIN / RETURN
DRAIN/RETURN MANIFOLD
32
28
Printable Version Click Here
31
30
29
DRIVE MOTOR
120 of 1148
Printed In U.S.A.
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
S530 (S/N ALR813068 AND ABOVE)
(S/N B42T11001 - B42T11009)
(PRINTED OCTOBER 2017)
7204248 (C)
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
S530 (S/N B42T11010 AND ABOVE)
(PRINTED OCTOBER 2017)
V-1653legend
Printable Version Click Here
LEGEND
1
2
3
4
5
6
RESERVOIR:
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal)
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
SIGHT GUAGE
DIFFERENTIAL PRESSURE SWITCH:
107 kPa (1,07 bar) (15 psi)
Normally Closed
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE: 172 kPa (1,7 bar) (25 psi)
DIAGNOSTIC COUPLER
6A
DIAGNOSTIC COUPLER – FILL
PORT – Factory Hydraulic Oil
7
RELIEF VALVE - MAIN:
23787 - 24476 kPa (238 - 245 bar)
(3450 - 3550 psi) at Front Quick Couplers
8
9
10
11
RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)
RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
LOAD CHECK VALVE
12
ANTICAVITATION VALVE
13
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring
38
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
39
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 34500 kPa (345 bar) (5000 psi)
63
RELIEF VALVE - CHARGE INLET:
2861 kPa (28,6 bar) (415 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
64
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Male
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
21 ANTICAVITATION VALVE
22 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
(108 - 123 bar) (1566 - 1784 psi)
15
16
26 SENSOR – CHARGE PRESSURE
27 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
121 of 1148
CHECK VALVE – COLD WEATHER BY-PASS
With 345 kPa (3,45 bar) (50 psi) Spring
29 FLUSHING RELIEF VALVE
30
DRIVE MOTOR SHUTTLE VALVE
32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR
65 FLOW DIVIDER ADJUSTMENT VALVE
42
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
43
FILTER
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
67 CHECK VALVE - BUCKET POSITION
VALVE
44
SERVO PISTON – Swash Plate
68
66
69
70
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
NOT USED ON THIS MODEL
NOT USED ON THIS MODEL
47
FILTER - BOB-TACH VALVE
71 NOT USED ON THIS MODEL
48
RESTRICTION - 1,17 mm (0.46 in)
72 NOT USED ON THIS MODEL
49
50
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
NOT USED ON THIS MODEL
SOLENOID ACTIVATED DIRECTIONAL
73 CONTROL VALVE – Ride Control (OPTIONAL)
51
NOT USED ON THIS MODEL
52
NOT USED ON THIS MODEL
75 ORIFICE WITH CHECK VALVE:
2,54 mm (0.10 in)
53
RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
76 ORIFICE: 1,60 mm (0.063 in)
54
CHECK VALVE
28 SENSOR – HYD. TEMPERATURE
33 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HIGH / LOW SPEED
55
RESTRICTION - 0,25 mm (0.10 in)
56
NOT USED ON THIS MODEL
34 NOT USED FOR THIS MODEL
57
59
HYDRAULIC PUMP . . . . . . . Gear Type
64,7 L/min (17.1 U.S. gpm) at High Engine Idle
60
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
RESTRICTOR - 0,8 mm (0.031 in)
61
LOAD SHUTTLE VALVE - BLEED OFF
58
74 ACCUMULATOR – Ride Control (OPTIONAL)
77 FAN REVERSING VALVE (OPTIONAL)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY
RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
35 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Brake Valve
36 CHARGE PUMP 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
37
Printed in U.S.A.
41
23 SPRING LOADED FILTER BY-PASS VALVE:
45 NOT USED ON THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
Dealer
Copy
-Not for Resale
24 FIXED CAPACITY DISPLACEMENT
46 PILOT ACTIVATED DIRECTIONAL CONTROL
HYDRAULIC MOTOR
VALVE – HYDRAULIC POWERED BOB-TACH
With Build-up Valve 275 kPa (2,75 bar) (40 psi)
25 FILTER - HYDRAULIC (CANISTER)
31 HIGH PRESSURE SHUTTLE
14
40
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-1653legend (9-27-17)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
DRIVE MOTOR
27
29
30
Male
Female
31
74
RIDE CONTROL (OPTION)
OUT
HYDRAULIC CONTROL VALVE
T2
32
ACC
NOTE: Cushioned Lift Cylinder
Pistons On Later Models Only.
75
T
LIFT CYLINDERS
76
9
REAR AUXILIARY VALVE
(OPTIONAL)
FEMALE
P
MALE
A
73
9
REAR QUICK COUPLERS
10
B
33
CR
CR2
CB
61
10
Auxiliary Spool
63
6A
62
59
BUCKET POSITIONING
VALVE (OPTIONAL)
R
HYDROSTATIC PUMP
38
T
42
11
60
8
43
X1
E2
E1
A1
E3
64
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
65
B
8
58
X2
A2
66
39
57
MA
2-SPEED VALVE
(OPTIONAL)
MB
P in
43
13
P out
12
11
MG
A1
Dealer Copy -- Not for Resale
T
40
POWER BOBTACH CYLINDER
(OPTIONAL)
G
A
A
68
C2
14
8
POWER BOBTACH
VALVE (OPTIONAL)
B
P
D2
T
B
A
67
Tilt Spool
C1
D1
MB
51
43
MA
Lift Spool
50
35
20
49
39
52
X2
11
17
15
44
18
IN
D
X1
7
48
43
42
6
17
2
16
47
T
38
R
1
46
41
Oil Cooler
19
37
4
VARIABLE SPEED
HYDRAULIC FAN MOTOR W/
INTEGRATED FILTER (Show n
With OPTIONAL Reversing
Valve)
36
HYDRAULIC RESERVOIR
(VENTED)
2
5
HYDRAULIC
FILTER
25
1
3
23
26
33
B
1
4
3
2
A
WORKING CIRCUIT
21
24
77
DR
32
CHARGE
PRESSURE
22
DRAIN / RETURN
P
DRAIN/RETURN MANIFOLD
28
Printable Version Click Here
31
30
29
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
S530 (S/N B42T11010 AND ABOVE)
DRIVE MOTOR
122 of 1148
Printed In U.S.A.
(PRINTED OCTOBER 2017)
7204248 (E)
TILT CYLINDERS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
SYMBOL
SYMBOL
DESCRIPTION
DESCRIPTION
BASIC and MISCELLANEOUS SYMBOLS
FLOW LINES and CONNECTIONS
WORKING CIRCUITS - Continuous,
Solid Line - Working (Main) Line,
Return Line (line conducting fluid
from working devices to the reservoir)
and Feed line (main line conductor).
RESTRICTION - Line with Fixed
Restriction - Affected by Viscosity
(property of resistance to flowing
fluid).
PILOT PRESSURE - Dashed Line Pilot Line (Line which conducts
control fluid).
DRAIN CIRCUITS - Dotted Line Drain Line (drain or bleed line - line
conducting fluid from a component
housing to the reservoir.)
COMPONENTS - Long Chain Line Enclosure
outline
for
several
components assembled in one unit.
MECHANICAL CONNECTIONS Double Line (Shaft, Lever, Piston
Rod).
CROSSING
-
TEMPERATURE
INDICATOR
(temperature
measurement
thermometer).
-
FILTER (strainer or screen) - For fluid
conditioning.
VENTED
RESERVOIR
atmosphere).
AND
FILTERED
(reservoir open to
PRESSURIZED,
VENTED
AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection).
OIL LINES
Connected).
TEMPERATURE
CONTROL
(Indication of temperature).
OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
(NOT
PRESSURE SENSOR electric signal with pressure.
Varies
DIFFERENTIAL
PRESSURE
SWITCH - Switch activates when
pressure difference reaches specified
level.
COUPLER - Quick - Acting Coupling
(uncoupled, closed by non-return
valve).
PRESSURE SWITCH - Switch
activates when pressure reaches
specified level.
MUFFLER
noise.
123 of 1148
20-10-1
(silencer)
-
Reduces
S530 Service Manual
Dealer Copy -- Not for Resale
VARIABLE
ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
SYMBOL
DESCRIPTION
CYLINDER: Equipment to convert hydraulic energy into
linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward
strokes).
DOUBLE
ACTING
HYDRAULIC
CYLINDER,
UNEQUAL
DISPLACEMENT - With single piston
rod.
DOUBLE
ACTING
HYDRAULIC
CYLINDER,
UNEQUAL
DISPLACEMENT and CUSHION ON
ONE END - With single piston rod.
PUMP: To convert mechanical energy into hydraulic
energy.
DESCRIPTION
CONTROL MECHANISMS
CONTROL VALVE WITH DETENT
(Holds Valve in Position) - device for
maintaining
a
given
position
(mechanical).
CONTROL VALVE ACTIVATED BY A
PULL BUTTON (manual).
CONTROL VALVE ACTIVATED BY A
PUSH-PULL BUTTON (manual).
CONTROL VALVE ACTIVATED BY A
LEVER (manual).
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
VARIABLE
CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two
directions of flow (bidirectional).
CONTROL VALVE WITH SPRING
RETURN (mechanical).
CONTROL VALVE ACTIVATED BY
AN
ELECTRIC
SOLENOID
(electrical).
MOTOR: To convert hydraulic energy into rotary
mechanical energy.
CONTROL VALVE ACTIVATED BY A
PROPORTIONAL
ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL
HYDRAULIC
MOTOR - With two directions of flow
(bidirectional.
CONTROL VALVE ACTIVATED BY
DUAL ELECTRICAL SOLENOID
(electrical).
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).
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SYMBOL
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
SYMBOL
DESCRIPTION
DESCRIPTION
NON-RETURN VALVE, SHUTTLE VALVE: Valve which
allows free flow in one direction only.
DIRECTIONAL CONTROL VALVE: Valve providing for the
opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).
NON-RETURN VALVE (Check Valve)
- Used as Replenishing Valve, Lock
Check Valve or Anticavitation Valve Opens if the Inlet pressure is higher
than the Outlet pressure. Often
contains internal spring which has NO
significant pressure value.
TWO PORTS and CLOSED FLOW
PATHS
OUT
OUT
IN
SPRING LOADED VALVE (bypass
Valve) - Opens if the Inlet pressure is
greater than the Outlet pressure plus
the spring pressure.
IN
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE (Two Position) controlled by pressure (with return
spring).
PILOT
CONTROLLED
NONRETURN VALVE- It is possible to
open the valve by pilot pressure.
IN
OUT
SOLENOID
ACTIVATED
DIRECTIONAL CONTROL VALVE
(Two Position) - controlled by an
electric solenoid (with return spring).
MANUALLY ACTIVATED DIRECTION
CONTROL VALVE (Variable Position)
Joystick Controlled, variable pressure
to shift the pilot activated directional
control valve spool.
T
IN
OUT
ST
SHUTTLE VALVE - The Inlet port
connected to the higher pressure is
automatically connected to the Outlet
port while the other Inlet port is
closed.
D
IS
IN
O
P
FRONT
BACK
MANUALLY
ACTIVATED
FLOW
CONTROL VALVE (Two Position)
allows for changing pilot flow to
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING
CONTROL
VALVE
(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.
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SYMBOL
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
SYMBOL
SYMBOL
DESCRIPTION
PRESSURE CONTROL VALVE: Valve ensuring the
control of pressure.
OUT
IN
IN
OUT
OUT
MISCELLANEOUS
ACCUMULATOR
Supplies
temporary reserve pressure to the
hydraulic system when the engine
has been stopped.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE When the Inlet pressure overcomes
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE When the Inlet pressure overcomes
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
Dealer Copy -- Not for Resale
IN
RELIEF VALVE - When the Inlet
pressure overcomes the opposing
force of the spring, the valve opens
permitting flow from the Outlet port.
DESCRIPTION
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).
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HYDRAULIC SYSTEM INFORMATION (CONT’D)
WARNING
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat service personnel
only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
If a service code appears in the left instrument panel.
(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM
CAUSE
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
Dealer Copy -- Not for Resale
The hydraulic system will not operate.
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 SPEC50-1.)
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.
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CYLINDER (LIFT)
Figure 20-20-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
2
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Figure 20-20-1
1
P101721
Install a cap (Item 1) [Figure 20-20-2] on the hose and
tighten.
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.
1
P101720
Test only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-20-1] from the base end of the
cylinder.
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Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
CYLINDER (LIFT) (CONT’D)
Figure 20-20-4
Removal And Installation
NOTE: Remove only one cylinder at a time.
2
IMPORTANT
1
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P100298
I-2003-0888
Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
Place the hoses (Item 2) [Figure 20-20-4] in a suitable
container to collect the hydraulic fluid as the lift arms are
raised.
1
Recycle or dispose of used fluid in an environmentally
safe manner.
WARNING
P101720
Mark and disconnect the two hydraulic hoses (Item 1)
[Figure 20-20-3].
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2072-0807
W-2103-0508
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NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
CYLINDER (LIFT) (CONT’D)
DANGER
Removal And Installation (Cont’d)
Figure 20-20-5
P-90328
•
1
•
P101724
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Installation: Tighten the bolt and nut to 48 - 54 N•m (35 40 ft-lb) torque.
Figure 20-20-6
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
1
P101723
Remove the pin (Item 1) [Figure 20-20-6] from the rod
end of the cylinder.
NOTE: The center of the pin is threaded to allow the
use of a suitable puller for pin removal.
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Remove the bolt and nut (Item 1) [Figure 20-20-5] from
the pin on the rod end of the cylinder.
CYLINDER (LIFT) (CONT’D)
Open the rear door.
Removal And Installation (Cont’d)
NOTE: When removing the left side cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Figure 20-20-7
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Figure 20-20-9
1
P-90605
Using a chain hoist raise the lift arms and install an
approved lift arm support device on the cylinder that is
connected to the lift arm.
Figure 20-20-8
P-90834
Remove the bolt and nut (Item 1) [Figure 20-20-9] from
the pin on the base end of the cylinder.
Installation: Tighten the bolt and nut to 48 - 54 N•m (35 40 ft-lb) torque.
2
1
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder
and install a strap (Item 2) [Figure 20-20-8] to secure the
cylinder.
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1
Install a sling (Item 1) [Figure 20-20-7] in the middle of
the Bob-Tach.
CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)
Figure 20-20-10
2
1
P-90825
Dealer Copy -- Not for Resale
NOTE: The center of the pin is threaded. Remove the
grease fitting (Item 1) [Figure 20-20-10] and
use a suitable puller to remove the pin.
Installation: Tighten the grease fitting to 20 N•m (15 ftlb) torque.
Remove the pin (Item 2) [Figure 20-20-10] from the base
end of the cylinder.
Figure 20-20-11
1
P-90823
Using a chain hoist remove the cylinder (Item 1) [Figure
20-20-11] from the loader.
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CYLINDER (LIFT) (CONT’D)
Parts Identification
1
1.
2.
3.
4.
5.
6.
7.
8.
2
Plug
O-ring
Tube
Nut
Seal
Piston
Spacer
Back-up Ring
9.
10.
11.
12.
13.
Head
Rod Seal
Wiper
Rod
Grease Fitting
3
1
2
4
Dealer Copy -- Not for Resale
5
2
6
7
2
8
2
9
10
11
12
13
NA6766S
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CYLINDER (LIFT) (CONT’D)
Figure 20-20-14
Disassembly
2
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
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.
3
P-48038
Figure 20-20-12
NOTE: If the fiber surface (Item 3) [Figure 20-20-14]
on the piston becomes damaged, the piston
must be replaced.
1
Figure 20-20-15
3
1
P-81032
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-20-12] to loosen the head.
2
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
1
Figure 20-20-13
P-48039
4
3
Remove the O-ring (Item 1), back-up ring (Item 2), and
the O-ring (Item 3) [Figure 20-20-15].
2
1
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-20-13].
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Remove the seal (Item 1) and O-ring (Item 2) from the
piston (Item 3) [Figure 20-20-14].
CYLINDER (LIFT) (CONT’D)
Disassembly (Cont’d)
Figure 20-20-16
3
4
2
1
P-81036
Dealer Copy -- Not for Resale
Remove the wiper seal (Item 1) and rod seal (Item 2)
from the inside of the head (Item 3) [Figure 20-20-16].
Remove the wear ring (Item 4) [Figure 20-20-16].
Figure 20-20-17
2
1
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-2017].
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CYLINDER (LIFT) (CONT’D)
Figure 20-20-19
Assembly
3
Clean all parts in solvent and dry with compressed air.
1
2
Inspect the cylinder parts for wear or damage. Replace
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
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-20-19].
Figure 20-20-20
N-22358
P-7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-18].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-20-20].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Figure 20-20-18
CYLINDER (LIFT) (CONT’D)
Figure 20-20-23
Assembly (Cont’d)
Figure 20-20-21
P-7425
Install the rod seal in the head [Figure 20-20-23].
P-7427
Figure 20-20-24
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-20-22
1
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 2020-24] toward the outside of the head.
Figure 20-20-25
N20613
1
Rotate the handles to collapse the rod seal [Figure 2020-22].
N-22356
Install the wear ring (Item 1) [Figure 20-20-25].
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Install the rod seal on the rod seal tool [Figure 20-20-21].
CYLINDER (LIFT) (CONT’D)
Figure 20-20-28
Assembly (Cont’d)
Figure 20-20-26
1
1
2
2
81039
3
Install the O-ring (Item 1) and plug (Item 2) [Figure 2020-28].
P-48039
Tighten the plug to 50 N•m (37 ft-lb) torque.
Install the O-ring (Item 1) [Figure 20-20-26].
Dealer Copy -- Not for Resale
Put the base end of the cylinder in a vise.
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
4
1
P-81032
P-48036
Install the head (Item 1), spacer (Item 2), and the piston
(Item 3) [Figure 20-20-27] on the rod.
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-20-29] to tighten the head. Tighten
the head to 373 N•m (275 ft-lb) torque.
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.
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Figure 20-21-2
CYLINDER (TILT)
Testing
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
1
WARNING
2
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P106670
Install a plug (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.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-21-2]. Remove the cylinder for repair.
1
Repeat procedure to test the other cylinder.
P106669
Test only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-21-1] from the base end of the
cylinder.
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Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
CYLINDER (TILT) (CONT’D)
Figure 20-21-5
Removal And Installation
Remove the attachment from the Bob-Tach. Roll the BobTach forward.
2
Stop the engine. Raise the seat bar.
1
Figure 20-21-3
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-215] from the cylinder.
Dealer Copy -- Not for Resale
Remove the base end pivot bolt and washer (Item 2)
[Figure 20-21-5].
Figure 20-21-6
P-85554
Remove the bolt and nut (Item 1) [Figure 20-21-3] from
the rod end pivot pin.
1
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 20-21-4
1
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].
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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
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 2021-9].
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P106671
CYLINDER (TILT) (CONT’D)
Parts Identification
Tube
Grease Fitting
O-ring
Plug
Nut
Seal
Piston
Back-up Ring
Head
Rod Seal
Wiper
Rod
Bushing
2
1
3
4
5
6
4
3
3
7
Dealer Copy -- Not for Resale
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
3
8
3
9
10
11
2
12
13
NA6577S
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CYLINDER (TILT) (CONT’D)
Figure 20-21-12
Disassembly
3
2
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
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.
P-48071
Figure 20-21-10
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
2
1
P-53073
3
Remove the bushing (Item 1) [Figure 20-21-10].
Figure 20-21-11
P-48073
Remove the seal (Item 1) and O-ring (Item 2) from the
piston (Item 3) [Figure 20-21-13].
1
1
P-81032
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-21-11] to loosen the head.
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
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Figure 20-21-13
1
CYLINDER (TILT) (CONT’D)
Figure 20-21-16
Disassembly (Cont’d)
Figure 20-21-14
1
2
1
3
2
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-2116].
P-48039
Dealer Copy -- Not for Resale
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
3
4
2
1
P-81036
Remove the wiper seal (Item 1) and rod seal (Item 2)
from the inside of the head (Item 3) [Figure 20-21-15].
Remove the wear ring (Item 4) [Figure 20-21-15].
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CYLINDER (TILT) (CONT’D)
Figure 20-21-18
Assembly
2
Clean all parts in solvent and dry with compressed air.
1
Inspect the cylinder parts for wear or damage. Replace
any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during
installation.
3
Use the following tools to assemble the cylinder:
P-48073
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-21-18].
Figure 20-21-19
N-22358
P-7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-17].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-21-19].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Figure 20-21-17
CYLINDER (TILT) (CONT’D)
Figure 20-21-22
Assembly (Cont’d)
Figure 20-21-20
P-7425
Install the rod seal in the head [Figure 20-21-22].
P-7427
Figure 20-21-23
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-21-21
1
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 2021-23] toward the outside of the head.
N20613
Rotate the handles to collapse the rod seal [Figure 2021-21].
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Install the rod seal on the rod seal tool [Figure 20-21-20].
CYLINDER (TILT) (CONT’D)
Figure 20-21-26
Assembly (Cont’d)
1
2
Figure 20-21-24
3
1
P-48071
Install the wear ring (Item 1) [Figure 20-21-24].
Grease the piston where the nut contacts the piston. Do
not get grease on the threads.
Figure 20-21-25
Provide an adequate support for the cylinder before
tightening.
1
NOTE: Clean and dry the rod threads. Install a NEW
NUT with preapplied Loctite®.
Install the nut (Item 3) [Figure 20-21-26].
Tighten the nut to 1152 N•m (850 ft-lb) torque.
2
Figure 20-21-27
3
P-48039
P101716
Install the O-ring (Item 1) [Figure 20-21-25].
Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-21-25].
1
2
81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 2021-27].
Tighten the plug to 20 N•m (15 ft-lb) torque.
Put the base end of the cylinder in a vise.
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Dealer Copy -- Not for Resale
Install the head (Item 1) and the piston (Item 2) [Figure
20-21-26] on the rod.
N-22356
CYLINDER (TILT) (CONT’D)
Assembly (Cont’d)
Figure 20-21-28
1
1
P-81032
Dealer Copy -- Not for Resale
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-21-28] to tighten the head. Tighten
the head to 373 N•m (275 ft-lb) torque.
Figure 20-21-29
1
P-53073
Install the bushing (Item 1) [Figure 20-21-29]. The
bushing must be aligned with the grease channel in the
cylinder.
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CYLINDER (LIFT) (B42T11022 & ABOVE)
Figure 20-22-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
2
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Figure 20-22-1
1
P101721
Install a cap (Item 1) [Figure 20-22-2] on the hose and
tighten.
Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-22-2], remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
1
P101720
Test only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-22-1] from the base end of the
cylinder.
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Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-4
Removal And Installation
NOTE: Remove only one cylinder at a time.
2
IMPORTANT
1
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P100298
I-2003-0888
Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-22-4].
Figure 20-22-3
Place the hoses (Item 2) [Figure 20-22-4] in a suitable
container to collect the hydraulic fluid as the lift arms are
raised.
1
Recycle or dispose of used fluid in an environmentally
safe manner.
WARNING
P101720
Mark and disconnect the two hydraulic hoses (Item 1)
[Figure 20-22-3].
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2072-0807
W-2103-0508
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Dealer Copy -- Not for Resale
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-22-4].
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Removal And Installation (Cont’d)
Figure 20-22-5
1
P101724
Dealer Copy -- Not for Resale
Remove the bolt and nut (Item 1) [Figure 20-22-5] from
the pin on the rod end of the cylinder.
Installation: Tighten the bolt and nut to 48 - 54 N•m (35 40 ft-lb) torque.
Figure 20-22-6
1
P101723
Remove the pin (Item 1) [Figure 20-22-6] from the rod
end of the cylinder.
NOTE: The center of the pin is threaded to allow the
use of a suitable puller for pin removal.
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CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-7
Removal And Installation (Cont’d)
DANGER
1
P-90605
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Install a sling (Item 1) [Figure 20-22-7] in the middle of
the Bob-Tach.
Using a chain hoist raise the lift arms and install an
approved lift arm support device on the cylinder that is
connected to the lift arm.
Figure 20-22-8
WARNING
2
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder
and install a strap (Item 2) [Figure 20-22-8] to secure the
cylinder.
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•
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-10
Removal And Installation (Cont’d)
2
Open the rear door.
NOTE: When removing the left side cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
1
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Figure 20-22-9
P-90825
Installation: Tighten the grease fitting to 20 N•m (15 ftlb) torque.
1
Remove the pin (Item 2) [Figure 20-22-10] from the base
end of the cylinder.
Figure 20-22-11
P-90834
Remove the bolt and nut (Item 1) [Figure 20-22-9] from
the pin on the base end of the cylinder.
Installation: Tighten the bolt and nut to 48 - 54 N•m (35 40 ft-lb) torque.
1
P-90823
Using a chain hoist remove the cylinder (Item 1) [Figure
20-22-11] from the loader.
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NOTE: The center of the pin is threaded. Remove the
grease fitting (Item 1) [Figure 20-22-10] and
use a suitable puller to remove the pin.
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Parts Identification
1.
2.
3.
4.
5.
2
Tube
Grease Fitting
Nut
Piston
Seal
6.
7.
8.
9.
10.
O-ring
Spacer
Head
Wiper
Rod
1
3
4
5
6
7
Dealer Copy -- Not for Resale
6
5
6
6
8
5
9
10
2
NA14140S
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CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-13
Disassembly
1
3
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
MEL1076 - Adjustable Gland Nut Wrench
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.
2
Figure 20-22-12
P131804
Remove the nut (Item 1), piston (Item 2), and spacer
(Item 3) [Figure 20-22-13].
1
1
2
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the
notch (Item 2) [Figure 20-22-12] to loosen the head.
2
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 2022-14] from the piston.
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Figure 20-22-14
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-17
Disassembly (Cont’d)
1
2
Figure 20-22-15
1
P131810
Remove the wiper (Item 1) and seal (Item 2) [Figure 2022-17] from the inside of the head.
P131809
Figure 20-22-18
Remove the O-ring (Item 1) [Figure 20-22-15] from the
spacer.
Figure 20-22-16
1
1
2
P131811
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-22-18] from the outside of the head.
P131805
Remove the head (Item 1) [Figure 20-22-16] from the
rod.
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1
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-20
Assembly
2
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace
any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during
installation.
1
Use the following tools to assemble the cylinder:
P131807
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1076 - Adjustable Gland Nut Wrench
Install the seal (Item 1) and O-ring (Item 2) [Figure 2022-20] on the piston.
Figure 20-22-21
N-22358
P-7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-19].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-22-21].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Figure 20-22-19
CYLINDER (LIFT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-22-24
Assembly (Cont’d)
Figure 20-22-22
1
1
2
N20613
Rotate the handles to collapse the rod seal [Figure 2022-24].
P131811
Figure 20-22-25
Figure 20-22-23
P-7425
Install the rod seal in the head [Figure 20-22-25].
P-7427
Install the rod seal on the rod seal tool [Figure 20-22-23].
NOTE: During installation, the spring side of the seal
must be toward the inside of the cylinder.
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Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-22-22] onto the outside of the head.
CYLINDER (LIFT) (B3GZ11341 & ABOVE) (CONT'D)
Figure 20-22-28
Assembly (Cont’d)
1
Figure 20-22-26
1
P131809
Install the O-ring (Item 1) [Figure 20-22-28] in the
spacer.
P131810
Figure 20-22-29
1
Figure 20-22-27
1
P131808
Install the spacer (Item 1) [Figure 20-22-29] on the rod.
P131805
Install the head (Item 1) [Figure 20-22-27] onto the rod.
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Install the wiper seal with the wiper (Item 1) [Figure 2022-26] toward the outside of the head.
CYLINDER (LIFT) (B3GZ11341 & ABOVE) (CONT'D)
Figure 20-22-32
Assembly (Cont’d)
Figure 20-22-30
1
1
P131804
Install the nut (Item 1) [Figure 20-22-32].
P131806
Tighten the nut to 780 N•m (575 ft-lb) torque.
Put the base end of the cylinder in a vise.
Figure 20-22-31
Figure 20-22-33
Dealer Copy -- Not for Resale
Install the piston (Item 1) [Figure 20-22-30] on the rod.
1
2
1
P131816
P131818
Provide an adequate support for the cylinder before
tightening.
NOTE: Clean and dry the rod threads. Apply thread
locking adhesive (Item 1) [Figure 20-22-31].
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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 20-2233] onto the head. Tighten to 550 N•m (405 ft-lb) torque.
20-22-12
S530 Service Manual
Figure 20-23-2
CYLINDER (TILT) (B42T11022 & ABOVE)
Testing
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
1
WARNING
2
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P106670
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.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-23-2], remove the cylinder for repair.
1
Repeat procedure to test the other cylinder.
P106669
Test only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-23-1] from the base end of the
cylinder.
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Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-5
Removal And Installation
Remove the attachment from the Bob-Tach. Roll the BobTach forward
2
Stop the engine. Raise the seat bar.
1
Figure 20-23-3
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-235] from the cylinder.
Dealer Copy -- Not for Resale
Remove the base end pivot bolt and washer (Item 2)
[Figure 20-23-5].
Figure 20-23-6
P-85554
Remove the bolt and nut (Item 1) [Figure 20-23-3] from
the rod end pivot pin.
1
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 20-23-4
1
P-85648
Remove the nut and washer (Item 1) [Figure 20-23-6]
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 20-23-4].
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CYLINDER (TILT) (B42T11022 & 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
Removal And Installation on Page 20-23-2.)
Figure 20-23-7
Figure 20-23-8
1
P106673
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 2023-9].
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P106671
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Parts Identification
2
1.
2.
3.
4.
5.
1
Tube
Grease Fitting
Nut
Piston
Seal
3
6.
7.
8.
9.
10.
O-ring
Head
Wiper
Rod
Bushing
4
5
Dealer Copy -- Not for Resale
6
6
5
6
7
5
8
9
2
6
6
10
NA14141S
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CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-11
Disassembly
1
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
MEL1076 - Adjustable Gland Nut Wrench
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.
2
Figure 20-23-10
P131889
Remove the nut (Item 1), and piston (Item 2) [Figure 2023-11].
1
1
2
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the
notch (Item 2) [Figure 20-23-10] to loosen the head.
2
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 2023-12] from the piston.
167 of 1148
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Dealer Copy -- Not for Resale
Figure 20-23-12
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-15
1
Disassembly (Cont’d)
Figure 20-23-13
1
1
2
P131811
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-23-15] from the outside of the head.
P131805
Dealer Copy -- Not for Resale
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 2023-14] from the inside of the head.
168 of 1148
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CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-17
Assembly
2
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace
any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during
installation.
1
Use the following tools to assemble the cylinder:
P131807
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1076 - Adjustable Gland Nut Wrench
Install the seal (Item 1) and O-ring (Item 2) [Figure 2023-17] on the piston.
Figure 20-23-18
N-22358
P-7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-23-16].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-23-18].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Figure 20-23-16
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-21
Assembly (Cont’d)
Figure 20-23-19
1
1
2
N20613
Rotate the handles to collapse the rod seal [Figure 2023-21].
P131811
Figure 20-23-22
Figure 20-23-20
P-7425
Install the rod seal in the head [Figure 20-23-22].
P-7427
Install the rod seal on the rod seal tool [Figure 20-23-20].
NOTE: During installation, the spring side of the seal
must be toward the inside of the cylinder.
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Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-23-19] onto the outside of the head.
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Figure 20-23-25
Assembly (Cont’d)
1
Figure 20-23-23
1
P131806
Install the piston (Item 1) [Figure 20-23-25] on the rod.
P131810
Figure 20-23-26
Install the wiper seal with the wiper (Item 1) [Figure 2023-23] toward the outside of the head.
Figure 20-23-24
1
P131816
Provide an adequate support for the cylinder before
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.
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1
CYLINDER (TILT) (B42T11022 & ABOVE) (CONT'D)
Assembly (Cont’d)
Figure 20-23-27
1
P131889
Dealer Copy -- Not for Resale
Install the nut (Item 1) [Figure 20-23-27].
Tighten the nut to 780 N•m (575 ft-lb) torque.
Put the base end of the cylinder in a vise.
Figure 20-23-28
2
1
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 20-2328] onto the head. Tighten to 550 N•m (405 ft-lb) torque.
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Figure 20-24-2
CYLINDER (BOB-TACH)
Testing
WARNING
1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
P106674
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-24-2] from the
cylinder base end port.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
1
W-2103-0508
Figure 20-24-1
2
P106675
Install a plug in the hose (Item 1) [Figure 20-24-3] and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch
(Front Accessory Panel).
P106772
Tilt the Bob-Tach forward, parallel to the floor [Figure 2024-1].
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-24-3], remove the cylinder for repair.
Push and hold BOB-TACH “WEDGES UP” switch until
levers are in the unlocked position (Wedges fully raised).
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Figure 20-24-3
CYLINDER (BOB-TACH) (CONT'D)
Removal And Installation
Figure 20-24-4
1
P106672
Dealer Copy -- Not for Resale
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.
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 ftlb) torque.
Remove the cylinder from the lever pivots.
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CYLINDER (BOB-TACH) (CONT’D)
Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Tube
Nut
Seal
O-ring
Piston
Spacer
Back-up Ring
Head
Seal
Wiper
Rod
1
2
4
5
3
Dealer Copy -- Not for Resale
6
4
7
4
8
9
10
11
NA2603S
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20-24-3
S530 Service Manual
Figure 20-24-8
CYLINDER (BOB-TACH) (CONT’D)
Disassembly
3
2
Clean the outside of the cylinder before disassembly.
1
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
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.
P-16295
Figure 20-24-6
Remove the seal (Item 1) and O-ring (Item 2) from the
piston (Item 3) [Figure 20-24-8].
Figure 20-24-9
5
2
1
1
P-81032
3
4
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-24-6] to loosen the head.
N-20611
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
Remove the wiper seal (Item 1), rod seal (Item 2), backup ring (Item 3), O-ring (Item 4) and O-ring (Item 5)
[Figure 20-24-9] from the head.
Figure 20-24-7
4
3
2
1
P-16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-24-7].
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1
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-24-11
Assembly
3
Clean all parts in solvent and dry with compressed air.
1
2
Inspect the cylinder parts for wear or damage. Replace
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:
P16295
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-24-11].
Figure 20-24-12
N-22358
P-7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-24-10].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-24-12].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Figure 20-24-10
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-24-15
Assembly (Cont’d)
Figure 20-24-13
P-7425
Install the rod seal in the head [Figure 20-24-15].
P-7427
Figure 20-24-16
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-24-14
1
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 2024-16] toward the outside of the head.
N20613
Rotate the handles to collapse the rod seal [Figure 2024-14].
178 of 1148
20-24-6
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Dealer Copy -- Not for Resale
Install the rod seal on the rod seal tool [Figure 20-24-13].
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-24-19
Assembly (Cont’d)
Figure 20-24-17
1
1
2
1
P-81032
3
Insert the Adjustable Gland Nut Wrench into the holes
(Item 1) [Figure 20-24-19] to tighten the head. Tighten
the head to 183 N•m (135 ft-lb) torque.
P101716
Dealer Copy -- Not for Resale
Install the O-ring (Item 1) [Figure 20-24-17].
Install the back-up ring (Item 2) and O-ring (Item 3)
[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.
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 20-24-18].
Tighten the nut to 190 N•m (140 ft-lb) torque.
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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.)
Dealer Copy -- Not for Resale
The main relief valve is adjustable and is located on the
hydraulic control valve near the bottom, facing the front of
the loader.
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20-30-1
S530 Service Manual
MAIN RELIEF VALVE (CONT’D)
Figure 20-30-1
Testing
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
1
I-2024-0284
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
cause injury or death.
Connect the IN port (Item 1) [Figure 20-30-1] of the
hydraulic tester to the bottom (female) quick coupler on
the loader.
W-2006-1209
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.
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.
Figure 20-30-2
W-2017-0286
The tools listed will be needed to do the following
procedure:
2
1
MEL10003 or MEL1744 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure on Page 10-101.)
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
hydraulic tester without using any type of
quick coupler on the connection to the tester.
182 of 1148
Press the AUXILIARY HYDRAULICS button (Item 1)
once to engage the auxiliary hydraulics. The light (Item 2)
[Figure 20-30-2] will be on.
20-30-2
S530 Service Manual
Dealer Copy -- Not for Resale
P106632
MAIN RELIEF VALVE (CONT’D)
Figure 20-30-4
Testing (Cont’d)
Figure 20-30-3
1
1
P106632
1
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-30-3]
to allow constant auxiliary hydraulic fluid flow to the front
female coupler (female coupler is pressurized).
To stop continuous auxiliary hydraulic fluid flow, press the
front auxiliary hydraulic switch (Item 1) [Figure 20-30-3]
a second time.
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System
(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.
NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
Turn the restrictor control (Item 1) [Figure 20-30-4]
counterclockwise to obtain free flow.
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.
Start turning the restrictor clockwise, causing more
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
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.
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Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 1) [Figure 20-30-4] clockwise on the tester
until it reads 6895 kPa (69 bar) (1000 psi).
P106677
MAIN RELIEF VALVE (CONT’D)
Adjusting
Raise the operator cab. (See Raising on Page 10-30-2.)
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
Dealer Copy -- Not for Resale
1
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.
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MAIN RELIEF VALVE (CONT’D)
Figure 20-30-7
Removal And Installation
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2
I-2003-0888
P107745A
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-30-7] from the main relief valve.
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.
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
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.)
1
P106708
Remove the main relief valve (Item 1) [Figure 20-30-6].
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Clean the area around the control valve.
Dealer Copy -- Not for Resale
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HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P107871
Dealer Copy -- Not for Resale
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.
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HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Removal And Installation
Remove the control linkage. (See Linkage Removal And
Installation on Page 50-90-2.)
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
DANGER
Clean area around control valve.
Open rear door.
Figure 20-40-2
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
3
2
D-1009-0409
1
P114643
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.
Disconnect the electrical connector (Item 1), remove the
two bolts (Item 2), and reposition the fuel filter assembly
(Item 3) [Figure 20-40-2].
Figure 20-40-3
3
W-2059-0598
4
IMPORTANT
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
5
P114645
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.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
188 of 1148
Reposition clamp (Item 1), remove nut / bolt (Item 2),
remove the fuel tank vent hose (Item 3), and remove the
two mounting bracket nuts / bolts (Item 4) [Figure 20-403].
Remove the filler neck assembly and plug the fuel tank
inlet.
20-40-2
S530 Service Manual
Dealer Copy -- Not for Resale
•
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-6
Removal And Installation (Cont’d)
Figure 20-40-4
1
2
1
P106832
Remove the hose (Item 1) [Figure 20-40-6] that routes
from the control valve to the filter.
P106822
Dealer Copy -- Not for Resale
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed
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 20-40-4].
Remove the tubeline (Item 2) [Figure 20-40-6] that
routes from the control valve to the fan motor.
Figure 20-40-7
Figure 20-40-5
1
1
2
3
1
P106833
1
Remove the auxiliary hydraulic tubelines (Item 1) [Figure
20-40-7].
1
P106831
Disconnect the wire harness (Item 1) [Figure 20-40-5]
from the control valve.
Remove the hose (Item 2) [Figure 20-40-5] that routes
from the control valve to the drain manifold.
Remove the tubeline (Item 3) [Figure 20-40-5] that
routes from the control valve to the brake valve.
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S530 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-10
Removal And Installation (Cont’d)
Figure 20-40-8
1
3
2
P106836
1
P106834
Remove the bolt (Item 1) [Figure 20-40-8] and tubeline
clamp.
Remove the lift arm bypass drain hose (Item 2) [Figure
20-40-10] from the control valve.
Remove the hose (Item 3) [Figure 20-40-10] that runs
from the control valve to the outlet fitting of the hydraulic
pump.
Figure 20-40-9
1
1
P-106835
Remove the three tubelines (Item 1) [Figure 20-40-9]
that route from the control valve to the junction block at
the rear of the loader.
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Remove the hose (Item 1) [Figure 20-40-10] that routes
from the control valve to the junction block at the rear of
the machine.
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Mount Bracket Removal And Installation
Figure 20-40-13
Removal And Installation (Cont’d)
Figure 20-40-11
1
1
P-90280
Support the mounting bracket (Item 1) [Figure 20-40-13].
Remove the clips and pins (Item 1) [Figure 20-40-11]
from the linkage.
Figure 20-40-14
Figure 20-40-12
1
Dealer Copy -- Not for Resale
P106837
1
1
P110095
Remove the two control valve mount bolts (Item 1)
[Figure 20-40-14].
P-106838
Support the control valve and remove the two bolts (Item
1) [Figure 20-40-12].
Remove the control valve bracket from the loader.
Remove the control valve from the loader.
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HYDRAULIC CONTROL VALVE (STANDARD) (CONT’D)
Identification Chart
Figure 20-40-15
C2
B3
F2
J4
C3
J2
E3
E3 G1
G2
D5
A3
A2
B2
D4
D6
F4
D3
E2
C4
H2
D1
D2
F3
MR
H1
F1
J1
C1
H3
E1
J3
NA5826
ITEM
DESCRIPTION
ITEM
DESCRIPTION
A1
A2
A3
B1
B2
B3
C1
C2
C3
C4
D1
Lift Cylinder Base End
Tilt Cylinder Base End
Auxiliary Hydraulic Female Coupler
Lift Cylinder Rod End
Tilt Cylinder Rod End
Auxiliary Hydraulics Male Coupler
Load Check
Load Check Valve Tilt Function
Load Check Valve Auxiliary Function
Check Valve
Anti-Cavitation Valve
Lift (Rod End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(276 bar) (4000 psi)
Lift (Base End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(276 bar) (4000 psi)
Tilt (Base End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(276 bar) (4000 psi)
Tilt (Rod End)
Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)
Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)
E1
E2
E3
F1
F2
F3
F4
G1
G2
H1
Lift Spool Detent
Tilt Spool Centering Spring
Auxiliary Spool / Centering Springs
Lift Spool
Tilt Spool
Lift Spool Lock Solenoid
Tilt Spool Lock Solenoid
Auxiliary Solenoid Stem
Auxiliary Solenoid Stem
H2
BICS™ Lock Valve (Tilt)
H3
BICS™ Lock Valve (Lift)
J1
J2
J3
J4
Inlet Fluid Flow (From Pump)
Outlet Fluid Flow (Return to Tank)
Lift Arm Bypass Orifice
D2
D3
D4
D5
D6
192 of 1148
MR
20-40-6
BICS™ Solenoid
Drain (Case)
Main Relief Valve – 24131 kPa (241 bar)
(3500 psi)
S530 Service Manual
Dealer Copy -- Not for Resale
A1
B1
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-17
Lift Load Check Valve Removal And Installation
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P107873
Figure 20-40-16
Remove the lift load check valve (Item 1) [Figure 20-4017] and fitting from the top of the control valve.
Figure 20-40-18
1
1
5
P107872
2
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS™ valve fitting on the top of the lift load
check valve.
3
4
P107716
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-18].
Inspect the spring (Item 3) for free movement in the load
check valve (Item 4) [Figure 20-40-18].
Inspect the orifice (Item 5) [Figure 20-40-18] to make
sure it is not plugged.
193 of 1148
20-40-7
S530 Service Manual
Dealer Copy -- Not for Resale
Installation: Lubricate the O-ring and threads and
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-20
Load Check Valve Removal And Installation (Tilt And
Auxiliary)
Figure 20-40-19
1
2
4
1
3
2
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-20].
At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-4019].
Installation: Install a new O-ring (Item 4) [Figure 20-4020] and lubricate with oil before installing. Tighten the
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
20-40-19].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
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Inspect the orifice (Item 3) [Figure 20-40-20] in the
poppet to make sure it is not plugged.
P107874
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End)
Figure 20-40-23
Figure 20-40-21
1
1
P107628
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Remove the lift circuit port relief / anti-cavitation valve
and the port relief / anti-cavitation seat (Item 1) [Figure
20-40-23].
Figure 20-40-24
Figure 20-40-22
1
2
2
1
4
P107952
3
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-22].
Inspect the orifice (Item 3) [Figure 20-40-22] in the
poppet to make sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-4022] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb)
torque.
195 of 1148
Remove the O-ring (Item 1) [Figure 20-40-24] from the
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-24] for wear or damage and replace as
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.
20-40-9
S530 Service Manual
Dealer Copy -- Not for Resale
P107628
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT'D)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Figure 20-40-27
Figure 20-40-25
1
1
P107628
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-40-25] from the base end of the tilt section.
Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-27]
from the rod end of the tilt section.
Figure 20-40-28
Figure 20-40-26
2
1
1
P107952
P107629
Remove the O-ring (Item 1) [Figure 20-40-26] from the
port relief / anti-cavitation relief valve.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Remove the O-ring (Item 1) [Figure 20-40-28] from the
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-28] for wear or damage and replace as
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.
196 of 1148
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Dealer Copy -- Not for Resale
P107628
Figure 20-40-31
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT'D)
Port Relief Valve Removal And Installation
Figure 20-40-29
1
1
P107628
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-40-31].
P107628
Remove the auxiliary port relief valve.
Figure 20-40-32
Dealer Copy -- Not for Resale
Remove the port relief plug (Item 1) [Figure 20-40-29]
from the auxiliary circuit of the control valve.
Figure 20-40-30
1
1
P107629
2
Remove the O-ring (Item 1) [Figure 20-40-32] from the
optional auxiliary port relief valve.
P107630
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-30] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
197 of 1148
20-40-11
S530 Service Manual
Figure 20-40-35
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-33
1
1
P107628
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-40-35].
P107628
Remove the auxiliary port relief valve.
Figure 20-40-36
Dealer Copy -- Not for Resale
Remove the port relief plug (Item 1) [Figure 20-40-33]
from the auxiliary circuit of the control valve.
Figure 20-40-34
1
1
2
P107629
Remove the O-ring (Item 1) [Figure 20-40-36] from the
optional auxiliary port relief valve.
P107630
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-34] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
198 of 1148
20-40-12
S530 Service Manual
Figure 20-40-39
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Plug Removal And Installation
Figure 20-40-37
1
1
P107632
At the bottom side of the control valve remove the plug
(Item 1) [Figure 20-40-39].
P107631
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-37].
Figure 20-40-38
1
1
P107633
Remove the O-ring (Item 1) [Figure 20-40-40] from the
plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.
Remove the O-ring (Item 1) [Figure 20-40-38] from the
plug.
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.
199 of 1148
20-40-13
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-40-40
End Cap Block Removal And Installation
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT'D)
Figure 20-40-43
Rubber Boot Removal And Installation
Figure 20-40-41
1
1
2
1
1
P107772
Remove the three screws (Item 1) [Figure 20-40-41] on
the rubber boot retainer plate.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-43] from the
end cap block.
Dealer Copy -- Not for Resale
P-51506
Figure 20-40-44
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-42
1
1
2
P107666
Disconnect the tubeline (Item 1) [Figure 20-40-44] from
the end cap block.
P107664
Remove the rubber boots (Item 1) from the retainer plate
(Item 2) [Figure 20-40-42].
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HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Lift Spool And Detent Removal And Installation
The tools listed will be needed to do the following
procedure:
End Cap Block Removal And Installation (Cont’d)
Figure 20-40-45
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 20-4014.)
Figure 20-40-46
2
1
Remove the end cap block mount screw (Item 1) [Figure
20-40-45].
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
P107776
Remove the end cap block (Item 2) [Figure 20-40-45]
from the control valve.
Remove the O-ring (Item 1) [Figure 20-40-46].
Installation: Replace the O-ring, and lubricate the O-ring
lightly with grease or oil before installation of the end cap
block.
Figure 20-40-47
2
1
P107775
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-47] from the lift spool.
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1
P107773
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-50
Lift Spool And Detent Removal And Installation
(Cont’d)
Figure 20-40-48
2
1
P107846
P107779
Remove the four screws (Item 1) [Figure 20-40-48] from
the spool centering block.
Dealer Copy -- Not for Resale
NOTE: Do not remove the sleeve detent (Item 1) or
retaining ring (Item 2) [Figure 20-40-50] from
the spool centering block. If removed, the
sleeve detent must be inserted with the
original orientation.
1
Figure 20-40-51
Figure 20-40-49
1
2
2
P107845A
1
P107778
Remove the spool centering block (Item 1) [Figure 2040-49].
Remove the O-ring (Item 2) [Figure 20-40-49].
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NOTE: If removed, use the following for correct
installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-40-51]
so it faces the opening of the spool centering
block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
[Figure 20-40-51] so it faces the opening when
seated. Install retaining ring over detent
sleeve.
20-40-16
S530 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-54
Lift Spool And Detent Removal And Installation
(Cont’d)
Figure 20-40-52
P107739
2
Clamp the linkage end of the spool in a vise [Figure 2040-54].
1
Remove the lift spool assembly (Item 1) and O-ring (Item
2) [Figure 20-40-52] from the control valve.
IMPORTANT
Figure 20-40-53
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-55
2
1
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-40-53]
from the linkage end of the valve.
P107674A
Install the spring tool (Item 1) [Figure 20-40-55] over the
centering spring.
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-55] from the centering
spring as it is under spring pressure.
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NOTE: Protect spool before clamping in vise.
P107790
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-58
1
Lift Spool And Detent Removal And Installation
(Cont'd)
Figure 20-40-56
3
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly
(Item 2) [Figure 20-40-58].
2
Remove the spring assembly / spring tool (Item 1) from
the spool (Item 2) [Figure 20-40-56].
3
2
1
4
NOTE: The detent adapter has two detent balls (Item
3) held under pressure from a detent spring
(Item 4) [Figure 20-40-58]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-40-57
P107677
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-59].
1
P107675
Remove the detent adapter (Item 1) [Figure 20-40-57]
from the spring assembly.
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Figure 20-40-59
P107674
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-62
Lift Spool And Detent Removal And Installation
(Cont'd)
Figure 20-40-60
1
N-18967
Clamp the collar (Item 1) [Figure 20-40-62] in a vise.
Figure 20-40-63
Remove the stud from the end of the spool [Figure 2040-60].
3
2
Figure 20-40-61
1
P107677
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-63].
15,2 mm
(0.60 inch)
Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-63] and compress
with the detent pliers (Item 1) [Figure 20-40-64].
B-14712B
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
20-40-61].
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N-18918
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-66
Lift Spool And Detent Removal And Installation
(Cont'd)
Figure 20-40-64
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-40-66].
Install the detent adapter to the collar [Figure 20-40-64].
Inspect the alignment of the detent adapter and the
washer.
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb)
torque.
Figure 20-40-65
Figure 20-40-67
NOTE: The adapter must fit in the center of the
washer.
2
1
1
3
P107675
P107790
Install the spring tool (Item 1) [Figure 20-40-65] over the
washer, spring, collar, and detent adapter.
Lubricate and install a new O-ring (Item 1) [Figure 20-4067].
Lubricate and install a new O-ring (Item 2) [Figure 20-4067].
Install the lift spool assembly (Item 3) [Figure 20-40-67]
in the spool bore.
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Remove the spring tool.
N-18968A
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-70
Lift Spool And Detent Removal And Installation
(Cont'd)
Figure 20-40-68
1
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure
20-40-70] on the lift spool.
2
Install the spool centering block (Item 1) [Figure 20-4068].
Install the four mounting screws (Item 2) [Figure 20-4068].
1
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-69
P107776
1
Install an O-ring (Item 1) [Figure 20-40-71] on the control
valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-40-69] on the
linkage end of the valve.
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Figure 20-40-71
P107779
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-74
Lift Spool And Detent Removal And Installation
(Cont'd)
Figure 20-40-72
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
Install the end cap block (Item 1) and the mount bolt
(Item 2) [Figure 20-40-72].
Installation: Install the lift spool (Item 1) and tilt spool
(Item 2) [Figure 20-40-74] lock solenoids and tighten to
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 20-40-72].
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-73
1
P107666
Connect the tubeline (Item 1) [Figure 20-40-73].
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The correct resistance for the coil is 16.02 - 19.58 ohm.
P107664A
Figure 20-40-77
HYDRAULIC CONTROL VALVE (STANDARD)
(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 20-40-75
1
P107778
Installation: Replace the O-ring (Item 2) [Figure 20-4077] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
2
P107777
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-75] from the tilt spool.
Figure 20-40-78
Installation: Install the spacer (Item 1) and an O-ring
(Item 2) [Figure 20-40-75].
2
Figure 20-40-76
1
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure
20-40-78].
1
Installation: Replace the O-ring (Item 2) [Figure 20-4078] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
P107779
Remove the four screws (Item 1) [Figure 20-40-76] from
the spool centering block.
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
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Remove the spool centering block (Item 1) [Figure 2040-77] from the control valve.
1
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-81
Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-79
1
1
P107647
Remove the bolt (Item 1) [Figure 20-40-81] holding the
centering spring to the spool.
P107781
Remove the tilt spool seal (Item 1) [Figure 20-40-79].
Remove the spring tool from the spring assembly.
Assembly: Always use a new spool seal.
Figure 20-40-82
Figure 20-40-80
2
1
3
1
4
N-18944B
P107646
Put the linkage end of the spool in the vise [Figure 2040-80].
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-82].
NOTE: Protect spool before clamping in vise.
Install the spring tool (Item 1) [Figure 20-40-80] over the
centering spring.
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Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-84
Auxiliary Spool Removal And Installation
Figure 20-40-83
1
3
2
4
1
2
4
P107783
Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-40-84] from the auxiliary spool.
3
P107782
Remove the spacer (Item 3) and O-ring (Item 4) [Figure
20-40-83] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure
20-40-83] must be replaced, replace the
retainer on the opposite end also.
NOTE: If the centering spring retainer (Item 2) [Figure
20-40-84] must be replaced, replace the
retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
[Figure 20-40-84].
Figure 20-40-85
Installation: Lubricate and install an O-ring (Item 4)
[Figure 20-40-83].
1
P107784
Remove the auxiliary spool (Item 1) [Figure 20-40-85].
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Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-40-83] from the auxiliary spool.
Remove the spacer (Item 3) and O-ring (Item 4) [Figure
20-40-84] from the auxiliary spool.
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-87
Auxiliary Solenoid Removal And Installation
1
Figure 20-40-86
2
1
2
2
P107798
1
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-40-87] from the solenoid stem.
P107876
Remove the solenoids (Item 2) [Figure 20-40-86] from
the control valves.
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 20-40-87].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9
in-lb) torque.
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Remove the screws (Item 1) [Figure 20-40-86] from both
solenoids.
Use an ohmmeter to measure the solenoid coil
resistance.
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-90
Solenoid Removal And Installation
Figure 20-40-88
1
1
2
P107876
Remove the solenoid stem (Item 1) [Figure 20-40-90].
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 20-40-88] from the
solenoid stem.
Figure 20-40-91
Dealer Copy -- Not for Resale
P107875
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-88].
3
2
Figure 20-40-89
1
1
1
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-40-91] from the stem.
Clean all parts in solvent and dry with compressed air.
N-18693A
Remove the O-rings (Item 1) [Figure 20-40-89] from both
ends of the solenoid coil.
Use an ohmmeter to measure the solenoid coil
resistance.
Inspect all parts for wear and replace any showing
excessive wear.
NOTE: The screen (Item 3) [Figure 20-40-91] may be
cleaned with solvent. If it is torn or worn,
replace the solenoid valve.
The correct resistance for the coil is 9.5 - 10.08 ohm.
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Figure 20-40-94
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Lock Valve Removal And Installation
Figure 20-40-92
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure
20-40-94] is threaded for easier removal and installation.
P107785
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-4092].
1
3
2
Figure 20-40-93
1
P107767
Remove the O-ring (Item 1) [Figure 20-40-95].
Remove and inspect the spring (Item 2) and BICS™
valve (Item 3) [Figure 20-40-95].
P107786
Remove the lift lock valve (Item 1) [Figure 20-40-93]
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.
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Figure 20-40-95
Figure 20-40-98
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-96
1
2
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure
20-40-98] is threaded for easier removal and installation.
P107788
Remove the lift spool lock solenoid (Item 1) [Figure 2040-96].
1
Remove the tilt spool lock solenoid (Item 2) [Figure 2040-96].
3
2
Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-97
P107767
Remove the O-ring (Item 1) [Figure 20-40-99].
Remove and inspect the spring (Item 2) and BICS™
valve (Item 3) [Figure 20-40-99].
1
P107789
Remove the tilt lock valve (Item 1) [Figure 20-40-97]
from the front 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.
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Figure 20-40-99
Main Relief Valve Removal And Installation
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-102
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-100
1
P107787
1
Remove the main relief valve (Item 1) [Figure 20-40102].
Remove the fitting (Item 1) [Figure 20-40-100] from the
valve.
Figure 20-40-103
Dealer Copy -- Not for Resale
P107693
Figure 20-40-101
1
1
2
P107745A
Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-40-103] from the main relief valve.
P-51437
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40101].
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve
casting.
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HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)
Figure 20-40-106
Check Valve Removal And Installation
Figure 20-40-104
3
1
2
1
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure
20-40-106].
P107693
Remove the tubeline (Item 1) [Figure 20-40-104].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ftlb) torque.
Figure 20-40-105
1
P107786
Remove the check valve fitting (Item 1) [Figure 20-40105] from the hydraulic control valve.
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Remove the O-ring (Item 1) [Figure 20-40-106].
Dealer Copy -- Not for Resale
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
Removal And Installation
Description
DANGER
Figure 20-41-1
P-90328
•
•
The hydraulic control valve is located inside the main
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.
The lift and tilt functions in the hydraulic control valve are
operated using electronic control handles / levers that
send an electronic signal to the electronic actuators to
move the lift and tilt spools in the control valve.
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 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
valve which is adjustable.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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P107847
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-3
3
Removal And Installation (Cont’d)
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
4
2
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
1
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
P114645
Clean area around control valve.
Figure 20-41-2
Remove the filler neck assembly and plug the fuel tank
inlet.
Figure 20-41-4
3
2
1
1
P109629
Disconnect the electrical connector (Item 1), remove the
two bolts (Item 2), and reposition the fuel filter assembly
(Item 3) [Figure 20-41-2].
P106822
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed
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 20-41-4].
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Reposition clamp (Item 1), remove nut / bolt (Item 2),
remove the fuel tank vent hose (Item 3), and remove the
two mounting bracket nuts / bolts (Item 4) [Figure 20-413].
Open rear door.
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-7
Removal And Installation (Cont’d)
Figure 20-41-5
1
3
1
2
P-90271
Disconnect the hose (Item 1) [Figure 20-41-7] that
routes from the top of the control valve to the hydraulic
filter.
P-90269
Disconnect the wire harness connectors (Item 1) [Figure
20-41-5] from the control valve.
Figure 20-41-8
Dealer Copy -- Not for Resale
1
Disconnect the hose (Item 2) [Figure 20-41-5] that
routes from the control valve to the drain manifold.
2
Disconnect the hose (Item 3) [Figure 20-41-5] that
routes from the control valve to the inlet fitting of the
hydraulic pump.
2
1
Figure 20-41-6
2
P-90272
Remove the tubeline clamp (Item 1) [Figure 20-41-8].
Disconnect the two tubelines (Item 2) [Figure 20-41-8]
that route from the control valve to the front auxiliary
hydraulics.
1
P107219
Disconnect the hose (Item 1) [Figure 20-41-6] that
routes from the control valve to the brake valve.
Disconnect the hose (Item 2) [Figure 20-41-6] that
routes from the control valve to the fan motor.
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-11
Removal And Installation (Cont’d)
1
Figure 20-41-9
2
P-90275
1
P-90273
Remove the tubeline clamp (Item 1) [Figure 20-41-9].
Disconnect the lift arm bypass drain hose (Item 2)
[Figure 20-41-11] from the control valve.
Figure 20-41-10
Figure 20-41-12
1
1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-4110] that route from the control valve to the junction block
at the rear of the loader.
222 of 1148
Disconnect the hose (Item 1) [Figure 20-41-12] that
routes from the bottom of the control valve to the outlet
fitting of the hydraulic pump.
20-41-4
S530 Service Manual
Dealer Copy -- Not for Resale
Disconnect the hose (Item 1) [Figure 20-41-11] that
routes from the control valve to the junction block at the
rear of the machine.
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-41-13
1
P-90278
Dealer Copy -- Not for Resale
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-13].
Remove the control valve from the loader.
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-15
Actuator Removal And Installation (In Loader)
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-54587
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Remove the two bolts (Item 1) [Figure 20-41-15] from
the actuator retainer.
Stop the engine. Raise the seat bar.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 100 in-lb) torque.
Dealer Copy -- Not for Resale
Mark the actuator wiring harness connectors for proper
installation.
Figure 20-41-16
Figure 20-41-14
2
1
1
P-54566
P-90330
Disconnect the actuator wire harness (Item 1) [Figure
20-41-14].
Pull the actuator (Item 1) [Figure 20-41-16] away from
the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure
20-41-16] 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 60-160-4.)
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Actuator Removal And Installation (In Loader)
(Cont’d)
Figure 20-41-17
2
1
Dealer Copy -- Not for Resale
P-54568
Inspect the O-ring (Item 1) [Figure 20-41-17] on the face
of the actuator and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-17] and
replace as needed.
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-20
Actuator Removal And Installation (Out Of Loader)
Remove the control valve from the loader.
Figure 20-41-18
1
1
P101625
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-41-20] from the actuator
and the spool.
1
Remove the two mount bolts (Item 1) [Figure 20-41-18]
from the actuator.
Dealer Copy -- Not for Resale
Remove the actuator and linkage pin from the valve.
P101623
Figure 20-41-21
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Figure 20-41-19
1
2
P-54340
Inspect the O-ring (Item 1) [Figure 20-41-21] on the face
of the actuator and replace as needed.
1
Inspect the linkage pin (Item 2) [Figure 20-41-21] and
replace as needed.
P101624
Slide the actuator retainer (Item 1) [Figure 20-41-19]
away from the control valve.
Pull the actuator away from the control valve [Figure 2041-19].
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-24
Actuator Removal And Installation (Out Of Loader)
(Cont’d)
Figure 20-41-22
1
1
P-54343
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-41-24] from the actuator
and the spool.
1
P101626
Remove the two mount bolts (Item 1) [Figure 20-41-22]
from the actuator.
Dealer Copy -- Not for Resale
Remove the actuator and linkage pin from the valve.
Figure 20-41-25
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Figure 20-41-23
1
2
P-54340
1
Inspect the O-ring (Item 1) [Figure 20-41-25] on the face
of the actuator and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-25] and
replace as needed.
P101627
Slide the actuator retainer (Item 1) [Figure 20-41-23]
away from the control valve.
Pull the actuator away from the control valve [Figure 2041-23].
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Actuator Removal And Installation (Out Of Loader)
(Cont’d)
Figure 20-41-26
2
4
1
P101629
Dealer Copy -- Not for Resale
3
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 2041-26].
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 100 in-lb) torque (Item 1) [Figure 20-41-26].
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (CONT’D)
Identification Chart
Figure 20-41-27
F2
J4
B3
E3
C3
J2
C2
E3
G2
G1
D5
A3
D6
A2
B2
C4
D4
D3
E2
D1
H2
D2
H3
A1
C1
H1
J3
J1
NA5825
ITEM
DESCRIPTION
ITEM
DESCRIPTION
A1
A2
A3
B1
B2
B3
C1
C2
C3
C4
D1
Lift Cylinder Base End
Tilt Cylinder Base End
Auxiliary Hydraulics Female Coupler
Lift Cylinder Rod End
Tilt Cylinder Rod End
Auxiliary Hydraulics Male Coupler
Load Check
Load Check Valve Tilt Function
Load Check Valve Auxiliary Function
Check Valve
Anti-Cavitation Valve
Lift (Rod End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(276 bar) (4000 psi)
Lift (Base End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(2756 bar) (4000 psi)
Tilt (Base End)
Port Relief / Anti-Cavitation Valve – 27579 kPa
(276 bar) (4000 psi)
Tilt (Rod End)
Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)
D6
Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)
E1
E2
E3
F1
F2
G1
G2
H1
Lift Spool Detent
Tilt Spool Centering Spring
Auxiliary Spool / Centering Springs
Lift Spool
Tilt Spool
Auxiliary Solenoid Stem
Auxiliary Solenoid Stem
H2
BICS™ Lock Valve (Tilt)
H3
BICS™ Lock Valve (Lift)
J1
J2
J3
J4
MR
Inlet Fluid Flow (From Pump)
Outlet Fluid Flow (Return to Tank)
Lift Arm Bypass Orifice
Drain (Case)
Main Relief Valve – 24132 kPa (241 bar)
(3500 psi)
D2
D3
D4
D5
229 of 1148
20-41-11
BICS™ Solenoid
S530 Service Manual
Dealer Copy -- Not for Resale
MR
F1
E1
B1
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Lift Load Check Valve Removal And Installation
Mount Bracket Removal And Installation
IMPORTANT
Figure 20-41-28
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-41-30
1
P-90280
1
Figure 20-41-29
1
P107848
Remove the charge tubeline (Item 1) [Figure 20-41-30]
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 20-41-29].
Remove the control valve bracket from the loader.
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Dealer Copy -- Not for Resale
Support the mounting bracket (Item 1) [Figure 20-41-28].
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Load Check Valve Removal And Installation (Tilt And
Auxiliary)
Lift Load Check Valve Removal And Installation
(Cont’d)
Figure 20-41-33
Figure 20-41-31
2
1
1
P107849
Remove the lift load check valve (Item 1) [Figure 20-4131] 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.
At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-4133].
At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
20-41-33].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
Figure 20-41-32
Figure 20-41-34
1
5
1
2
2
3
4
4
P107716
3
P107624
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-32].
Inspect the spring (Item 3) and the free movement in the
check valve (Item 4) [Figure 20-41-32].
Inspect the orifice (Item 5) [Figure 20-41-32] to make
sure it is not plugged.
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-34].
Inspect the orifice (Item 3) [Figure 20-41-34] in the
poppet to make sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-4134] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
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P107850
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End)
Figure 20-41-37
Figure 20-41-35
1
1
P107628
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-35].
Remove the lift circuit port relief / anti-cavitation valve
and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-37].
Figure 20-41-38
Figure 20-41-36
1
2
2
1
4
P107952
3
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-36].
Inspect the orifice (Item 3) [Figure 20-41-36] in the
poppet to make sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-4136] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb)
torque.
232 of 1148
Remove the O-ring (Item 1) [Figure 20-41-38] from the
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-38] for wear or damage and replace as
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.
20-41-14
S530 Service Manual
Dealer Copy -- Not for Resale
P107628
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Figure 20-41-41
Figure 20-41-39
1
1
P107628
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-39] from the base end of the tilt section.
Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-41]
from the rod end of the tilt section.
Figure 20-41-42
Figure 20-41-40
2
1
1
P107952
P107629
Remove the O-ring (Item 1) [Figure 20-41-40] from the
port relief / anti-cavitation relief valve.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Remove the O-ring (Item 1) [Figure 20-41-42] from the
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-42] for wear or damage and replace as
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.
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P107628
Figure 20-41-45
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-41-43
1
1
P107628
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-41-45].
P107628
Remove the auxiliary port relief valve.
Figure 20-41-46
Dealer Copy -- Not for Resale
Remove the port relief plug (Item 1) [Figure 20-41-43]
from the auxiliary circuit of the control valve.
Figure 20-41-44
1
1
2
P107629
Remove the O-ring (Item 1) [Figure 20-41-46] from the
optional auxiliary port relief valve.
P107630
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-44] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
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S530 Service Manual
Figure 20-41-49
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-47
1
1
P107628
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-41-49].
P107628
Remove the auxiliary port relief valve.
Figure 20-41-50
Dealer Copy -- Not for Resale
Remove the port relief plug (Item 1) [Figure 20-41-47]
from the auxiliary circuit of the control valve.
Figure 20-41-48
1
1
2
P107629
Remove the O-ring (Item 1) [Figure 20-41-50] from the
optional auxiliary port relief valve.
P107630
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-48] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
235 of 1148
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S530 Service Manual
Figure 20-41-53
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Plug Removal And Installation
Figure 20-41-51
1
1
P107632
At the bottom side of the control valve, remove the plug
(Item 1) [Figure 20-41-53].
P107631
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-51].
Figure 20-41-52
1
1
P107633
Remove the O-ring (Item 1) [Figure 20-41-54] from the
plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.
Remove the O-ring (Item 1) [Figure 20-41-52] from the
plug.
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.
236 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-41-54
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Lift Spool Removal And Installation
The tool listed will be needed to do the following
procedure:
End Cap Block Removal And Installation
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on
Page 20-41-6.)
MEL1285 - Spring Tool
Figure 20-41-55
Figure 20-41-57
Remove the end cap block from the control valve.
1
2
P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-55] from
the end cap block.
Remove the two end cap block mount screws (Item 2)
[Figure 20-41-55].
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
Remove the O-ring (Item 1) [Figure 20-41-57].
Installation: Replace the O-ring, and lubricate lightly
with oil before installation of the end cap block.
Figure 20-41-58
Figure 20-41-56
2
1
P107753
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-58] from the lift spool.
P107852
Remove the end cap block (Item 1) [Figure 20-41-56]
from the control valve.
237 of 1148
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1
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-61
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-59
2
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item
2) [Figure 20-41-61] from the control valve.
1
P107854
Remove the four screws (Item 1) [Figure 20-41-59] from
the spool centering block.
Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-60
1
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-41-62]
from the actuator end of the valve.
1
P107855
Remove the spool centering block (Item 1) and O-ring
(Item 2) [Figure 20-41-60] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-4160] and lubricate lightly with oil before installation of the
spool centering block.
238 of 1148
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Dealer Copy -- Not for Resale
Figure 20-41-62
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-65
Lift Spool Disassembly And Assembly
Figure 20-41-63
1
P107647
Remove the bolt (Item 1) [Figure 20-41-65] holding the
centering spring to the spool.
P107740
NOTE: Protect spool before clamping in vise.
Remove spring tool from the spring assembly.
Figure 20-41-66
Figure 20-41-64
3
2
4
1
1
P-51776B
P107646
Install the spring tool (Item 1) [Figure 20-41-64] over the
centering spring.
239 of 1148
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-66].
20-41-21
S530 Service Manual
Dealer Copy -- Not for Resale
Clamp the actuator end of the spool in a vise [Figure 2041-63].
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-69
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block
Removal And Installation on Page 20-41-19.)
2
Figure 20-41-67
1
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item
2) [Figure 20-41-69].
1
P107856
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-67] from the tilt spool.
Figure 20-41-68
1
1
P107770
Remove the spool seal (Item 1) [Figure 20-41-70].
P107769
Remove the O-ring (Item 1) [Figure 20-41-68].
Installation: Replace the O-ring, and lubricate lightly
with oil before installation of the spool centering block.
240 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-41-70
2
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-73
Tilt Spool Disassembly And Assembly
2
Figure 20-41-71
1
3
4
1
N-18944B
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-73].
P107646
Dealer Copy -- Not for Resale
Put the actuator end of the spool in the vise [Figure 2041-71].
NOTE: Protect spool before clamping in vise.
Install the spring tool (Item 1) [Figure 20-41-71] over the
centering spring.
Figure 20-41-72
1
P107647
Remove the bolt (Item 1) [Figure 20-41-72] holding the
centering spring to the spool.
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
Remove the spring tool from the spring assembly.
241 of 1148
20-41-23
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HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-76
Auxiliary Spool Removal And Installation
Figure 20-41-74
2
1
2
P107760
Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-41-76] from the auxiliary spool.
1
Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-41-74] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure
20-41-74] must be replaced, replace the
retainer on the opposite end also.
NOTE: If the centering spring retainer (Item 2) [Figure
20-41-76] must be replaced, replace the
retainer on the opposite end also.
Figure 20-41-77
Figure 20-41-75
2
1
2
P107761
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-77] from the auxiliary spool.
P107759
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-75] from the auxiliary spool.
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P107758
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Auxiliary Solenoid Removal And Installation
Figure 20-41-79
Figure 20-41-78
2
1
2
1
1
P107847
Remove the auxiliary spool (Item 1) [Figure 20-41-78].
Remove the screws (Item 1) [Figure 20-41-79] from both
solenoids.
Remove the solenoids (Item 2) [Figure 20-41-79].
Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 23.9 in-lb) torque.
Figure 20-41-80
1
2
P107798
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-80] 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 20-41-80].
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P107762
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-83
Solenoid Removal And Installation
1
Figure 20-41-81
1
2
P107857
Remove the solenoid stem (Item 1) [Figure 20-41-83].
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 20-41-81] from the
solenoid stem.
Figure 20-41-84
Dealer Copy -- Not for Resale
P107847
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-81].
3
2
Figure 20-41-82
1
1
1
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-84] from the stem.
Clean all parts in solvent and dry with compressed air.
N-18693A
Remove the O-rings (Item 1) [Figure 20-41-82] from both
ends of the solenoid coil.
Use an ohmmeter to measure the solenoid coil
resistance.
Inspect all parts for wear and replace any showing
excessive wear.
NOTE: The screen (Item 3) [Figure 20-41-84] may be
cleaned with solvent. If it is torn or worn the
solenoid stem needs to be replaced.
The correct resistance for the coil is 9.5 - 10.08 ohm.
244 of 1148
20-41-26
S530 Service Manual
Figure 20-41-87
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-85
1
1
2
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure
20-41-87] is threaded for easier removal and installation.
P107858
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-4185].
1
Figure 20-41-86
3
2
1
P107767
Remove the O-ring (Item 1) [Figure 20-41-88].
Remove and inspect the spring (Item 2) and BICS™
valve (Item 3) [Figure 20-41-88].
P107859
Remove the lift lock valve retaining cap (Item 1) [Figure
20-41-86] 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.
245 of 1148
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Figure 20-41-88
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-90
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-89
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure
20-41-90] is threaded for easier removal and installation.
P107860
Remove the tilt lock valve retaining cap (Item 1) [Figure
20-41-89] from the front of the control valve.
1
Installation: Lightly lubricate the lock valve retaining cap
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.
3
2
P107767
Remove the O-ring (Item 1) [Figure 20-41-91].
Remove and inspect the spring (Item 2) and BICS™
valve (Item 3) [Figure 20-41-91].
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-41-91
Main Relief Valve Removal And Installation
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-94
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-92
1
1
P107862
Remove the main relief valve (Item 1) [Figure 20-41-94].
Remove the fitting (Item 1) [Figure 20-41-92] from the
valve.
Figure 20-41-95
Dealer Copy -- Not for Resale
P107861
Figure 20-41-93
2
1
1
P107659
Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-41-95] from the main relief valve.
P-51437
Inspect the lift arm bypass orifice (Item 1) [Figure 20-4193].
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve
casting.
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S530 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-98
Check Valve Removal And Installation
Figure 20-41-96
3
1
2
P107625
1
Inspect the spring (Item 2) and poppet (Item 3) [Figure
20-41-98].
P107848
Remove the tubeline (Item 1) [Figure 20-41-96].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ftlb) torque.
Figure 20-41-97
1
P107864
Remove the check valve fitting (Item 1) [Figure 20-4197] from the hydraulic control valve.
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20-41-30
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Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 20-41-98].
LIFT ARM BYPASS CONTROL VALVE
Description
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
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.
Testing
Figure 20-50-1
P-85290B
Dealer Copy -- Not for Resale
1
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.
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20-50-1
S530 Service Manual
LIFT ARM BYPASS CONTROL VALVE (CONT’D)
Figure 20-50-2
Removal And Installation
1
DANGER
3
2
P-90328
•
D-1009-0409
P-85670
Hold the lift arm bypass control knob (Item 1) [Figure 2050-2] and loosen the nut on the lift arm bypass valve
shaft.
Remove the knob (Item 1). Remove the nut (Item 2)
[Figure 20-50-2] from the valve shaft.
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
2
Lower the lift arms.
1
Raise the operator cab. (See Raising on Page 10-30-2.)
P-85671
IMPORTANT
Disconnect the hydraulic tubeline (Item 1) and hose (Item
2) [Figure 20-50-3].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Remove the two bolts and nuts (Item 2) [Figure 20-50-3].
Installation: Tighten the bolts to 21 - 23 N•m (180 - 200
in-lb) torque.
I-2003-0888
Remove the lift arm bypass valve.
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20-50-2
S530 Service Manual
Dealer Copy -- Not for Resale
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
LIFT ARM BYPASS CONTROL VALVE (CONT’D)
Disassembly And Assembly
Bracket Removal And Installation
Figure 20-50-5
Figure 20-50-4
1
2
1
P-85673
P-85672
Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ftlb) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.
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20-50-3
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the two bolts (Item 1) [Figure 20-50-4] and
remove the bypass valve bracket.
Remove the lift arm bypass valve (Item 1) [Figure 20-505] from the valve block. Inspect the bypass valve for
damage and replace if necessary.
Dealer Copy -- Not for Resale
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20-50-4
S530 Service Manual
HYDRAULIC PUMP
Description
The hydraulic pump is attached to the end of the
hydrostatic pump 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.
Dealer Copy -- Not for Resale
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.
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20-60-1
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Figure 20-60-1
HYDRAULIC PUMP (CONT’D)
Pump Test At Quick Couplers
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
1
I-2024-0284
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
cause injury or death.
Connect the IN port (Item 1) [Figure 20-60-1] of the
hydraulic tester to the bottom (female) quick coupler on
the loader.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-60-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
The tools listed will be needed to do the following
procedure:
MEL10003 or MEL1744- Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure on Page 10-101.)
NOTE: When testing the hydraulic flow of a machine,
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.
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P106632
HYDRAULIC PUMP (CONT’D)
Pump Test At Quick Couplers (Cont’d)
If no flow is indicated on the tester, the hoses are
connected wrong. With the hoses connected correctly,
increase the engine speed to full rpm.
Figure 20-60-2
Figure 20-60-4
2
1
1
P-16903
P106632
Start the engine and run at low idle. Press the
AUXILIARY HYDRAULICS button (Item 1) once to
activate the auxiliary hydraulics. The light (Item 2)
[Figure 20-60-2] will be on.
Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 1) [Figure 20-60-4] clockwise on the tester
so it reads 6895 kPa (69 bar) (1000 psi).
Figure 20-60-3
NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
Turn the restrictor control (Item 1) [Figure 20-60-4]
counterclockwise to obtain free flow.
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
1
P106677
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-60-3]
to allow constant auxiliary hydraulic fluid flow to the front
female coupler (female coupler is pressurized).
To stop continuous auxiliary hydraulic fluid flow, press the
front auxiliary hydraulic switch (Item 1) [Figure 20-60-3]
a second time.
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System
(Front and Rear) will deactivate.
255 of 1148
Start turning the restrictor clockwise, causing more
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
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
20-60-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
If pressure does not match the above information, the
main relief valve needs to be adjusted. (See Adjusting on
Page 20-30-4.)
If flow does not match specifications go to the Direct
Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-60-4.)
20-60-3
S530 Service Manual
Dealer Copy -- Not for Resale
NA3267
HYDRAULIC PUMP (CONT’D)
Figure 20-60-5
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following
procedure:
MEL1563 or 7217666 - Remote Start Tool
MEL10003 or MEL1744- Hydraulic Tester
MEL10006 - Fitting Kit
1
WARNING
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-101.)
P106709
Disconnect the OUTLET hose (Item 1) [Figure 20-60-5]
that comes from the gear pump, and connects to the
control valve.
Figure 20-60-6
Dealer Copy -- Not for Resale
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.
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
WARNING
2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P106631
W-2059-0598
Raise the operator cab.
Connect the Remote Start Tool. (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.)
256 of 1148
1
Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-5]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-6] from the tester to the control valve fitting on the
control valve.
20-60-4
S530 Service Manual
HYDRAULIC PUMP (CONT’D)
Direct Pump Test (Standard Section) (Cont'd)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.
Dealer Copy -- Not for Resale
Warm the fluid to 60°C (140°F) by turning the restrictor
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.)
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20-60-5
S530 Service Manual
HYDRAULIC PUMP (CONT’D)
Figure 20-60-7
Direct Pump Test (Charge Section)
Earlier Models
The tools listed will be needed to do the following
procedure:
MEL1563 or 7217666 - Remote Start Tool
MEL10003 or MEL1744- Hydraulic Tester
MEL10006 - Fitting Kit
1
WARNING
P114639
Figure 20-60-8
W-2017-0286
Later Models
Lift and block the loader. (See Procedure on Page 10-101.)
1
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P115656
Disconnect the inlet hose (Item 1) [Figure 20-60-7] or
[Figure 20-60-8].
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.
Raise the operator cab. (See Raising on Page 10-30-2.)
Open the rear door of the loader.
Connect the Remote Start Tool. (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.)
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Dealer Copy -- Not for Resale
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.
HYDRAULIC PUMP (CONT’D)
IMPORTANT
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-60-9
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
1
Warm the fluid to 60°C (140°F) by turning the restrictor
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*.
P106631
Connect the INLET hose (Item 1) [Figure 20-60-9] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-7]
or [Figure 20-60-8] of the pump. Connect the OUTLET
hose (Item 2) [Figure 20-60-9] from the tester to the inlet
fitting on the fan (Item 1) [Figure 20-60-7] or [Figure 2060-8].
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.
%=
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.)
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S530 Service Manual
Dealer Copy -- Not for Resale
2
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*.
HYDRAULIC PUMP (CONT’D)
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10120-2.)
Removal And Installation
Open the rear door of the loader.
WARNING
Figure 20-60-10
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.
1
W-2059-0598
1
1
1
DANGER
Disconnect the four hoses (Item 1) [Figure 20-60-10]
from the hydraulic pump.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Remove the Power Bob-Tach block (if equipped). (See
Removal And Installation on Page 20-120-1.)
Figure 20-60-11
1
D-1009-0409
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-90509
Disconnect the outlet hoses (Item 1) [Figure 20-60-11]
from the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
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20-60-8
S530 Service Manual
Dealer Copy -- Not for Resale
P-90180
HYDRAULIC PUMP (CONT’D)
Figure 20-60-14
Removal And Installation (Cont’d)
Figure 20-60-12
1
2
1
P-43940
Remove and replace the O-ring (Item 1) [Figure 20-6014] from the hydraulic pump.
Remove the bracket mounting bolt / nut (Item 1) [Figure
20-60-12].
Reverse the removal procedure to install the hydraulic
pump.
Dealer Copy -- Not for Resale
P114386
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28
ft-lb) torque.
Figure 20-60-13
2
P106594
Remove the two mounting bolts (Item 2) [Figure 20-6012] and [Figure 20-60-13].
Installation: Tighten the bolts to 75 - 85 N•m (55 - 60 ftlb) torque.
Remove the hydraulic pump.
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S530 Service Manual
Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
HYDRAULIC PUMP (CONT’D)
Hydraulic Pump Startup
NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-60-15
1
Start the loader from the operator’s cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
Dealer Copy -- Not for Resale
With the loader parked on a level surface and lift arms
down, check and fill the hydraulic reservoir as required.
Inspect for hydraulic leaks.
P100685
Figure 20-60-16
1
2
P114478
Attach a push button starter switch (MEL1712) (Item 1)
[Figure 20-60-15] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-16].
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S530 Service Manual
HYDRAULIC PUMP (CONT’D)
Parts Identification
Figure 20-60-17
13.Auxiliary Pump Center Section
14. Auxiliary Pump End Section
15. Shaft Seal
1. Bolt
2. Charge Pump End Section
3. Section 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
Dealer Copy -- Not for Resale
10
3
1
8
6
2
3
4
5
4
11
7
8
4
11
10
4
8
6
3
12
13
3
15
14
P-66540
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HYDRAULIC PUMP (CONT’D)
Disassembly And Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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.
Dealer Copy -- Not for Resale
Assembly: Tighten the eight pump housing bolts (Item 1)
[Figure 20-60-17] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plates (Item 4) [Figure 2060-17] 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.
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S530 Service Manual
HYDRAULIC / HYDROSTATIC FILTERS
Description
The hydraulic / hydrostatic filters help to remove
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one
main filter and one charge flow filter.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The main filter removes contaminants before entering
gear pumps including fluid returning from the main valve.
The charge flow filter removes contaminants after the
charge pump.
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Housing Removal And Installation
Drain the fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
DANGER
2
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
2
1
P114481
Disconnect the wire harness (Item 1) [Figure 20-70-1]
from the hydraulic / hydrostatic filter sender.
Disconnect the three hoses (Item 2) [Figure 20-70-1]
from the hydraulic / hydrostatic filter housing.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
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20-70-1
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-70-1
HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
1
1
P114480
Dealer Copy -- Not for Resale
Remove the two hoses (Item 1) [Figure 20-70-2] from
the bottom of the hydraulic / hydrostatic filter housing.
Figure 20-70-3
1
P106683
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the
loader.
266 of 1148
20-70-2
S530 Service Manual
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.
The hydraulic fluid reservoir is located behind the
operator’s cab under the rear grille on the right side of the
loader.
1
Removal And Installation
P110098
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Drain the fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the clamps and the hoses (Item 1) [Figure 2080-2].
Remove the rear grille. (See Removing on Page 50-601.)
Figure 20-80-1
1
1
2
P110099
Remove the two bolts (Item 1) [Figure 20-80-3].
1
Remove the hydraulic fluid reservoir from the loader.
1
Installation: Tighten the bolts and nuts to 21,7 - 24,4
N•m (16 - 18 ft-lb) torque.
P110097
Remove the bolts (Item 1) and grille (Item 2) [Figure 2080-1].
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Dealer Copy -- Not for Resale
Figure 20-80-3
Remove the Hydraulic / Hydrostatic Filter Housing. (See
Housing Removal And Installation on Page 20-70-1.)
HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Remove the rear grille. (See Removing on Page 50-601.)
Figure 20-80-4
1
Dealer Copy -- Not for Resale
P-90506
Remove the hydraulic fluid reservoir breather cap
[Figure 20-80-4] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 2080-4] from the reservoir.
Wash the screen in clean solvent and air dry before
replacing.
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S530 Service Manual
OIL COOLER
Removal And Installation
Dealer Copy -- Not for Resale
The oil cooler and radiator are removed from the loader
as a unit. (See Radiator / Oil Cooler Removal And
Installation on Page 70-40-1.) or (See Radiator / Oil
Cooler Removal And Installation on Page 70-41-1.)
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20-90-1
S530 Service Manual
Dealer Copy -- Not for Resale
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20-90-2
S530 Service Manual
BUCKET POSITION VALVE
Solenoid Removal And Installation
Description
DANGER
The Bucket Position Valve is an option that allows the
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
right rear side of the loader frame.
See the Hydraulic Schematic for more circuit information.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
271 of 1148
20-100-1
S530 Service Manual
Dealer Copy -- Not for Resale
D-1009-0409
BUCKET POSITION VALVE (CONT’D)
Figure 20-100-3
Solenoid Removal And Installation (Cont’d)
Figure 20-100-1
3
2
3
1
1
2
P-90197
Disconnect the wire harness (Item 1) [Figure 20-100-3]
from the bucket position shut-off solenoid.
P114272
Figure 20-100-2
Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-3].
Installation: Tighten the solenoid stem to 40,7 - 50,2
N•m (30 - 40 ft-lb) torque. Tighten the solenoid nut to 8
N•m (6 ft-lb) torque. Overtightening may cause valve
failure.
3
NOTE: The engine is shown removed for photo
clarity.
1
Figure 20-100-4
1
1
2
2
P114272
Remove the bolts / nuts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and place the fuel inlet
assembly (Item 3) [Figure 20-100-2] off to the side.
Cover the fuel tank inlet.
N-18191
Remove the O-rings (Item 1) and the back-up ring (Item
2) [Figure 20-100-4].
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20-100-2
S530 Service Manual
Dealer Copy -- Not for Resale
Disconnect the two tubelines (Item 2) [Figure 20-100-3].
Remove the two bolts (Item 1), disconnect the wire
harness (Item 2), and place the fuel filter assembly (Item
3) [Figure 20-100-1] off to the side.
Figure 20-100-6
BUCKET POSITION VALVE (CONT’D)
Solenoid Testing
3
Refer to Bobcat Advanced Troubleshooting System
(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
1
Removal And Installation
1
DANGER
2
P114272
Remove the bolts / nuts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and place the fuel inlet
assembly (Item 3) [Figure 20-100-6] off to the side.
Cover the fuel tank inlet.
•
•
Figure 20-100-7
Dealer Copy -- Not for Resale
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-100-5
1
P-90197
Disconnect the wire harness (Item 1) [Figure 20-100-7].
NOTE: The engine is shown removed for photo
clarity.
3
1
2
P114272
Remove the two bolts (Item 1), disconnect the wire
harness (Item 2), and place the fuel filter assembly (Item
3) [Figure 20-100-5] off to the side.
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20-100-3
S530 Service Manual
BUCKET POSITION VALVE (CONT'D)
Figure 20-100-10
Removal And Installation (Cont'd)
Figure 20-100-8
2
2
1
1
1
2
P-90197A
3
Disconnect the lift base outlet hose and tubeline (Item 1),
and the lift rod outlet hose and tubeline (Item 2) [Figure
20-100-10] that route from the lift cylinders.
P-90188
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 20-100-8].
Figure 20-100-11
Dealer Copy -- Not for Resale
4
Figure 20-100-9
1
P-90190A
1
2
Remove the bolts (Item 1) [Figure 20-100-11].
P-90189A
Remove the bucket position valve from the loader.
Disconnect the tilt cylinder hose (Item 1) and the tilt
cylinder base end hose (Item 2) [Figure 20-100-9] from
the valve block.
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S530 Service Manual
BUCKET POSITION VALVE (CONT'D)
Figure 20-100-14
Disassembly And Assembly
Figure 20-100-12
3
1
2
1
3
4
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-14].
P-90192
Assembly: Tighten the nut to of 8 N•m (6 ft-lb) torque.
Overtightening may cause valve failure. Tighten the
solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb) torque.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
ft-lb) torque.
Figure 20-100-15
Figure 20-100-13
1
2
3
1
4
2
P-90193
Remove the plug (Item 1), spring (Item 2), and unloading
spool (Item 3) [Figure 20-100-15].
P-90195
Remove the flow adjustment valve (Item 1). Remove the
O-ring (Item 2) [Figure 20-100-13].
Remove the O-ring (Item 4) [Figure 20-100-15].
Assembly: Tighten the flow adjustment valve to 36,6 48,8 N•m (27 - 36 ft-lb) torque.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and damage. Replace all worn
and damaged parts.
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20-100-5
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the O-ring (Item 4) [Figure 20-100-14].
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-12].
Dealer Copy -- Not for Resale
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20-100-6
S530 Service Manual
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 20110-2]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.
Dealer Copy -- Not for Resale
Figure 20-110-3
P9137
Use a test meter to measure coil resistance [Figure 20110-1]. Solenoid coil wires do not have polarity. Correct
resistance is 8.6 - 9.5 ohm.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Use a test meter to measure coil resistance [Figure 20110-3]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a molded connector
is 8.1 - 9.9 ohm.
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S530 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-4
Removal And Installation
DANGER
1
P-90583
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Disconnect the tubelines (Item 1) [Figure 20-110-4].
Figure 20-110-5
D-1009-0409
1
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-93303
Disconnect the tubelines (Item 1) [Figure 20-110-5].
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
278 of 1148
20-110-2
S530 Service Manual
Dealer Copy -- Not for Resale
•
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
assembly.
Figure 20-110-6
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
new O-rings and back-up rings.
1
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent and dry with compressed air.
Figure 20-110-8
P100810
Figure 20-110-7
1
1
2
P-48751
Remove the plugs (Item 1) [Figure 20-110-8].
1
Figure 20-110-9
1
P-90581
Remove the two bolts (Item 1) and remove the valve
(Item 2) [Figure 20-110-7].
P-48752
Remove the O-ring (Item 1) [Figure 20-110-9] from the
plug.
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20-110-3
S530 Service Manual
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Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-6] from the main harness.
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-12
Disassembly And Assembly (Cont'd)
Figure 20-110-10
1
1
P-48755
Remove the differential sensing valve (Item 1) [Figure
20-110-12].
Remove the shuttle valve (Item 1) [Figure 20-110-10].
Installation: Tighten the sensing valve to 68 - 75 N•m
(50 - 55 ft-lb) torque.
Installation: Tighten the shuttle valve to 14 - 16 N•m (10
- 12 ft-lb) torque.
Figure 20-110-13
Dealer Copy -- Not for Resale
P-48755
Figure 20-110-11
1
1
1
1
1
2
2
2
1
P-48757
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-110-13].
P-48756
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-110-11].
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S530 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-16
Disassembly And Assembly (Cont'd)
Figure 20-110-14
1
P-48759
1
Remove the relief valve (Item 1) [Figure 20-110-14].
Installation: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
torque.
Installation: Tighten the relief valve to 27 - 34 N•m (20 25 ft-lb) torque.
NOTE: Before removing the solenoid coils, mark the
coils for proper alignment.
Figure 20-110-15
Figure 20-110-17
2
2
1
1
P-48754
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-110-15].
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P-48760
Remove the spacer (Item 1) and solenoid valve coils
(Item 2) [Figure 20-110-17].
20-110-5
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the nut (Item 1) [Figure 20-110-16] from the
solenoid valve stem.
P-48753
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-20
Disassembly And Assembly (Cont'd)
Figure 20-110-18
1
1
2
P-48763
2
Remove the O-rings (Item 1) [Figure 20-110-20] and
back-up rings.
P-48761
Figure 20-110-21
1
Installation: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
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 20110-21].
1
Installation: Tighten the solenoid valve stem to 41 - 47
N•m (30 - 35 ft-lb) torque.
P-48762
Remove the solenoid valve stem (Item 1) [Figure 20110-19].
Installation: Tighten the solenoid valve stem to 27 - 34
N•m (20 - 25 ft-lb) torque.
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S530 Service Manual
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Remove the nuts (Item 1) [Figure 20-110-18] from the
solenoid valve stems.
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-24
Disassembly And Assembly (Cont'd)
Figure 20-110-22
1
1
P-48766
Remove and inspect the orifice (Item 1) [Figure 20-11024] for dirt and debris.
Remove the O-rings (Item 1) [Figure 20-110-22] and
back-up rings.
Installation: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.
Dealer Copy -- Not for Resale
P-48764
Figure 20-110-25
Figure 20-110-23
1
1
P-48765
P-48765
Remove the plug (Item 1) [Figure 20-110-25].
Remove the plug (Item 1) [Figure 20-110-23].
Installation: Tighten the plug to 51,5 N•m (38 ft-lb)
torque.
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Installation: Tighten the plug to 13,6 N•m (10 ft-lb)
torque.
20-110-7
S530 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-110-26
1
P-48786
Dealer Copy -- Not for Resale
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
1
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].
Installation: Tighten the plugs to 19 N•m (14 ft-lb)
torque.
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S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067)
Removal And Installation
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.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
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.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
285 of 1148
20-120-1
S530 Service Manual
Dealer Copy -- Not for Resale
DANGER
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-1
Removal And Installation (Cont'd)
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-90968
Disconnect the two electrical solenoid connectors (Item
1) [Figure 20-120-1] from the loader electrical harness.
Figure 20-120-2
1
2
4
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
3
3
Raise the operator cab. (See Raising on Page 10-30-2.)
3
P-90969
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Mark the hydraulic hoses for proper installation.
Disconnect the outlet hose (Item 1) [Figure 20-120-2]
from block.
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.
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ftlb) torque.
Remove the Power Bob-Tach block.
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S530 Service Manual
Dealer Copy -- Not for Resale
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.
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-5
Disassembly And Assembly
2
Figure 20-120-3
1
1
3
P100770
Remove the spring (Item 1) and spool (Item 2) [Figure
20-120-5].
P100820
Do not remove the plugs (Item 1) [Figure 20-120-3].
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.
Dealer Copy -- Not for Resale
Remove the O-ring (Item 3) [Figure 20-120-5] on the
plug and replace as needed.
Figure 20-120-6
Figure 20-120-4
1
2
1
P100823
Remove the plug (Item 1) [Figure 20-120-6].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
P100769
Clean the block (Item 1) [Figure 20-120-4] to remove dirt
before disassembly. Block ports are labeled for correct
assembly.
Remove the plug (Item 2) [Figure 20-120-4].
Installation: Tighten the plug to 67,8 N•m (50 ft-lb)
torque.
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20-120-3
S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-9
Disassembly And Assembly (Cont'd)
Figure 20-120-7
1
3
1
P100821
2
Remove the orifice (Item 1) [Figure 20-120-9].
Installation: Tighten the orifice to 8,1 - 10,8 N•m (6 - 8 ftlb) torque.
Remove the spool (Item 1), the spring (Item 2) and the
orifice (Item 3) [Figure 20-120-7].
Figure 20-120-10
Dealer Copy -- Not for Resale
P107069
Installation: Clean threads on the orifice and apply
Loctite® 603 before installing the orifice.
Figure 20-120-8
1
1
P100774
Remove the solenoid coil nut (Item 1) [Figure 20-12010].
Installation: Tighten the solenoid coil valve stem nut to
6,8 N•m (5 ft-lb) torque.
P100826
Remove the plug (Item 1) [Figure 20-120-8].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
288 of 1148
NOTE: Mark the solenoid coil orientation for ease of
assembly.
20-120-4
S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-13
Disassembly And Assembly (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
Figure 20-120-12
1
1
P100828
Remove the fitting (Item 1) [Figure 20-120-14].
P100827
Remove the solenoid coil stem (Item 1) [Figure 20-12012].
Installation: Tighten the solenoid coil stem to 27,14 N•m
(20 ft-lb) torque.
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20-120-5
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the solenoid coils (Item 1) [Figure 20-120-11].
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-17
Disassembly And Assembly (Cont'd)
Figure 20-120-15
1
P100841
1
Remove the filter assembly (Item 1) [Figure 20-120-17].
Figure 20-120-18
P100829
Figure 20-120-16
1
1
P100842
Remove the plug (Item 1) [Figure 20-120-18].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
P100840
Remove the plug (Item 1) [Figure 20-120-16].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
290 of 1148
20-120-6
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 20-120-15].
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-21
Disassembly And Assembly (Cont'd)
Figure 20-120-19
1
2
1
P100839
Remove the plug (Item 1) [Figure 20-120-21].
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 20-120-19].
Figure 20-120-22
Dealer Copy -- Not for Resale
P100843
Figure 20-120-20
1
2
1
P100835
Remove the spring (Item 1) and the check ball (Item 2)
[Figure 20-120-22].
P100845
Remove the plug (Item 1) [Figure 20-120-20].
Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
291 of 1148
20-120-7
S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-25
Disassembly And Assembly (Cont'd)
Figure 20-120-23
1
1
P100846
Remove the plug (Item 1) [Figure 20-120-25].
Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
P100837
Dealer Copy -- Not for Resale
Figure 20-120-26
Remove the plug (Item 1) [Figure 20-120-23].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
Figure 20-120-24
1
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].
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20-120-8
S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Figure 20-120-29
Disassembly And Assembly (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
Remove the back-up rings (Item 1) and the O-ring (Item
2) [Figure 20-120-27].
1
Figure 20-120-28
1
P100850
Remove the plug (Item 1) [Figure 20-120-30].
Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
P100852
Remove the plug (Item 1) [Figure 20-120-28].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
293 of 1148
20-120-9
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 20-120-30
BOB-TACH (POWER) BLOCK (S/N ALR811001 ALR813067) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-31
1
P100851
Dealer Copy -- Not for Resale
Remove the plug (Item 1) [Figure 20-120-31].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
Figure 20-120-32
1
P100854
Remove the O-ring (Item 1) [Figure 20-120-32].
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.
294 of 1148
20-120-10
S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
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.
Dealer Copy -- Not for Resale
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.
295 of 1148
20-121-1
S530 Service Manual
Figure 20-121-2
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Testing Relief Valve
1
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
P106674
Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
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.
Engage the parking brake. Lower the seat bar. Start the
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 20121-1].
Push and hold BOB-TACH “WEDGES UP” switch until
levers are in the unlocked position (Wedges fully raised).
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20-121-2
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Dealer Copy -- Not for Resale
Figure 20-121-3
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Testing Relief Valve (Cont’d)
Figure 20-121-4
1
2
P122229
Dealer Copy -- Not for Resale
NOTE: Relief valve removed from block for photo
clarity.
If adjustment is required, loosen the locknut (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.
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BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Removal And Installation
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.
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.
Lift and block the loader. (See Procedure on Page 10-101.)
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
DANGER
Remove the fan duct panels (See Removal And
Installation on Page 50-190-1.)
Figure 20-121-5
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
1
D-1009-0409
P122161
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Disconnect the two wire connectors (Item 1) [Figure 20121-5] from the solenoid coils.
I-2003-0888
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20-121-4
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Dealer Copy -- Not for Resale
Drain the hydraulic reservoir. (See Removing And
Replacing Fluid on Page 10-130-1.)
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Removal And Installation (Cont'd)
Figure 20-121-6
2
1
2
2
P122162
Dealer Copy -- Not for Resale
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 20-1217].
Installation: Tighten the mounting bolts to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Remove the Power Bob-Tach block.
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BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Figure 20-121-9
Disassembly And Assembly
IMPORTANT
3
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
2
I-2003-0888
4
P122197
Figure 20-121-8
Installation: Tighten the plug to 67,8 N•m (50 ft-lb)
torque.
Replace the O-ring (Item 4) [Figure 20-121-9] on the
plug.
1
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.
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20-121-6
S530 Service Manual
Dealer Copy -- Not for Resale
Remove plug (Item 1), spring (Item 2), and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.
Figure 20-121-13
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd)
2
Figure 20-121-11
2
1
P122201
3
Replace the O-rings (Item 1) and the back-up rings (Item
2) [Figure 20-121-13].
1
P122199
Remove the first solenoid coil (Item 1), the spacer (Item
2), and the second solenoid coil (Item 3) [Figure 20-12111].
Figure 20-121-12
2
1
P122202
Remove the fitting (Item 2) [Figure 20-121-12] and
replace the O-ring (Item 1) [Figure 20-121-14].
1
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-12112].
Installation: Tighten the solenoid stem to 27,14 N•m
(20 ft-lb) torque.
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Figure 20-121-14
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Figure 20-121-17
Disassembly And Assembly (Cont'd)
Figure 20-121-15
1
2
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-17]. Inspect and replace
as needed.
Remove the plug (Item 1) [Figure 20-121-15] and
replace the O-ring.
Figure 20-121-18
Installation: Tighten the plug to 30,0 N•m (22 ft-lb)
torque.
Dealer Copy -- Not for Resale
P122203
1
Figure 20-121-16
P122205
Remove the plug (Item 1) [Figure 20-121-18].
1
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
P122205
Remove the plug (Item 1) [Figure 20-121-16].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
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20-121-8
S530 Service Manual
Figure 20-121-21
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-121-19
2
3
1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert
(Item 2) [Figure 20-121-21]. Inspect and replace as
needed.
P122207
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 20-121-22
Dealer Copy -- Not for Resale
1
Figure 20-121-20
1
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
Installation: Tighten the relief valve to 20 N•m (15 ft-lb)
torque.
P122208
Remove the plug (Item 1) [Figure 20-121-20].
Installation: Tighten the plug to 17,6 N•m (13 ft-lb)
torque.
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S530 Service Manual
BOB-TACH (POWER) BLOCK (S/N ALR813068 &
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-121-23
2
2
1
P122212
Dealer Copy -- Not for Resale
Replace the O-rings (Item 1) and the back-up rings (Item
2) [Figure 20-121-23].
Figure 20-121-24
1
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.
304 of 1148
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S530 Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
The front auxiliary hydraulic coupler block is the
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
For FFH/FH connector block. (See Disassembly And
Assembly (FFH/FH) on Page 20-130-4.)
Figure 20-130-3
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
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
but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
P115537
Figure 20-130-2
1
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and
[Figure 20-130-2] is located on the male coupler.
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S530 Service Manual
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P115535
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
(CONT’D)
Disassembly And Assembly (FFI/FI)
Figure 20-130-5
Removal And Installation
All Models
1
IMPORTANT
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
3
I-2003-0888
P-90003
Figure 20-130-4
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
1
Remove the two mounting bolts (Item 1) [Figure 20-1304].
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].
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
(CONT’D)
Figure 20-130-9
Disassembly And Assembly (FFI/FI) (Cont’d)
1
Figure 20-130-7
2
2
1
2
2
1
2
1
P-34665
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
1
Remove the O-rings (Item 2) [Figure 20-130-7] from the
fittings and coupler body.
Figure 20-130-8
1
2
P-34664
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and
lightly lubricate with oil before installation.
P-34701
Press center of male couplers down and inspect the seal
(Item 1) [Figure 20-130-8] for damage and replace as
needed.
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the springs (Item 1) [Figure 20-130-7].
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
(CONT’D)
Figure 20-130-13
1
Disassembly And Assembly (FFH/FH)
2
Figure 20-130-11
1
2
1
2
2
1
2
1
P115529B
Remove the springs (Item 1) [Figure 20-130-13].
Remove the O-rings (Item 2) [Figure 20-130-13] from the
fittings.
Remove the coupler fittings (Item 1) and the case drain
coupler fitting (Item 2) [Figure 20-130-11].
Figure 20-130-14
Dealer Copy -- Not for Resale
P-90002
Installation: Tighten the coupler fittings (Item 1) [Figure
20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
1
2
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.
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S530 Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
(CONT’D)
Figure 20-130-17
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 20130-17] and replace coupler if damaged.
P115536
Dealer Copy -- Not for Resale
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
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 20-13015] as an assemble if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20130-16] and replace coupler if damaged.
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S530 Service Manual
AUTOMATIC RIDE CONTROL
Description
Dealer Copy -- Not for Resale
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.
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20-140-1
S530 Service Manual
AUTOMATIC RIDE CONTROL (CONT'D)
Removal And Installation
WARNING
Open the rear door.
Remove the rear grille and engine cover. (See Removing
on Page 50-60-1.)
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
WARNING
W-2103-0508
W-2059-0598
DANGER
WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
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
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
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
3
D-1009-0409
2
1
IMPORTANT
P121154
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Disconnect the harness (Item 1) [Figure 20-140-1] from
the bottom of the filter.
Remove the two bolts (Item 2) and reposition the fuel
filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888
312 of 1148
20-140-2
S530 Service Manual
Dealer Copy -- Not for Resale
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.
AUTOMATIC RIDE CONTROL (CONT'D)
Figure 20-140-4
Removal And Installation (Cont’d)
Figure 20-140-2
2
1
1
P122354
P122353
Reposition the clamp (Item 1) and remove the fuel fill
hose (Item 2) [Figure 20-140-4] from the tank.
Cover the fuel tank inlet.
Remove the two bolts (Item 1) [Figure 20-140-2].
Figure 20-140-5
Dealer Copy -- Not for Resale
Figure 20-140-3
1
1
1
P128342
P122355
Remove the hose (Item 1) [Figure 20-140-3].
313 of 1148
Disconnect the three connectors (Item 1) [Figure 20140-5] from the manifold.
20-140-3
S530 Service Manual
AUTOMATIC RIDE CONTROL (CONT'D)
Figure 20-140-8
Removal And Installation (Cont’d)
2
Figure 20-140-6
1
1
P128335
Remove the two nuts (Item 1) and the accumulator /
manifold assembly (Item 2) [Figure 20-140-8].
P128096
Dealer Copy -- Not for Resale
Remove the hose (Item 1) [Figure 20-140-6].
Figure 20-140-7
1
P128339
Remove the two hoses (Item 1) [Figure 20-140-7] from
the manifold.
314 of 1148
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S530 Service Manual
AUTOMATIC RIDE CONTROL (CONT'D)
Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease
over time. This will result in decreased effectiveness of
the automatic ride control benefits.
NOTE: The signs of a low accumulator charge
include: excessive lift arm movement,
reduced ride control performance, or loss of
ride control function.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Remove the automatic ride control assembly. (See
Removal And Installation on Page 20-140-2.)
WARNING
The tools listed will be needed to do the following
procedure:
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
DANGER
WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
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
circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Figure 20-140-9
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
1
D-1009-0409
P128321
Remove the cap (Item 1) [Figure 20-140-9] from the
accumulator.
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W-2103-0508
AUTOMATIC RIDE CONTROL (CONT'D)
Figure 20-140-12
Checking The Pressure In The Accumulator (Cont’d)
1
Figure 20-140-10
2
1
P128489
Turn the T-handle (Item 1) [Figure 20-140-12]
counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Loosen the Allen screw (Item 1) [Figure 20-140-10]
approximately 1/4 turn.
Figure 20-140-11
Pressure in the accumulator should be 915 psi (63 bar).
Close the valve by turning the T-handle (Item 1) [Figure
20-140-12] clockwise.
Release any pressure by opening the manual bleed valve
(Item 2) [Figure 20-140-12].
2
Remove the tool / gauge from the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-10] 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 20-140-11] onto
the accumulator.
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Dealer Copy -- Not for Resale
P128322
Figure 20-140-14
AUTOMATIC RIDE CONTROL (CONT'D)
Adding Nitrogen To The Accumulator
Remove the automatic ride control assembly. (See
Removal And Installation on Page 20-140-2.)
The tools listed will be needed to do the following
procedure:
1
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
P128322
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
Loosen the Allen screw (Item 1) [Figure 20-140-14]
approximately 1/4 turn.
Figure 20-140-15
1
WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
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
circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Figure 20-140-13
2
P128488
Install the tool / gauge (Item 1) [Figure 20-140-15] onto
the accumulator.
Make sure the manual bleed valve (Item 2) [Figure 20140-15] is closed.
1
P128321
Remove the cap (Item 1) [Figure 20-140-13] from the
accumulator.
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W-2505-0604
AUTOMATIC RIDE CONTROL (CONT'D)
Figure 20-140-18
Adding Nitrogen To The Accumulator (Cont’d)
1
Figure 20-140-16
2
1
P128491
Install the hose (Item 1) [Figure 20-140-16] to the tool on
the accumulator.
Figure 20-140-17
Pressure in the accumulator should be 915 psi (63 bar).
Slowly open the valve on the nitrogen tank. Close the
valve by turning the T-handle (Item 1) [Figure 20-140-18]
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
20-140-18] clockwise.
Release any pressure by opening the manual bleed valve
(Item 2) [Figure 20-140-18].
Remove the hose from the tank and the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-14] to 20
N•m (15 ft-lb) torque.
P128327
Install the other end of the hose / fitting (Item 1) [Figure
20-140-17] to the nitrogen tank.
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S530 Service Manual
Dealer Copy -- Not for Resale
Turn the T-handle (Item 1) [Figure 20-140-18]
counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
P128490
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-20-1
30-20-1
30-20-1
30-20-4
30-20-5
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-30-1
30-30-1
30-30-2
30-30-4
30-30-6
30-30-7
30-30-9
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-31-1
30-31-1
30-31-2
30-31-4
30-31-6
30-31-7
30-31-9
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sender Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . .
Sender Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-40-1
30-40-1
30-40-2
30-40-4
30-40-6
30-40-6
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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
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-21
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-4
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-7
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-10
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioner Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . .
Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioner Pulley Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . .
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-60-1
30-60-1
30-60-1
30-60-2
30-60-4
30-60-4
30-60-5
30-60-5
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
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HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
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 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.
Dealer Copy -- Not for Resale
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.
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HYDROSTATIC SYSTEM INFORMATION (CONT’D)
WARNING
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
If a service code appears in the left instrument panel.
(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
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
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.
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KEY TO CORRECT THE CAUSE
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Description
DANGER
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps.
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
cool by mixing case drain 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.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
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Dealer Copy -- Not for Resale
D-1009-0409
HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-2
Removal And Installation (Cont’d)
Figure 30-20-1
1
1
P106945
Loosen the bolts (Item 1) [Figure 30-20-2] holding the
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 3020-1].
Figure 30-20-3
Dealer Copy -- Not for Resale
P106956
Installation: Tighten bolts to 20 - 27 N•m (15 - 20 ft-lb)
torque.
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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.
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HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-6
Removal And Installation (Cont’d)
1
Figure 30-20-4
2
2
3
1
P-82716
Remove the O-ring (Item 1) and shaft seal (Item 2)
[Figure 30-20-6].
P106968
Dealer Copy -- Not for Resale
Remove the two hoses (Item 1) [Figure 30-20-4] from
the hydrostatic motor.
Remove the case drain hose (Item 2) [Figure 30-20-4]
from the hydrostatic motor.
NOTE: The hydraulic fittings (Item 3) [Figure 30-20-4]
must be tightened to 156 - 170 N•m (115 - 125
ft-lb) torque.
Figure 30-20-5
1
P106965
Remove the bolts (Item 1) [Figure 30-20-5].
Installation: Tighten the bolt to 136 N•m (100 ft-lb)
torque.
Remove the motor from the loader.
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HYDROSTATIC DRIVE MOTOR (CONT’D)
Parts Identification
Description
Shaft
Seal
O-ring
Flange
Seal
Back-up Ring
Spring
Outer Balance Plate
Inner Balance Plate
Ball
Geroler®
Valve Plate
End Cap
Poppet
Spring
Plug
Bolt
Sleeve
Spring
Shuttle Valve
16
14
3
15
20
14
16
3
19
14
18
18
13
19
17
5
3
12
5
11
Dealer Copy -- Not for Resale
Ref.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
10
5
9
8
10
7
6
3
3
5
4
3
2
1
PE2620T
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HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-9
Disassembly And Assembly
3
8
6
5
IMPORTANT
9
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
7
4
I-2003-0888
P-68211
Drain the fluid from the motor.
Figure 30-20-7
Figure 30-20-10
1
P-64267
Put a mark across the sections of the motor for correct
assembly [Figure 30-20-7].
P-64267
Figure 30-20-8
Once the bolts have been removed and the motor begins
to separate, the drive shaft (Item 1) [Figure 30-20-10]
can be removed.
1
Assembly: Install drive shaft before tightening the bolts.
P-68211
Remove the bolts (Item 1) [Figure 30-20-8] from the
motor.
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Assembly: Tighten the bolts to 61 - 75 N•m (45 - 55 ft-lb)
torque in the order shown. Tighten the bolts to 75 - 88
N•m (55 - 65 ft-lb) torque in the order shown [Figure 3020-9].
Seal all open ports and clean the motor with solvent.
Figure 30-20-13
HYDROSTATIC DRIVE MOTOR (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 30-20-11
1
2
1
3
P-68213
Remove the plug (Item 1) and shuttle valve assembly
(Item 2). Remove the O-ring (Item 3) [Figure 30-20-13].
Remove the end cap (Item 1) [Figure 30-20-11] from the
motor.
Installation: Tighten the plug to 41 N•m (260 in-lb)
torque.
Dealer Copy -- Not for Resale
P-68212
Figure 30-20-14
Figure 30-20-12
1
3
2
4
1
P-39897
P-63785
Remove the plug (Item 1), spring (Item 2), and poppet
(Item 3) that make up the relief valve assembly. Remove
the O-ring (Item 4) [Figure 30-20-12].
Remove the remaining pieces to the shuttle valve
assembly (Item 1) [Figure 30-20-14] from the inside of
the end cap.
Installation: Tighten the plug to 41 N•m (260 in-lb)
torque.
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HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-17
Disassembly And Assembly (Cont’d)
1
Figure 30-20-15
1
2
1
1
P-39901
NOTE: Care should be taken to keep the Geroler®
assembly together. If rollers are removed,
install the rollers in the original bores.
Remove the O-rings (Item 1) [Figure 30-20-15].
Remove the valve plate (Item 2) [Figure 30-20-15].
Figure 30-20-16
Figure 30-20-18
1
2
2
3
1
P-64274
P-64268
Remove the O-ring (Item 1) [Figure 30-20-16].
Remove the Geroler® section as an assembly (Item 2)
[Figure 30-20-16].
Remove the inner balance plate (Item 1) [Figure 30-2018].
Remove the O-ring (Item 2) [Figure 30-20-18].
NOTE: There are two check balls on the backside of
the Geroler® section. Do not lose these check
balls. See [Figure 30-20-17].
329 of 1148
Remove the outer balance plate (Item 3) [Figure 30-2018].
30-20-7
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the two check balls (Item 1) [Figure 30-20-17]
from the Geroler®.
P-39898
HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-21
Disassembly And Assembly (Cont’d)
1
Figure 30-20-19
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-21].
P-64270
Assembly: If the belleville spring is no longer cone
shaped, replace with new.
Remove the back-up ring (Item 1) [Figure 30-20-19].
Dealer Copy -- Not for Resale
Figure 30-20-22
NOTE: One side of the back-up ring is grooved to fit
against the O-ring underneath.
Figure 30-20-20
1
1
1
P-64273
1
P-64271
Turn the mounting flange over and remove the seal (Item
1) [Figure 30-20-22].
Remove the O-rings (Item 1) [Figure 30-20-20].
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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.
Dealer Copy -- Not for Resale
There are two hydrostatic motors mounted to motor
carriers. The motor carriers are mounted to the
transmission chaincase which houses the drivechains.
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HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Remove the front and rear wheel / tire assemblies. (See
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
Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And
Installation on Page 20-90-1.)
Mark all hoses and tubelines before removing for correct
installation.
•
•
Figure 30-21-1
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
1
D-1009-0409
1
WARNING
2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P106956
Remove the motor cover bolts (Item 1) and remove the
motor cover (Item 2) [Figure 30-21-1] from the loader.
Figure 30-21-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
332 of 1148
P106945
Loosen the bolts (Item 1) [Figure 30-21-2] and swing the
panel open. The panel is located under the loader frame
directly below the drive motor.
30-21-2
S530 Service Manual
Dealer Copy -- Not for Resale
P-90328
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-5
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
Remove the case drain hose (Item 1) [Figure 30-21-3].
Dealer Copy -- Not for Resale
Installation: Tighten the bolt to 285 N•m (210 ft-lb)
torque.
Figure 30-21-6
Figure 30-21-4
2
1
1
P106958
P106957
Remove the hose (Item 1) [Figure 30-21-4] from the
motor.
Remove the shift pressure tubeline (Item 2) [Figure 3021-4] from the motor.
Remove two bolts (Item 1) [Figure 30-21-6] from the
motor.
Installation: Tighten the bolt to 285 N•m (210 ft-lb)
torque.
Remove the motor from the loader.
333 of 1148
30-21-3
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
1
P-82716
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 30-21-7].
Figure 30-21-8
1
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.
334 of 1148
30-21-4
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Mark all hoses and tubelines before removing for correct
installation.
Removal And Installation (Right Side)
Figure 30-21-9
DANGER
1
1
2
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
P106956
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)
torque.
Figure 30-21-10
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
1
IMPORTANT
P-73665
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Loosen the bolts (Item 1) [Figure 30-21-10] and swing
the panel open. The panel is located under the loader
frame directly below the drive motor.
I-2003-0888
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removal And
Installation on Page 20-90-1.)
335 of 1148
30-21-5
S530 Service Manual
Dealer Copy -- Not for Resale
•
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-13
Removal And Installation (Right Side) (Cont'd)
Figure 30-21-11
1
1
P106971
Disconnect the case drain tubeline (Item 1) [Figure 3021-13] from the motor.
P106970
Remove the shift pressure tubeline (Item 1) [Figure 3021-11] from the motor.
1
Figure 30-21-12
1
P-73664
Remove the lower bolt (Item 1) [Figure 30-21-14] from
the motor.
P106969
Remove the hoses (Item 1) [Figure 30-21-12] from the
motor.
336 of 1148
Installation: Tighten the bolt to 285 N•m (210 ft-lb)
torque.
30-21-6
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-14
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-17
Removal And Installation (Right Side) (Cont'd)
1
Figure 30-21-15
1
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
outward.
P-76145
Dealer Copy -- Not for Resale
Remove two bolts (Item 1) [Figure 30-21-15] from the
motor.
Installation: Tighten the bolt to 285 N•m (210 ft-lb)
torque.
Remove the motor from the loader.
Figure 30-21-16
1
P-82716
Remove the O-ring (Item 1) [Figure 30-21-16].
337 of 1148
30-21-7
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Parts Identification
Ref. Description
1. O-ring
2. Spool Housing
3. Plug
4. Bolt
5. Plug
6. Spool
7. Spring
8. Gasket
9. Selector Plate
10. Valve Drive
11. Geroler®
12. Main Drive
13. Mounting Flange
14. Shaft Seal
15. Bolt
16. Shuttle Valve Assembly
17. Ball Seat
18. Ball
19. Valve Housing
20. Poppet
21. Dowel
22. Back-up Ring
23. Inner Balance Ring
24. Outer Balance Ring
25. Valve
7
7
4
6
5
2
3
8
1
9
1
11
Dealer Copy -- Not for Resale
3
3
1
10
13
15
12
3
19
14
3
16
16
3
7
21
18
22
22
24
23
7
22
1
17
3
20
7
3
25
1
MS2315SA
338 of 1148
30-21-8
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-20
Disassembly
Drain the fluid from the motor casing.
Figure 30-21-18
1
P106490
Remove the O-ring (Item 1) [Figure 30-21-20].
Figure 30-21-21
Mark the side of the motor for ease of assembly [Figure
30-21-18].
1
Figure 30-21-19
1
P106491
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].
339 of 1148
30-21-9
S530 Service Manual
Dealer Copy -- Not for Resale
P106488
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-24
Disassembly (Cont'd)
1
Figure 30-21-22
1
P106494
Remove the outer balance ring (Item 1) [Figure 30-2124] from the valve housing.
P106492
Remove the inner balance ring (Item 1) [Figure 30-2122] 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 the four springs (Item 1) [Figure 30-21-23].
340 of 1148
30-21-10
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-25
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-28
Disassembly (Cont'd)
Figure 30-21-26
1
1
1
P106498
1
Remove the O-ring (Item 1) [Figure 30-21-28] from the
valve housing.
P106497
Figure 30-21-29
Figure 30-21-27
1
1
P106500
Remove the plug (Item 1) [Figure 30-21-29] from the
valve housing.
P106495
Remove the back-up ring (Item 1) [Figure 30-21-27] from
the valve housing.
341 of 1148
30-21-11
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the springs (Item 1) [Figure 30-21-26].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-32
Disassembly (Cont'd)
Figure 30-21-30
1
P106499
1
Remove the plug (Item 1) [Figure 30-21-32] from the
valve housing.
P-76394A
Figure 30-21-33
Figure 30-21-31
1
3
2
P-76394A
1
Remove the O-ring (Item 1) [Figure 30-21-33].
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.
342 of 1148
30-21-12
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 30-21-30].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-36
Disassembly (Cont'd)
Figure 30-21-34
1
4
3
P-76394A
2
1
Remove the O-ring (Item 1) [Figure 30-21-36].
Remove the spring seat (Item 1), spring (Item 2), spring
seat (Item 3), and shuttle valve (Item 4) [Figure 30-2134].
Figure 30-21-35
3
2
1
P106505
Remove spring seat (Item 1), spring (Item 2), and spring
seat (Item 3) [Figure 30-21-37].
1
P106504
Remove the plug (Item 1) [Figure 30-21-35].
343 of 1148
30-21-13
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-37
P106501
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-40
Disassembly (Cont'd)
Figure 30-21-38
1
P106506
1
Remove the plug (Item 1) [Figure 30-21-40].
P106503
Figure 30-21-41
Figure 30-21-39
1
P-76394A
1
Remove the O-ring (Item 1) [Figure 30-21-41].
P-76394A
Remove the O-ring (Item 1) [Figure 30-21-39].
344 of 1148
30-21-14
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the plug (Item 1) [Figure 30-21-38].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-44
Disassembly (Cont'd)
Figure 30-21-42
1
P106509
1
2
Remove the selector plate (Item 1) [Figure 30-21-44].
Remove the spring (Item 1) and poppet (Item 2) [Figure
30-21-42].
1
Figure 30-21-43
1
P106510
Remove the valve drive (Item 1) [Figure 30-21-45].
P106508
Remove the valve (Item 1) [Figure 30-21-43].
345 of 1148
30-21-15
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-45
P106507
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-48
Disassembly (Cont'd)
1
Figure 30-21-46
1
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
2
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].
Remove the O-ring (Item 2) [Figure 30-21-47].
346 of 1148
30-21-16
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 30-21-46].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-52
Disassembly (Cont'd)
Figure 30-21-50
1
1
P106622
Remove the O-ring (Item 1) [Figure 30-21-52] from the
groove in the seal.
P106621
Figure 30-21-53
Figure 30-21-51
1
1
P106513
Remove the shaft seal (Item 1) [Figure 30-21-53].
P106619
Remove the seal / O-ring assembly (Item 1) [Figure 3021-51].
347 of 1148
30-21-17
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the spring washer (Item 1) [Figure 30-21-50].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-56
1
1
1
1
Disassembly (Cont'd)
Figure 30-21-54
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
1
P106516
1
Remove the gasket (Item 1) [Figure 30-21-57].
P-76394A
Remove the O-ring (Item 1) [Figure 30-21-55] from the
plug.
348 of 1148
30-21-18
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the plug (Item 1) [Figure 30-21-54].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-60
Disassembly (Cont'd)
Figure 30-21-58
1
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
2
1
P-73523
Remove the inner spring (Item 1) from the outer spring
(Item 2) [Figure 30-21-61].
1
P106518
Remove the O-rings (Item 1) [Figure 30-21-59].
349 of 1148
30-21-19
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the plug (Item 1) [Figure 30-21-58].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-64
Disassembly (Cont'd)
Figure 30-21-62
1
1
P-76389
Remove the O-ring (Item 1) [Figure 30-21-64].
Remove the spool (Item 1) [Figure 30-21-62] from the
spool housing.
1
Figure 30-21-63
P106523
1
Remove the plug (Item 1) [Figure 30-21-65] from the
spool housing.
Figure 30-21-66
P106522
Remove the plug (Item 1) [Figure 30-21-63] from the
spool housing.
1
P-76389
Remove the O-ring (Item 1) [Figure 30-21-66].
350 of 1148
30-21-20
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-65
P106520
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-69
Assembly
Clean all parts in solvent and dry with compressed air.
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.
1
P-76389
1
Install the O-ring (Item 1) [Figure 30-21-67] on the plug.
Figure 30-21-68
P-73550A
Install the plug (Item 1) [Figure 30-21-70] in the spool
housing.
1
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.
Tighten the plug to 45 - 56 N•m (33 - 42 ft-lb) torque.
351 of 1148
30-21-21
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-70
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-73
Assembly (Cont’d)
Figure 30-21-71
1
1
P106518
Install the O-ring (Item 1) [Figure 30-21-73] on the plug.
Install the spool (Item 1) [Figure 30-21-71] into the spool
housing.
1
Figure 30-21-72
1
P106517
Install the plug (Item 1) [Figure 30-21-74] with a light
coat of oil.
Tighten the plug to 45 - 56 N•m (33 - 42 ft-lb) torque.
P106519
Install the inner and outer springs (Item 1) [Figure 30-2172] on the spool shaft.
352 of 1148
30-21-22
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-74
P106520
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-76
Assembly (Cont'd)
Figure 30-21-75
Apply Loctite® 262 Here
1
1
1
1
P106516
1
1
Install the gasket (Item 1) [Figure 30-21-76] on the
selector plate.
1
P-73775
Use the correct size tap to clean any remaining thread
lock from the threaded holes (Item 1) [Figure 30-21-75].
1
1
1
1
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
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
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.
353 of 1148
Install the screws (Item 1) [Figure 30-21-77].
30-21-23
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-77
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-80
Assembly (Cont'd)
Figure 30-21-78
4
10
1
6
7
1
1
P106514
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
groove.
1
P-76394A
Install the O-ring (Item 1) [Figure 30-21-79] on the plug.
354 of 1148
30-21-24
S530 Service Manual
Dealer Copy -- Not for Resale
9
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-84
Assembly (Cont'd)
Figure 30-21-82
2
1
1
P106620
Install the O-ring (Item 1) and back-up ring (Item 2)
[Figure 30-21-84].
P106619
Install the seal / O-ring assembly (Item 1) [Figure 30-2182].
Figure 30-21-83
1
1
P106618
Install the plate (Item 1) [Figure 30-21-85].
P106621
Install the spring washer (Item 1) [Figure 30-21-83].
355 of 1148
30-21-25
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-85
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-88
Assembly (Cont'd)
1
Figure 30-21-86
2
1
2
P106510
Install the valve drive (Item 1) and O-ring (Item 2) [Figure
30-21-88].
P106512
Dealer Copy -- Not for Resale
Install the main drive (Item 1) [Figure 30-21-86].
Install the O-ring (Item 2) [Figure 30-21-86].
Figure 30-21-87
2
1
3
3
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].
356 of 1148
30-21-26
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-91
Assembly (Cont'd)
1
Motor Timing
Figure 30-21-89
3
2
3
P-73545
2
P-73544
Locate a tooth (Item 1) [Figure 30-21-89] that lines up
with a star tip.
Mark the spline (Item 2) in the Geroler® star that is 11.25
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].
Align any one of the four grooves (Item 2) in the valve
with the marked tooth on the valve drive (Item 3) [Figure
30-21-91].
Rotate the valve clockwise until the spline teeth engage
in the valve.
Figure 30-21-90
1
2
P-73527
Install the selector plate (Item 1) with the slotted holes
facing up. Align the case drain holes (Item 2) [Figure 3021-90].
357 of 1148
30-21-27
S530 Service Manual
Dealer Copy -- Not for Resale
1
Install the valve (Item 1) [Figure 30-21-91] on the valve
drive. The round holes and four grooves must be facing
up.
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-94
Assembly (Cont’d)
Figure 30-21-92
1
P-76394A
1
Install the O-ring (Item 1) [Figure 30-21-94] on the plug.
P-76389
Figure 30-21-95
Figure 30-21-93
1
2
P106507
1
Install the poppet (Item 1) and spring (Item 2) [Figure 3021-95].
P106503
Install the plug (Item 1) [Figure 30-21-93].
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
358 of 1148
30-21-28
S530 Service Manual
Dealer Copy -- Not for Resale
Install the O-ring (Item 1) [Figure 30-21-92].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-98
Assembly (Cont’d)
Figure 30-21-96
1
P-76394A
1
Install the O-ring (Item 1) [Figure 30-21-98] on the plug.
Figure 30-21-99
P106506
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
Figure 30-21-97
1
P106504
1
2
Install the plug (Item 1) [Figure 30-21-99].
3
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
P106505
Install the spring seat (Item 1), spring (Item 2), and spring
seat (Item 3) [Figure 30-21-97].
359 of 1148
30-21-29
S530 Service Manual
Dealer Copy -- Not for Resale
Install the plug (Item 1) [Figure 30-21-96].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-102
Assembly (Cont’d)
Figure 30-21-100
1
1
2
3
P106499
4
Install the plug (Item 1) [Figure 30-21-102].
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3), and spring seat (Item 4) [Figure 30-21-100].
Figure 30-21-103
Dealer Copy -- Not for Resale
P106501
Figure 30-21-101
2
1
3
P106502
1
Install the O-ring (Item 1) on the orifice. Install the ball
(Item 2), and orifice (Item 3) [Figure 30-21-103].
P-76394A
Install the O-ring (Item 1) [Figure 30-21-101] on the plug.
360 of 1148
30-21-30
S530 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-106
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
1
P106497
1
Install the compression springs (Item 1) [Figure 30-21107].
P106498
Install the O-ring (Item 1) [Figure 30-21-105] on the
valve housing.
361 of 1148
30-21-31
S530 Service Manual
Dealer Copy -- Not for Resale
Install the plug (Item 1) [Figure 30-21-104].
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-110
Assembly (Cont’d)
Figure 30-21-108
1
1
P106493
1
Install the compression springs (Item 1) [Figure 30-21110].
P106496
Install the O-ring and two back-up rings (Item 1) [Figure
30-21-108] on the outer balance ring.
Figure 30-21-109
1
1
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.
362 of 1148
30-21-32
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-21-111
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Figure 30-21-114
Assembly (Cont’d)
1
2
Figure 30-21-112
1
P106489
Install the valve housing (Item 1) [Figure 30-21-114],
taking care to maintain correct alignment.
Install the dowel pin (Item 1) [Figure 30-21-112].
NOTE: When installing the valve housing, the
balance rings and springs must remain in
position.
Figure 30-21-113
Install the bolts (Item 2) [Figure 30-21-114].
Figure 30-21-115
5
1
8
2
3
7
P106490
6
4
9
1
Install the O-ring (Item 1) [Figure 30-21-113].
MS2317S
Initially, tighten the bolts to 68 - 95 N•m (50 - 70 ft-lb)
torque in the sequence shown [Figure 30-21-115].
Finally, tighten the bolts to 149 N•m (110 ft-lb) torque in
the sequence shown [Figure 30-21-115].
363 of 1148
30-21-33
S530 Service Manual
Dealer Copy -- Not for Resale
P106491
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Assembly (Cont'd)
Figure 30-21-116
1
P106544
Dealer Copy -- Not for Resale
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].
364 of 1148
30-21-34
S530 Service Manual
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.
365 of 1148
30-30-1
Dealer Copy -- Not for Resale
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.
S530 Service Manual
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
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-30-2].
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].
366 of 1148
30-30-2
S530 Service Manual
Dealer Copy -- Not for Resale
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
HYDROSTATIC MOTOR CARRIER (CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-4
1
P-82714
Dealer Copy -- Not for Resale
Install MEL1420 Carrier Seal Tool (Item 1) [Figure 3030-4] 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
Install the O-ring (Item 1) [Figure 30-30-5].
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.
367 of 1148
30-30-3
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-6
Removal And Installation
2
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-54227
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the loader operator cab. (See Raising on Page 1030-2.)
Drain the fluid from the chaincase. (See Removing And
Replacing Fluid on Page 10-130-1.)
Remove the parking brake disc (Item 1) [Figure 30-306]. (See BRAKE on Page 40-10-1.)
Remove the bolts (Item 2) [Figure 30-30-6] from the
inside of the chaincase.
Installation: Tighten the bolts to 170 - 190 N•m (125 140 ft-lb) torque.
Figure 30-30-7
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
1
Remove the control panel. (See Removal And Installation
on Page 50-100-2.) or (See Removal And Installation on
Page 50-101-1.)
2
Remove the lift arm bypass control valve. (See Removal
And Installation on Page 20-50-2.)
Remove the traction lock assembly. (See TRACTION
LOCK on Page 60-120-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the front chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-1.)
Remove the front axle and sprocket. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-204.)
P-54226
Fasten the front drive chain to the chaincase as shown
(Item 1) [Figure 30-30-7].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-307] from the sprocket.
Remove the hydrostatic motor. (See HYDROSTATIC
DRIVE MOTOR on Page 30-20-1.)
368 of 1148
30-30-4
S530 Service Manual
Dealer Copy -- Not for Resale
Lift and block the loader. (See Procedure on Page 10-101.)
HYDROSTATIC MOTOR CARRIER (CONT’D)
Removal And Installation (Cont’d)
Figure 30-30-8
P-54235A
Dealer Copy -- Not for Resale
Slide the motor carrier out of the chaincase [Figure 3030-8].
Installation: Clean and dry the motor carrier sealing
surface and transmission sealing face. Apply
polyurethane sealant to both surfaces.
Figure 30-30-9
1
P-39813
Fasten a chain hoist to the bolt (Item 1) on the motor
carrier and remove the carrier from the loader [Figure
30-30-9].
369 of 1148
30-30-5
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Parts Identification
Description
Shaft
Plug
Bearing
Race
Housing
Snap Ring
Seal
1
2
3
4
5
4
3
6
7
NA6549S
370 of 1148
30-30-6
S530 Service Manual
Dealer Copy -- Not for Resale
Ref.
1.
2.
3.
4.
5.
6.
7.
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-12
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
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.
Refer to [Figure 30-30-10] for the correct dimensions of
the tool needed.
Figure 30-30-13
Dealer Copy -- Not for Resale
MC-2102
Remove the shaft seal. (See Shaft Seal Removal And
Installation on Page 30-30-2.)
Figure 30-30-11
2
1
P-4365
Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-30-13] on the sprocket shaft.
1
Put the assembly in the hydraulic press and remove the
bearing (Item 2) [Figure 30-30-13] from the shaft.
P-82709
Remove the snap ring (Item 1) [Figure 30-30-11] from
the motor carrier shaft.
371 of 1148
30-30-7
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Disassembly
Figure 30-30-14
2
1
P-39817
Dealer Copy -- Not for Resale
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.
372 of 1148
30-30-8
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-17
Assembly
Clean all parts in solvent and dry with compressed air.
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 3030-17].
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
housing [Figure 30-30-16].
Press the bearing race in until it is fully seated in the
carrier housing.
373 of 1148
30-30-9
S530 Service Manual
Dealer Copy -- Not for Resale
Press the outer bearing race into the motor carrier
housing [Figure 30-30-17].
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-19
Assembly (Cont’d)
Figure 30-30-18
2
2
1
1
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 30-3018] on the shaft as shown.
374 of 1148
Put the outer bearing over the end of the shaft and press
the bearing on with the press tool (Item 2) [Figure 30-3019].
30-30-10
S530 Service Manual
Dealer Copy -- Not for Resale
3
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-22
Assembly (Cont’d)
Figure 30-30-20
1
P-4375
1
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-3022] and install the shaft seal.
P-82708
Figure 30-30-23
Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-30-21
P-39821
Use a rubber mallet [Figure 30-30-23], tap down on the
shaft.
1
P-82707
Install the seal (Item 1) [Figure 30-30-21] on the
sprocket shaft.
375 of 1148
30-30-11
S530 Service Manual
Dealer Copy -- Not for Resale
Install the snap ring (Item 1) [Figure 30-30-20].
HYDROSTATIC MOTOR CARRIER (CONT’D)
Assembly (Cont’d)
Figure 30-30-24
Dealer Copy -- Not for Resale
1
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).
376 of 1148
30-30-12
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
Figure 30-31-1
Description
Two-Speed
Single 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 drivechains.
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
carrier. The brake disk is mounted to the shaft in the
motor carrier.
P-73920
P-68214
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
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.
377 of 1148
30-31-1
S530 Service Manual
Dealer Copy -- Not for Resale
Single / Two-Speed
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-4
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-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.
378 of 1148
30-31-2
S530 Service Manual
Dealer Copy -- Not for Resale
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
Figure 30-31-8
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-31-6
2
1
P-82716
P-82713
Installation: Install a new seal over the motor carrier
shaft [Figure 30-31-6].
Figure 30-31-7
NOTE: Before installing the hydrostatic motor,
inspect the plug (Item 2) [Figure 30-31-8]
located in the center of the carrier shaft for
correct torque. If the plug becomes loosen,
case drain lubrication fluid from the
hydrostatic motor can leak into the chaincase.
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].
379 of 1148
30-31-3
S530 Service Manual
Dealer Copy -- Not for Resale
Install the O-ring (Item 1) [Figure 30-31-8].
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-9
Removal And Installation
WARNING
2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
W-2059-0598
P-39781
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the loader operator cab. (See Raising on Page 1030-2.)
Drain the fluid from the chaincase. (See Removing And
Replacing Fluid on Page 10-130-1.)
Remove the parking brake disc (Item 1) [Figure 30-319]. (See BRAKE on Page 40-10-1.)
Remove the six motor carrier mounting bolts (Item 2)
[Figure 30-31-9] from the inside of the chaincase.
Installation: Tighten the motor carrier mounting bolts to
170 - 190 N•m (125 - 140 ft-lb) torque.
Figure 30-31-10
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
1
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
2
Remove the lift arm bypass control valve. (See Removal
And Installation on Page 20-50-2.)
Remove the traction lock assembly. (See TRACTION
LOCK on Page 60-120-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the front chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-1.)
Remove the front axle and sprocket. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-204.)
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.)
380 of 1148
P-54226
For ease of removal, fasten the front drivechain
(previously removed) to the chaincase as shown (Item 1)
[Figure 30-31-10].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drivechain (Item 2) [Figure 30-3110] from the sprocket.
30-31-4
S530 Service Manual
Dealer Copy -- Not for Resale
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Removal And Installation (Cont’d)
Figure 30-31-11
P-54235A
Dealer Copy -- Not for Resale
Slide the motor carrier out of the chaincase [Figure 3031-11].
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
1
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].
381 of 1148
30-31-5
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) (CONT’D)
Parts Identification
Description
Shaft
Plug
Bearing
Race
Housing
Snap Ring
Seal
1
2
3
5
4
4
3
6
7
NA6550S
382 of 1148
30-31-6
S530 Service Manual
Dealer Copy -- Not for Resale
Ref.
1.
2.
3.
4.
5.
6.
7.
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-15
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
(7.000 in)
P-39816
Put the motor carrier in the hydraulic press as shown
[Figure 30-31-15].
MC-2102
Figure 30-31-14
NOTE: The outer bearing will now be free from the
shaft.
Figure 30-31-16
2
1
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 motor carrier shaft seal. (See Shaft Seal
Removal And Installation on Page 30-31-2.).
Remove the snap ring (Item 1) [Figure 30-31-14] from
the motor carrier shaft using the snap ring pliers.
383 of 1148
Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-31-16] on the shaft.
Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 3031-16] from the shaft.
NOTE: The sensor disc (Item 2) [Figure 30-31-16] 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.
30-31-7
S530 Service Manual
Dealer Copy -- Not for Resale
It is necessary to locate or fabricate a press tool for this
procedure [Figure 30-31-13].
Use 57,2 mm (2-1/4 in) driver tool and press the shaft out
of the housing [Figure 30-31-15].
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Disassembly (Cont’d)
Figure 30-31-17
2
1
P-39817
Dealer Copy -- Not for Resale
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.
384 of 1148
30-31-8
S530 Service Manual
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-20
Assembly
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and damage. Replace any worn
or damaged parts.
Figure 30-31-19
P-39819
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
Put the motor carrier housing in the press as shown
[Figure 30-31-19].
Press the bearing race in until it is fully seated in the
carrier housing.
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].
Press the bearing race in until it is fully seated in the
carrier housing.
385 of 1148
30-31-9
S530 Service Manual
Dealer Copy -- Not for Resale
Turn the motor carrier housing over as shown [Figure 3031-20].
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-22
Assembly (Cont’d)
Figure 30-31-21
1
1
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
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 driver tools from the sprocket
shaft.
Remove the press and drive tools from the shaft.
386 of 1148
30-31-10
S530 Service Manual
Dealer Copy -- Not for Resale
2
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-25
Assembly (Cont’d)
Figure 30-31-23
1
1
P-82708
NOTE: Use the snap ring pliers to spread the snap
ring so it will fit over the sprocket shaft.
Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-23] over the shaft.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-3125] and install the shaft seal.
Figure 30-31-26
Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-31-24
P-76463
Use a rubber mallet [Figure 30-31-26], tap down on the
shaft.
1
P-82707
Put the shaft seal (Item 1) [Figure 30-31-24] on the
shaft.
387 of 1148
30-31-11
S530 Service Manual
Dealer Copy -- Not for Resale
P-4375
Put the snap ring (Item 1) [Figure 30-31-23] over the end
of the sprocket shaft.
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Assembly (Cont’d)
Figure 30-31-27
1
P-76467
Dealer Copy -- Not for Resale
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).
388 of 1148
30-31-12
S530 Service Manual
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.
Dealer Copy -- Not for Resale
The charge pressure sender is located on the hydraulic
fan motor. Charge pressure alarm settings are preprogrammed into the main controller and are based on
loader type and options installed.
389 of 1148
30-40-1
S530 Service Manual
CHARGE PRESSURE (CONT’D)
Testing
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 30-40-2
The tools listed will be needed to do the following
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
locally. Must be rated for pressures above 6895 kPa (68,9
bar) (1000 psi).
3
2
3
Figure 30-40-1
P-43196D
1
3
Assemble the gauge (Item 1), hose (Item 2), and the
correct test coupler (Item 3) [Figure 30-40-2]. Tighten all
fittings.
WARNING
2
4
P121789
Test ports have changed on the main valve. If your test
port looks like (Item 2), use test coupler (Item 1). If your
test port looks like (Item 4), use test coupler (Item 3)
[Figure 30-40-1].
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
390 of 1148
30-40-2
S530 Service Manual
Dealer Copy -- Not for Resale
WARNING
CHARGE PRESSURE (CONT’D)
Connect the Remote Start Tool. (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.)
Testing (Cont’d)
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 3040-2].
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 - 32,0 bar) (365 - 465 psi) with the pump
in neutral.
P109149B
Dealer Copy -- Not for Resale
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].
391 of 1148
30-40-3
S530 Service Manual
CHARGE PRESSURE (CONT’D)
Figure 30-40-6
Adjusting
Non SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
N-19568
I-2003-0888
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 ftlb) torque.
Inspect the poppet, spring, and poppet seat for wear or
damage.
Inspect the seat inside the hydrostatic pump case for
wear or damage.
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30-40-4
S530 Service Manual
Dealer Copy -- Not for Resale
There are several different thickness of the shims (Item 1)
[Figure 30-40-6] used to adjust the charge pressure.
Figure 30-40-5
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
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 30-40-7
There are several different thickness of shims (Item 1)
[Figure 30-40-8] used to adjust the charge pressure.
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.
1
The charge pressure is 2688 - 3033 kPa (26,8 - 30,3 bar)
(390 - 440 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 ftlb) torque.
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S530 Service Manual
Dealer Copy -- Not for Resale
P-64435
CHARGE PRESSURE (CONT’D)
Sender Removal And Installation (Later Models)
Sender Removal And Installation (Earlier Models)
Figure 30-40-11
Remove the fan duct. (See Fan Duct Removal And
Installation on Page 70-40-4.)
Figure 30-40-9
1
2
P115656
1
P106779
Dealer Copy -- Not for Resale
Disconnect the wiring harness (Item 1) and remove the
hydraulic charge pressure sender (Item 2) [Figure 30-4011].
Disconnect the wire harness (Item 1) [Figure 30-40-9]
from the sender.
Figure 30-40-10
1
P106780
Remove the sender (Item 1) [Figure 30-40-10] from the
motor.
Installation: Tighten the charge pressure sender to 10 10,9 N•m (7.4 - 8.1 ft-lb) torque.
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30-40-6
S530 Service Manual
HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bidirectional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The
function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the fluid 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.
Dealer Copy -- Not for Resale
The hydrostatic pump is located in the center of the
mainframe mounted to the engine flywheel housing.
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30-50-1
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-2
Removal And Installation
Remove the hydrostatic pump / engine assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-14.)
Remove the Hydraulic Pump. (See Removal And
Installation on Page 20-60-8.)
Remove the Drive Belt. (See DRIVE BELT on Page 3060-1.)
1
P-90222
IMPORTANT
I-2003-0888
Use a puller (Item 1) [Figure 30-50-2] to loosen the
pulley from the pump drive shaft.
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-1
Figure 30-50-3
1
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-50-1] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque.
P-90223
Remove the two bolts (Item 1) [Figure 30-50-3] and nuts.
Installation: Tighten the bolts and nuts to 88 - 95 N•m
(65 - 70 ft-lb) torque.
396 of 1148
30-50-2
S530 Service Manual
Dealer Copy -- Not for Resale
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
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.
Dealer Copy -- Not for Resale
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.)
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30-50-3
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-5
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
There are four replenishing / high pressure relief valves
(Item 1) [Figure 30-50-4] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
Inspect for damage and replace as needed.
Inspect the O-ring (Item 2) [Figure 30-50-5] for damage
and replace as needed.
If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
The pressure setting for a new high pressure relief valve
is 34500 kPa (345 bar) (5000 psi).
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S530 Service Manual
Dealer Copy -- Not for Resale
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
torque.
HYDROSTATIC PUMP (CONT’D)
1
11
4
10
5
8
3 4
1
3
2
1
7
9
1
26
6
9
9
12
10
4
9
11
8
14
16
13
2
17
2
15
12
17
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Snap Ring
Washer
Seal
Bearing
Key
Shaft
Housing
Plug
O-ring
Cover
Bolt
Pin
Swash Plate
Thrust Plate
Piston Assembly
Piston Retainer
Retainer
Block
Spring
Valve Plate
Gasket
Poppet
Shim
Replenishing/High
Pressure Relief Valve
Coupler
Dust Seal
25.
26.
2
20
18
19
8
17
9
12
23
19
21
22
24
8
9
9
8
12
4
9
25
9
9
12
24
9
399 of 1148
11
30-50-5
D-2428C
S530 Service Manual
Dealer Copy -- Not for Resale
Parts Identification (Left Half)
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
Ref. Description
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Bolt
End Cap
Plug
O-ring
Replenishing/High
Pressure Relief Valve
Gasket
Bearing
Pin
Valve Plate
Washer
Spring
Block
Retainer
Piston Assembly
Thrust Plate
Swash Plate
Housing
Seal
Cover
Shaft
Snap Ring
Dust Seal
Piston Retainer
3
4
5
3
4
2
1
1
4
5
6
4
7
9
3
10
10
8
Dealer Copy -- Not for Resale
1.
2.
3.
4.
5.
13
11
13
10
23
12
8
15
13
14
22
1
16
3
4
7
17
4
8
19
18
7
21
21
7
19
4
20
4
4
3
1
21
D-2427B
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30-50-6
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-8
Disassembly
NOTE: The disassembly procedure is shown on the
left half of the hydrostatic pump. The
procedure is the same for the right half of the
hydrostatic pump.
3
Figure 30-50-6
1
2
3
1
N-19571
1
Remove the pump coupler (Item 1) [Figure 30-50-8].
Remove the O-ring (Item 2) [Figure 30-50-8].
Remove the two O-rings (Item 3) [Figure 30-50-8].
P-43858
Dealer Copy -- Not for Resale
1
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].
401 of 1148
30-50-7
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-12
Disassembly (Cont’d)
2
1
Figure 30-50-10
1
N-17194
2
N-19551
Remove the valve plate locating pin (Item 1) [Figure 3050-12].
Remove the needle bearing (Item 2) [Figure 30-50-12].
Remove the end cap (Item 1) [Figure 30-50-10].
Dealer Copy -- Not for Resale
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].
402 of 1148
30-50-8
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-16
Disassembly (Cont’d)
2
2
Figure 30-50-14
1
2
2
1
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.
Figure 30-50-17
Dealer Copy -- Not for Resale
Remove the piston retainer (Item 1) and pistons [Figure
30-50-14] from the cylinder block.
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 30-5015] from the cylinder block.
403 of 1148
30-50-9
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-20
Disassembly (Cont’d)
Figure 30-50-18
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-20] from
the pump housing. Remove the drive shaft and bearing
from the housing.
Turn the pump over and remove the drive shaft key (Item
1), snap ring (Item 2), and the washer (Item 3) [Figure
30-50-18].
Figure 30-50-21
Dealer Copy -- Not for Resale
N-17481
Figure 30-50-19
1
1
N-17241
Remove the snap ring (Item 1) [Figure 30-50-21] from
the drive shaft. Remove the bearing.
N-17239
Remove the seal (Item 1) [Figure 30-50-19] from the
pump housing.
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S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-24
Disassembly (Cont’d)
Figure 30-50-22
2
1
1
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)
[Figure 30-50-24] from the pump housing.
N-17242
Figure 30-50-25
Figure 30-50-23
2
1
1
1
1
N-17246
Remove the bolts (Item 1) from the pump housing.
Remove the linkage bracket (Item 2) [Figure 30-50-25].
N-17243
Remove the bolts (Item 1) [Figure 30-50-23] from the
trunnion cover. Remove the cover.
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30-50-11
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the snap ring (Item 1) [Figure 30-50-22].
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-28
Disassembly (Cont’d)
Figure 30-50-26
1
2
1
N-17248
N-17247
Remove the O-ring (Item 1) and bearing race (Item 2)
[Figure 30-50-28] from the pump housing.
Figure 30-50-29
Figure 30-50-27
1
1
N-17251
N-17250
Remove the bearing (Item 1) [Figure 30-50-29].
Remove the seal (Item 1) [Figure 30-50-27].
406 of 1148
30-50-12
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the trunnion cover (Item 1) [Figure 30-50-26].
HYDROSTATIC PUMP (CONT’D)
Disassembly (Cont’d)
Figure 30-50-30
1
N-17252
Dealer Copy -- Not for Resale
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
1
N-17253
Remove the bearing (Item 1) [Figure 30-50-31] from the
swash plate.
407 of 1148
30-50-13
S530 Service Manual
Figure 30-50-34
HYDROSTATIC PUMP (CONT’D)
Assembly
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn
or damaged parts.
1
Figure 30-50-32
1
N-17249
Install the bearing (Item 1) [Figure 30-50-34] on the
swash plate shaft.
N-17253
Install the bearing (Item 1) [Figure 30-50-32] on the
swash plate.
Figure 30-50-33
1
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
housing [Figure 30-50-33].
408 of 1148
30-50-14
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-50-35
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-38
Assembly (Cont’d)
Figure 30-50-36
1
2
1
2
N-17246
Install the linkage bracket (Item 1) and the bolts (Item 2)
[Figure 30-50-38]. Tighten to 24 - 30 N•m (18 - 22 ft-lb)
torque.
Install the seal (Item 1) [Figure 30-50-36] in the trunnion
cover.
Figure 30-50-39
Figure 30-50-37
2
1
1
N-17244
N-17247
Install the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-50-39].
Install the trunnion cover (Item 1) [Figure 30-50-37].
409 of 1148
30-50-15
S530 Service Manual
Dealer Copy -- Not for Resale
N-17250
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-42
Assembly (Cont’d)
Figure 30-50-40
1
N-17241
1
1
Install the bearing and snap ring (Item 1) [Figure 30-5042] on the shaft.
N-17243
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.
410 of 1148
30-50-16
S530 Service Manual
Dealer Copy -- Not for Resale
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.
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-46
Assembly (Cont’d)
1
1
Figure 30-50-44
1
1
1
2
3
N-17200
Install the four pins (Item 1) [Figure 30-50-46] into the
cylinder block.
Install the seal (Item 1) [Figure 30-50-44] into the pump
housing.
Install the washer (Item 2) into the retainer (Item 3)
[Figure 30-50-46].
Dealer Copy -- Not for Resale
N-17239
Figure 30-50-47
Figure 30-50-45
1
3
2
1
N-17199
N-17481
Install the washer (Item 1), snap ring (Item 2), and the
drive shaft key (Item 3) [Figure 30-50-45].
411 of 1148
Install the ball guide and washer (Item 1) [Figure 30-5047] onto the pins.
30-50-17
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-50
Assembly (Cont’d)
1
2
Figure 30-50-48
2
N-17194
1
Install the needle bearing (Item 1) and valve plate
locating pin (Item 2) [Figure 30-50-50].
N-17198
Figure 30-50-49
2
1
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
surface of the end cap.
N-17197
Install the cylinder block (Item 1) [Figure 30-50-49] and
piston assembly over the shaft and into the housing.
412 of 1148
The valve plate locating spring pin (Item 2) [Figure 3050-51] must protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the end cap.
30-50-18
S530 Service Manual
Dealer Copy -- Not for Resale
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.
HYDROSTATIC PUMP (CONT’D)
Figure 30-50-54
Assembly (Cont’d)
1
1
Figure 30-50-52
1
2
N-19550
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-50-54] to 47 - 61
N•m (35 - 45 ft-lb) torque.
Coat the backside of the valve plate with assembly lube.
Install the valve plate (Item 1) [Figure 30-50-52] onto the
end cap.
Figure 30-50-55
Dealer Copy -- Not for Resale
N-17193
The notch (Item 2) [Figure 30-50-52] on the valve plate
must engage the locating pin.
Figure 30-50-53
1
2
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.
413 of 1148
30-50-19
S530 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-56
2
1
N-19570
Dealer Copy -- Not for Resale
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
1
P-43858
Install the four bolts (Item 1) [Figure 30-50-57]. Tighten
to 47 - 61 N•m (35 - 45 ft-lb) torque.
414 of 1148
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S530 Service Manual
HYDROSTATIC PUMP (SJC)
Description
The SJC hydrostatic pump is a fully proportional dual
piston pump in one pump casing. The end caps are
removable to gain access to the rotating assemblies.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a
spool in the hydraulic controller that directs flow to a
servo piston.
The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
forward or reverse drive motor rotation is obtained.
There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
Ports are labeled on the hydrostatic pump casting.
Dealer Copy -- Not for Resale
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
415 of 1148
30-51-1
S530 Service Manual
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
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
1
Controller solenoids can be bled of trapped air in the
controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
P-90239
Disconnect the electrical harness connectors (Item 1)
[Figure 30-51-3] from both sides of the hydrostatic
pump.
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Raise the operator cab. (See Raising on Page 10-30-2.)
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 30-51-2
Figure 30-51-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 3051-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.
416 of 1148
30-51-2
S530 Service Manual
Dealer Copy -- Not for Resale
Removal:
WARNING
Figure 30-51-7
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Removal And Installation
(Cont'd)
1
Figure 30-51-5
2
1
1
3
P-90210
2
P-90210
Remove the controller (Item 1) [Figure 30-51-5] from the
pump.
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump.
NOTE: When a hydraulic controller is replaced, the
hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Page 30-51-26.)
Figure 30-51-8
Installation:
Figure 30-51-6
1
2
2
P-64978
1
P-90209
NOTE: Do NOT remove the three screens (Item 2)
[Figure 30-51-6] they will be damaged during
removal and must be replaced.
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in
the center of the servo piston groove (Item 1) [Figure 3051-6].
With the engine running and the loader on jackstands,
bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
two turns. Leave the screw loose until fluid comes
dripping out of the set screw. Tighten set screw to 2 N•m
(18 in-lb) torque.
Repeat the bleed procedure for all the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].
417 of 1148
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S530 Service Manual
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Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4
N•m (7.7 ft-lb) torque. Ensure bolts are tightened to
specifications.
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-10
Removal And Installation
Remove the hydrostatic pump / engine assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-14.)
Remove the Hydraulic Pump. (See Removal And
Installation on Page 20-60-8.)
Remove the Drive Belt. (See Belt Replacement on Page
30-60-2.)
1
P-90222
IMPORTANT
I-2003-0888
Use a puller (Item 1) [Figure 30-51-10] to loosen the
pulley from the pump drive shaft.
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.
Figure 30-51-9
Figure 30-51-11
1
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-9] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque.
Remove the two mounting bolts and nuts (Item 1) [Figure
30-51-11].
Installation: Tighten the mounting bolts and nuts to 88 95 N•m (65 - 70 ft-lb) torque.
418 of 1148
30-51-4
S530 Service Manual
Dealer Copy -- Not for Resale
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
HYDROSTATIC PUMP (SJC) (CONT'D)
Removal And Installation (Cont’d)
Figure 30-51-12
1
P114386
Dealer Copy -- Not for Resale
Remove the mounting bolt (Item 1) [Figure 30-51-12] at
the hydraulic pump mounting bracket.
Installation: Tighten the mounting bolt to 125 - 135 N•m
(90 - 100 ft-lb) torque.
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 30-51-6.)
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S530 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
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.
Dealer Copy -- Not for Resale
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 the plugs to 25 N•m (18 ft-lb) torque.
420 of 1148
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S530 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Parts Identification
O-ring
Bolt
End Housing
Right Rotating Assembly
Timing Pin
Bearing
Spacer/Coupler
Pin
Positioning Pin
Position Sensor
Washer
Steel Cover
Hydraulic Controller
High Pressure Relief
Case Housing
Plug
Dowel Pin
Charge Pressure Relief
Left Servo
Right Servo
Left Rotating Assembly
End Housing
3
4
6
1
1
5
7
9
8
1
1
2
10
11
2
12
2
16
2
16
17
14
15
13
13
20
18
14
22
19
5
6
2
21
8
9
10
12
421 of 1148
1
1
1
11
2
2
P-90240
30-51-7
S530 Service Manual
Dealer Copy -- Not for Resale
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-16
High Pressure Relief And Bypass Valve
Figure 30-51-14
1
2
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-16]
for scratches and replace as needed.
There are four system check relief valves (Item 1)
[Figure 30-51-14] in the back of the hydrostatic pump.
Inspect the spring (Item 2) [Figure 30-51-16] for
breakage.
Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-14].
Assembly: Tighten the cap to 150 - 170 N•m (111 - 125
ft-lb) torque.
Factory setting on the relief valve is 35000 kPa (350 bar)
(5075 psi).
Figure 30-51-15
4
2
Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.
3
1
P-64436
Replace the valve cap O-ring (Item 1) and back-up ring
(Item 2) [Figure 30-51-15].
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.
422 of 1148
30-51-8
S530 Service Manual
Dealer Copy -- Not for Resale
P-64431
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-18
Charge Relief Valve
1
Figure 30-51-17
4
2
3
6
5
P-64435
1
Inspect the O-ring (Item 1) [Figure 30-51-18].
P-64431
Inspect the sealing ring (Item 4) [Figure 30-51-18] and
the mating seat in the pump housing for damage or
foreign material.
Remove the charge relief valve.
Assembly: Tighten the 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.
423 of 1148
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S530 Service Manual
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The charge relief valve (Item 1) [Figure 30-51-17] is
located on the back of the hydrostatic pump.
Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-51-18] for damage or foreign material. Ensure
the poppet moves freely in its bore.
HYDROSTATIC PUMP (SJC) (CONT'D)
Note the connectors facing each other.
Disassembly And Assembly
Figure 30-51-21
Remove the hydrostatic pump / engine assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-14.)
1
Remove the hydrostatic pump. (See Removal And
Installation on Page 30-51-4.)
Figure 30-51-19
1
2
P-90228
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 30-5119]. (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.
424 of 1148
30-51-10
S530 Service Manual
Dealer Copy -- Not for Resale
1
HYDROSTATIC PUMP (SJC) (CONT'D)
Right End Housing
Disassembly And Assembly (Cont'd)
Figure 30-51-24
Figure 30-51-22
3
1
2
2
1
1
P-64445
P-90217
Left End Housing
Figure 30-51-25
3
Dealer Copy -- Not for Resale
Assembly: Note the slotted portion (Item 1) of the
positioning pin tightly fits the machined section on the
swash plate angle sensor shaft (Item 2) [Figure 30-5122].
1
Figure 30-51-23
1
2
1
P-64447
P-90218
Replace the O-ring (Item 1) [Figure 30-51-23].
425 of 1148
Remove the four mount bolts (Item 1) securing the end
housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-24] and [Figure 30-51-25].
Assembly: Alternately, tighten mount bolts to 130 N•m
(96 ft-lb) torque.
30-51-11
S530 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-28
Disassembly And Assembly (Cont'd)
Figure 30-51-26
1
P-64466
Ensure servo follower (Item 2) [Figure 30-51-27] is
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 3051-26].
Figure 30-51-29
Dealer Copy -- Not for Resale
P-64464
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].
426 of 1148
30-51-12
S530 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-30
RIGHT SIDE
1
2
P-64454
Dealer Copy -- Not for Resale
Figure 30-51-31
LEFT SIDE
1
2
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.
427 of 1148
30-51-13
S530 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-34
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
LEFT SIDE
P-64503
1
2
P-64502
Assembly: Align the timing pin (Item 1) [Figure 30-5132] 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.
428 of 1148
30-51-14
S530 Service Manual
Dealer Copy -- Not for Resale
1
2
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-38
Disassembly And Assembly (Cont'd)
Figure 30-51-36
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-38].
B25012
Figure 30-51-39
Figure 30-51-37
1
P-64475
B25011
Remove the pistons (Item 1) [Figure 30-51-39] from the
rotating block.
Left Side Rotating Group [Figure 30-51-37].
429 of 1148
30-51-15
S530 Service Manual
Dealer Copy -- Not for Resale
Right Side Rotating Group [Figure 30-51-36].
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-42
Disassembly And Assembly (Cont'd)
1
Figure 30-51-40
1
P-64471
Remove the spherical washer (Item 1) [Figure 30-5142].
P-64476
1
Figure 30-51-41
1
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].
430 of 1148
30-51-16
S530 Service Manual
Dealer Copy -- Not for Resale
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
plugged.
Figure 30-51-46
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
3
Figure 30-51-44
1
1
2
P-64479
Inspect mating surface for the slippers on the swash plate
(Item 1) [Figure 30-51-46].
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-51-44].
Remove the swash plate from the end cap housing (Item
2) [Figure 30-51-46].
Remove the slide ring (Item 3) [Figure 30-51-46], ensure
it pivots freely.
Figure 30-51-45
Figure 30-51-47
1
2
1
3
2
P-64478
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.
P-64480
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.
431 of 1148
30-51-17
S530 Service Manual
Dealer Copy -- Not for Resale
P-64474
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-50
2
Disassembly And Assembly (Cont'd)
1
1
Figure 30-51-48
2
3
1
P-64483
Assembly: Ensure bearing pins are in the holes of the
swash plate (Item 1) [Figure 30-51-48].
Assembly: Note shell bearing races have an edge (Item
2) [Figure 30-51-50] on them. The edges face towards
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
1
1
2
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.
432 of 1148
30-51-18
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the shell bearing races (Item 1) [Figure 30-5150].
P-64481
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-54
Disassembly And Assembly (Cont'd)
Figure 30-51-52
LEFT SIDE
1
1
P-76742
The pump seal (Item 1) [Figure 30-51-54] is removed by
inserting a screw into the seal and prying out.
P-64486
Figure 30-51-55
RIGHT SIDE
1
2
1
P-64488
P-76743
Remove the snap ring (Item 1) [Figure 30-51-52] and
[Figure 30-51-53] from the end housing.
The drive shaft can be tapped out of the end housing with
a rubber mallet.
Inspect wear surfaces for scratches and inspect splines
for excessive wear.
Inspect bearing (Item 1). If bearing needs replacement,
remove snap ring (Item 2) [Figure 30-51-55] and remove
bearing.
433 of 1148
30-51-19
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-51-53
Figure 30-51-58
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-56
1
1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 3051-58].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Dealer Copy -- Not for Resale
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].
434 of 1148
30-51-20
S530 Service Manual
Figure 30-51-62
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-60
1
P-64466
Assembly: Align the servo piston so the guide slot
(Item 1) [Figure 30-51-62] is parallel to the drive shaft
centerline. Measure with a straight-edge [Figure 30-5161].
Slide the servo piston assembly out of the bore. [Figure
30-51-60].
Figure 30-51-63
Dealer Copy -- Not for Resale
P-90237
Figure 30-51-61
1
2
1
2
P-64493
P-64467
Remove the bushings (Item 1), seals, and O-rings (Item
2) [Figure 30-51-63] from the pump housing.
435 of 1148
30-51-21
S530 Service Manual
Figure 30-51-66
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-64
1
1
2
2
P-64496
3
Remove the servo cover (Item 1) [Figure 30-51-66] from
the servo piston.
Each servo has a pair of bushings (Item 1), O-rings (Item
2), and square-cut seals (Item 3) [Figure 30-51-64].
Remove the O-ring (Item 2) [Figure 30-51-66] from the
cover.
Dealer Copy -- Not for Resale
P-64494
Figure 30-51-67
Figure 30-51-65
1
1
P-64497
P-64495
Remove the locknut (Item 1) [Figure 30-51-65] from the
servo piston.
Remove snap ring (Item 1) [Figure 30-51-67] from the
servo piston.
Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.
436 of 1148
30-51-22
S530 Service Manual
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
relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
Figure 30-51-68
1
2
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
P-64498
Inspect mechanism for broken parts.
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Replace O-ring (Item 2) [Figure 30-51-68]
Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.)
Figure 30-51-69
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
find an accessible connector to disconnect.
2
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.
Inspect center coupler (Item 2) [Figure 30-51-69].
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
437 of 1148
30-51-23
S530 Service Manual
Dealer Copy -- Not for Resale
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-68] from the servo piston.
Figure 30-51-72
HYDROSTATIC PUMP (SJC) (CONT'D)
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-70
1
1
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-72] from the
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]
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 30-51-73
Figure 30-51-71
1
1
1
1
1
1
P-90243
P-90242
Remove the plugs (Item 1) [Figure 30-51-71] from the
MB ports on the front side of the pump, and install 51711
kPa (517,1 bar) (7500 psi) pressure gauges.
438 of 1148
Remove drive hoses from the A and B ports (Item 1)
[Figure 30-51-73]. Plug the ports with metal caps. The
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
pump mechanical neutral setting.
30-51-24
S530 Service Manual
Dealer Copy -- Not for Resale
P-64973
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-76
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-74
1
1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-76]
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
Dealer Copy -- Not for Resale
P-90226
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
Turn the adjustment screw (Item 1) [Figure 30-51-77]
clockwise to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-75]
clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
439 of 1148
30-51-25
S530 Service Manual
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
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
Figure 30-51-78
NOTE: Procedure is shown for the left side hydraulic
controller. Procedure is the same for the right
side hydraulic controller except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
2
1
P-90238
WARNING
Shut loader OFF.
Remove the hydraulic hose from the X1 and X2 ports on
the pump. Install the plugs and tighten to 25 N•m (18 ftlb) torque.
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.
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
W-2017-0286
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-5126.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Connect the Remote Start Tool. (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.)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
440 of 1148
30-51-26
S530 Service Manual
Dealer Copy -- Not for Resale
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.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-81
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-79
1
P-64975
1
Install 3447 kPa (34,5 bar) 500 psi pressure gauges in
the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting [Figure 30-51-81].
Disconnect the hydraulic controller connectors (Item 1)
[Figure 30-51-79] from the loader wiring harness for the
hydraulic controller you are adjusting.
Figure 30-51-82
Dealer Copy -- Not for Resale
P-90239
Figure 30-51-80
1
1
2
P-90236
Loosen the locking screw (Item 1) [Figure 30-51-82].
P-90226
Start the loader using the Remote Start Tool and run at
an idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[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
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HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-85
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-83
1
1
P-90236
Turn the adjustment screw (Item 1) [Figure 30-51-85]
clockwise to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
Turn the adjustment screw (Item 1) [Figure 30-51-83]
clockwise until one of the gauges registers an increase in
system pressure. Mark the position of the adjustment
screw.
Figure 30-51-86
Dealer Copy -- Not for Resale
P-90236
Figure 30-51-84
1
2
1
P-90236
While holding the adjustment screw (Item 1) in position,
tighten the locking screw (Item 2) [Figure 30-51-86] to
6,1 N•m (4.5 ft-lb) torque.
P-90236
Turn the adjustment screw (Item 1) [Figure 30-51-84]
counterclockwise until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Shut loader OFF.
Remove the pressure gauges from the X1 and X2 ports
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the
loader wiring harness.
Perform a controller calibration
CALIBRATION on Page 60-160-1.)
442 of 1148
30-51-28
procedure.
(See
S530 Service Manual
DRIVE BELT
Figure 30-60-2
Belt Adjustment
1
The drive belt does not need adjustment. The belt has a
spring loaded idler that constantly maintains the correct
belt tension. The spring loaded idler stop adjustment,
detailed below, is critical for long belt life.
Stop Adjustment
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine and open the rear door.
P121579
Figure 30-60-1
Loosen the spring loaded idler adjustment bolt and pivot
bolt (Item 1) [Figure 30-60-2].
1
2
P109785
The spring loaded idler is located above the battery on
the left side of the engine [Figure 30-60-1].
P121578A
Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-60-3].
Tighten the spring loaded idler adjustment bolt and pivot
bolt (Item 1) [Figure 30-60-2] to 105 - 115 N•m (78 - 85
ft-lb) torque.
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 30-60-3
DRIVE BELT (CONT’D)
Figure 30-60-6
Belt Replacement
1
Stop the engine and open the rear door.
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Figure 30-60-4
2
1
P109783
Tighten the adjustment bolt (Item 1) [Figure 30-60-6] to
hold the spring loaded idler off the drive belt.
P109781
Remove the drive belt shield bolt (Item 1) [Figure 30-604].
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley. Inspect the pulleys for wear.
Figure 30-60-5
Install new drive belt.
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-6] and allow the idler to contact the drive
belt.
1
Continue the procedure on the next page.
2
P109782
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
the shield from the top and bottom drive belt shield
mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-60-5].
444 of 1148
30-60-2
S530 Service Manual
Dealer Copy -- Not for Resale
Loosen the spring loaded idler adjustment bolt and pivot
bolt (Item 1). Insert a breaker bar (Item 2) [Figure 30-606] into the slot provided in the stop arm as shown and
push the breaker bar down to release tension on the
drive belt.
DRIVE BELT (CONT’D)
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].
Belt Replacement (Cont’d)
Figure 30-60-7
Figure 30-60-9
1
1
2
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
torque wrench (Item 2) [Figure 30-60-7] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated.
Install the drive belt shield bolt (Item 1) [Figure 30-60-9].
Maintain torque on the stop arm and tighten the spring
loaded idler adjustment bolt and pivot bolt (Item 1)
[Figure 30-60-7] to 105 - 115 N•m (78 - 85 ft-lb) torque.
Close the rear door.
Install the battery. (See Removal And Installation on
Page 60-20-1.)
NOTE: The stop arm MUST be adjusted after 50 hours
operation with the new drive belt. (See Stop
Adjustment on Page 30-60-1.)
Figure 30-60-8
Top Mounting Bolt
See the SERVICE SCHEDULE for the correct
service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)
1
P107207A
Bottom Mounting Bolt
2
P107206
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NOTE: This procedure is required to preload a new
drive belt in order to achieve the correct stop
adjustment after the initial belt break-in
period.
P109781
DRIVE BELT (CONT’D)
Tensioner Disassembly And Assembly
Tensioner Removal And Installation (Earlier Models)
Figure 30-60-12
Stop the engine and open the rear door.
2
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
1
Remove the drive belt. (See Belt Replacement on Page
30-60-2.)
Figure 30-60-10
P114387
1
Remove the nut (Item 1) from the idler assembly and
remove the wheel (Item 2) [Figure 30-60-12].
2
Dealer Copy -- Not for Resale
Figure 30-60-13
3
P114385
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-60-10].
Installation: Tighten the adjustment bolt and the
mounting bolt to 105 - 115 N•m (78 - 85 ft-lb) torque.
1
Figure 30-60-11
2
P117155
Disassemble the tensioner assembly as shown [Figure
30-60-13].
Inspect the parts for wear and replace as needed.
1
NOTE: The wheel (Item 1) and the tensioner arm (Item
2) [Figure 30-60-13] are not serviceable and
must be replaced as a complete assembly.
P114384
Remove the tensioner assembly (Item 1) [Figure 30-6011].
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DRIVE BELT (CONT’D)
Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation (Later
Models)
Figure 30-60-16
Tensioner removal shown with engine removed for photo
clarity.
1
3
2
Stop the engine and open the rear door.
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Remove the drive belt. (See Belt Replacement on Page
30-60-2.)
Figure 30-60-14
P126275
1
Remove the nut (Item 1), bolt (Item 2) and tuned weight
(Item 3) [Figure 30-60-16] from the tensioner assembly.
2
Dealer Copy -- Not for Resale
Figure 30-60-17
3
2
P126273
1
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2), and remove the stop arm (Item 3)
[Figure 30-60-14].
Installation: Tighten the adjustment bolt and the
mounting bolt to 105 - 115 N•m (78 - 85 ft-lb) torque.
P126277
Figure 30-60-15
Remove the bolt (Item 1) and wheel (Item 2) [Figure 3060-17] from the tensioner assembly.
1
P126274
Remove the tensioner assembly (Item 1) [Figure 30-6015].
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DRIVE BELT (CONT’D)
Tensioner Pulley Disassembly And Assembly
(Cont’d)
Figure 30-60-18
1
2
P126284
Dealer Copy -- Not for Resale
Disassemble the tensioner assembly as shown [Figure
30-60-18].
Inspect the parts for wear and replace as needed.
NOTE: The wheel (Item 1) and the tensioner arm (Item
2) [Figure 30-60-18] are not serviceable and
must be replaced as a complete assembly.
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TWO-SPEED
Figure 30-70-1
Valve Block Removal And Installation
DANGER
1
1
P106954
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Remove the four hydraulic lines (Item 1) [Figure 30-70-1]
from the two-speed valve block.
Figure 30-70-2
D-1009-0409
2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
P106955
W-2059-0598
Disconnect the wire harness connector (Item 1) [Figure
30-70-2] from the two-speed solenoid.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Remove the two bolts (Item 2) [Figure 30-70-2] and
remove the valve block.
W-2017-0286
Raise the operator cab. (See Raising on Page 10-30-2.)
Mark all hydraulic hoses for proper installation.
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S530 Service Manual
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•
TWO-SPEED (CONT’D)
Valve Block Disassembly And Assembly
Figure 30-70-3
1
2
1
P106951
Dealer Copy -- Not for Resale
Remove the two bolts (Item 1) [Figure 30-70-3] from the
valve.
Remove the solenoid (Item 2) [Figure 30-70-3].
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].
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S530 Service Manual
DRAIN MANIFOLD
Description
The drain manifold is an external assembly in the drain
circuit that returns the hydraulic fluid to the reservoir.
Drain Manifold Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the operator cab. (See Raising on Page 10-30-2.)
Dealer Copy -- Not for Resale
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 30-80-1
1
2
3
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 30-801].
Remove the bolts (Item 3) [Figure 30-80-1].
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
40-20-1
40-20-1
40-20-2
40-20-4
40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40-30-1
40-30-1
40-30-1
40-30-2
40-30-3
Dealer Copy -- Not for Resale
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . .
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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40-02
S530 Service Manual
BRAKE
Disc Removal And Installation
Description
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Figure 40-10-1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
W-2059-0598
Raise the loader operator cab. (See Raising on Page 1030-2.)
P-85491
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier
shafts. An electric solenoid is sent power from a relay to
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the
discs.
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the traction lock assembly.
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
LOCK on Page 60-120-1.)
1
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are
located beneath the center chaincase cover.
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S530 Service Manual
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The brake is used to hold the machine in place. The
brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the front accessory panel.
Remove the control panel from the loader. (See Removal
And Installation on Page 50-100-2.)
BRAKE (CONT’D)
Figure 40-10-5
Disc Removal And Installation (Cont’d)
Figure 40-10-3
1
N-19083A
1
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 60-120-3.)
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.
Figure 40-10-4
1
2
N-19082A
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S530 Service Manual
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Remove the snap ring (Item 1) [Figure 40-10-4] from the
end of the sprocket on the hydrostatic motor carrier.
N-19105
DRIVE COMPONENTS
NA90845S
The drive components consist of the chaincase, drivechains, 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.
457 of 1148
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Description
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
MEL1407 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)
Lift and block the loader. (See Procedure on Page 10-101.)
NOTE: If the axle and bearings are being replaced,
loosen the sprocket mounting bolt inside the
chaincase before lifting and blocking the
loader. (See Axle, Sprocket And Bearings
Removal And Installation on Page 40-20-4.)
1
P114335
Install the puller (Item 1) [Figure 40-20-2] on the hub.
Remove the tire / wheel assembly. (See Mounting on
Page 10-160-2.)
Remove the fluid from the chaincase. (See Removing
And Replacing Fluid on Page 10-130-1.)
Figure 40-20-1
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
2
Remove the hub from the axle.
Figure 40-20-3
1
1
2
P114334
Remove the bolt (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolt to 1053 - 1119 N•m (775 825 ft-lb) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1]
across from each other.
458 of 1148
P114336
Remove the key (Item 1) [Figure 40-20-3] from the axle.
40-20-2
S530 Service Manual
Dealer Copy -- Not for Resale
WARNING
Remove the front chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-1.)
DRIVE COMPONENTS (CONT’D)
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
1
P114333
Dealer Copy -- Not for Resale
Install a slide hammer (Item 1) [Figure 40-20-4] with a
screw tip end into the axle seal.
Remove the axle seal.
Figure 40-20-5
P4814
Installation: Place the seal with the lip facing in [Figure
40-20-5].
Installation: Using a hammer, install the new axle seal
until the tool (MEL1407) is flush with the edge of the axle
tube [Figure 40-20-5].
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S530 Service Manual
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
Removal And Installation on Page 40-30-1.)
The tools listed will be needed to do the following
procedure:
MEL1242 - Port-a-Power
MEL1202 - Axle Bearing Service Set
Remove the fluid from the chaincase. (See Removing
And Replacing Fluid on Page 10-130-1.)
Figure 40-20-6
NOTE: The procedure shown for removal and
installation of the axle, sprocket, and bearings
is for a front axle. This procedure will be the
same for the rear axle.
2
DANGER
P-68196
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Remove the axle sprocket bolt (Item 1) and washer (Item
2) [Figure 40-20-6].
Installation: Tighten the axle sprocket bolt to 410 - 450
N•m (300 - 330 ft-lb) torque.
Remove the axle hub. (See Axle Seal Removal And
Installation on Page 40-20-2.)
Figure 40-20-7
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Lift and block the loader. (See Procedure on Page 10-101.)
P-4158A
Install a Port-a-Power ram between the two sprockets
[Figure 40-20-7].
Raise the operator cab. (See Raising on Page 10-30-2.)
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1
DRIVE COMPONENTS (CONT’D)
NOTE: Hold the axle during removal. It will slide
freely after the bearing is removed from the
mounting surface.
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-20-10
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drivechain from the sprocket.
Figure 40-20-8
1
2
Press the splined end of the axle free from the bearing
[Figure 40-20-10].
P5406A
Remove the sprocket (Item 1) and inner bearing (Item 2)
[Figure 40-20-8].
Installation: Pack the inner and outer bearing with
grease before installation.
Figure 40-20-9
1
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed to
do the following procedure:
Press the bearing off the mounting surface off of the axle
[Figure 40-20-9].
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P-4171
DRIVE COMPONENTS (CONT’D)
Figure 40-20-12
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-20-11
1
1
P4812
Use the long driver handle (Item 1) [Figure 40-20-12]
and the bearing cup removal tool to remove the inner
bearing cup.
P-4175
Figure 40-20-13
Dealer Copy -- Not for Resale
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation. It will slide
freely after the bearing is pressed over the
splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 4020-11] that contacts the inner race of the bearing only.
Press the bearing onto the mounting surface until the
bearing is fully seated [Figure 40-20-11].
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 40-20-13].
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DRIVE COMPONENTS (CONT’D)
Figure 40-20-16
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-20-14
2
1
P4811
Install the installation tool (Item 1) [Figure 40-20-16] on
the threaded rod. Install the nut.
P4816
Use the slide hammer to remove the bearing cup from
the axle tube [Figure 40-20-14].
Tighten the nut until the bearing cup is seated.
Figure 40-20-15
Remove the installation tool and threaded rod.
2
1
3
P5468A
Use the bearing cup installation tool (Item 1) [Figure 4020-15] and (Item 1) [Figure 40-20-16].
Put the inner cup (Item 2) [Figure 40-20-15] in the axle
tube.
Install the long threaded rod (Item 2) [Figure 40-20-16]
into the axle tube and through the installation tool (Item
1) [Figure 40-20-15].
Install the nut (Item 3) [Figure 40-20-15].
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Hold the inside nut (Item 3) [Figure 40-20-15] with a
wrench and tighten the outside nut [Figure 40-20-16].
DRIVE COMPONENTS (CONT’D)
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
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.
Dealer Copy -- Not for Resale
Figure 40-20-17
P4813
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-17].
464 of 1148
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DRIVE COMPONENTS (CONT’D)
Remove the brake disc. (See Disc Removal And
Installation on Page 40-10-1.)
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 40-20-18
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Front Drivechain
Rear Drivechain
P-68194
NOTE: It is necessary to remove the rear axle and
drivechain if the front chain has to be
removed.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front
Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the fluid from the chaincase. (See Removing
And Replacing Fluid on Page 10-130-1.)
465 of 1148
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Dealer Copy -- Not for Resale
•
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
Dealer Copy -- Not for Resale
Figure 40-20-19
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 40-20-19].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-19]. 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
466 of 1148
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S530 Service Manual
CHAINCASE
Figure 40-30-1
Description
3
3
The chaincase contains the drive components.
Front Cover Removal And Installation
1
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
2
Raise the loader operator cab. (See Raising on Page 1030-2.)
3
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
3
P-34255
Remove the front chaincase cover mounting screws
(Item 1) [Figure 40-30-1].
DANGER
NOTE: There are tabs (Item 3) [Figure 40-30-1] on the
side of the cover to help pry the covers off.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
467 of 1148
40-30-1
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the front chaincase cover (Item 2) [Figure 4030-1] from the loader.
Disconnect the lift control cross bar (Item 2) [Figure 4030-2] from the lift spool on the main control valve.
CHAINCASE (CONT’D)
Center Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the loader operator cab. (See Raising on Page 1030-2.)
Disconnect the electrical connector (Item 3) [Figure 4030-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 4030-2].
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
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.
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Dealer Copy -- Not for Resale
W-2059-0598
P-90328
Figure 40-30-3
1
D-1009-0409
3
2
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
1
Figure 40-30-2
4
P-90048
Remove the chaincase cover mounting screws (Item 1)
[Figure 40-30-3].
1
2
Remove the center chaincase cover (Item 2) [Figure 4030-3] from the loader.
3
NOTE: There are tabs (Item 3) [Figure 40-30-3] 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
screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
P-90047
If loader is equipped with SJC, skip to [Figure 40-30-3].
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].
468 of 1148
40-30-2
S530 Service Manual
Figure 40-30-4
CHAINCASE (CONT’D)
Rear Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
1
Raise the loader operator cab. (See Raising on Page 1030-2.)
3
2
1
DANGER
3
P-90056
Remove the rear chaincase cover mounting screws (Item
1) [Figure 40-30-4].
Remove chaincase cover (Item 2) [Figure 40-30-4].
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
NOTE: There are tabs (Item 3) [Figure 40-30-4] 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
screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
If loader is equipped with two-speed, remove the twospeed valve. (See Valve Block Removal And Installation
on Page 30-70-1.)
Remove the drain manifold. (See Drain Manifold Removal
And Installation on Page 30-80-1.)
Disconnect the front steering linkage bars from the rear
linkage bars. (See Removal And Installation on Page 50100-2.)
Move the linkage bars to allow adequate space to
remove the rear chaincase cover.
469 of 1148
40-30-3
S530 Service Manual
Dealer Copy -- Not for Resale
P-90328
Dealer Copy -- Not for Resale
470 of 1148
40-30-4
S530 Service Manual
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
50-10-1
50-10-1
50-10-1
50-10-2
50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-20-1
50-20-1
50-20-2
50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . .
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-30-1
50-30-1
50-30-1
50-30-2
50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-31-1
50-31-1
50-31-1
50-31-2
50-31-2
50-31-3
50-31-3
50-31-4
50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .
50-40-1
50-40-1
50-40-1
50-40-3
50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .
50-41-1
50-41-1
50-41-1
50-41-4
50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-50-1
50-50-1
50-50-2
50-50-4
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-60-1
50-60-1
50-60-1
50-60-2
471 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
MAINFRAME
50-70-1
50-70-1
50-70-2
50-70-2
50-70-3
50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-80-1
50-80-1
50-80-3
50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-90-1
50-90-1
50-90-1
50-90-2
50-90-3
50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-91-1
50-91-1
50-91-1
50-91-2
50-91-2
50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
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
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
472 of 1148
50-02
50-110-1
50-110-1
50-110-1
50-110-2
S530 Service Manual
Dealer Copy -- Not for Resale
REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Striker Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-111-1
50-111-1
50-111-1
50-111-4
50-111-5
50-111-5
50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-112-1
50-112-1
50-112-1
50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-130-1
50-130-1
50-130-1
50-130-1
50-130-2
50-130-2
50-130-3
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-140-1
50-140-1
50-140-1
50-140-2
50-140-3
50-140-4
50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-150-1
50-150-1
50-150-2
50-150-3
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Dealer Copy -- Not for Resale
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-4
RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-3
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Dealer Copy -- Not for Resale
FAN DUCT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
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SEAT BAR
Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ftlb) torque.
Description
The seat bar is the secondary restraint system that has a
sensor that automatically stops the loader functions until
the seat bar is lowered.
Lower the operator cab. (See Lowering on Page 10-303.)
Figure 50-10-3
The seat bar is located in the operator cab.
Removal And Installation
Figure 50-10-1
1
1
Remove the seat bar (Item 1) [Figure 50-10-3] from the
operator cab.
1
Reverse the above procedure to install the seat bar into
the operator cab.
P-85654
P-85653
Disconnect the seat bar sensor (Item 1) [Figure 50-10-1]
from the cab harness.
Lower the seat bar.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 50-10-2
1
P117625
Remove the seat bar mounting nuts (Item 1) [Figure 5010-2] (both sides).
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P-90021
SEAT BAR (CONT’D)
Disassembly And Assembly
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ftlb) torque.
Figure 50-10-4
Figure 50-10-6
4
6
5
5
7
4
3
6
3
2
9
7
2
8
10
1
1
P-90022
P-90023
Figure 50-10-5
4
4
5
9
8
3
3
6
2
Dealer Copy -- Not for Resale
Figure 50-10-7
5
6
2
7
10
1
1
7
N-19219
N-19220
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-105].
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-6] and [Figure 50-107].
Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure
50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ftlb) 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.
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SEAT BAR (CONT’D)
Figure 50-10-9
Compression Spring Disassembly And Assembly
7
6
Figure 50-10-8
1
5
4
8
3
2
1
P-90028
Disassemble and assemble the seat bar compression
spring and parts as shown in [Figure 50-10-9].
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 5010-9] out of the clevis.
Assembly: Apply Loctite® #518 adhesive to the bolt
threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Bushing (Item 4)
Clevis (Item 5)
Pin (Item 6)
Bushing (Item 7)
Rue Ring (Item 8)
Dealer Copy -- Not for Resale
N-19222
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
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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
Raise the operator cab. (See Raising on Page 10-30-2.)
P-85657
WARNING
Remove the two bolts (Item 1) [Figure 50-20-2].
Figure 50-20-3
W-2760-0309
1
Figure 50-20-1
2
3
1
P117625
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).
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S530 Service Manual
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AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
OPERATOR CAB (CONT’D)
Removal And Installation
Gas Spring Bracket Disassembly And Assembly
Figure 50-20-5
Figure 50-20-4
2
3
1
1
1
2
P100756
P-85661
Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: (See Installing on Page 80-70-1.)
Dealer Copy -- Not for Resale
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 5020-4].
Figure 50-20-6
Installation: Apply threadlocker on the threads of the
gas spring rod before installing the clevis.
WARNING
2
1
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
1
P117626
Disconnect the expansion / heater unit wiring harness
(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.
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OPERATOR CAB (CONT’D)
Figure 50-20-8
Removal And Installation (Cont’d)
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
1
W-2760-0309
P106769
Remove the operator cab gas spring(s). (See Gas Spring
Removal And Installation on Page 50-20-1.)
Remove the bolt and nut (Item 1) [Figure 50-20-8] from
both sides of the cab.
Installation: Tighten the bolts and nuts to 24,4 - 29,8
N•m (18 - 22 ft-lb) torque.
Figure 50-20-7
Figure 50-20-9
Dealer Copy -- Not for Resale
NOTE: Use the hoist connected to the operator cab
grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.
1
1
P-85662
P106768
Disconnect the cab wire harness (Item 1) [Figure 50-207].
481 of 1148
Using a strap and a hoist, remove the cab from the loader
[Figure 50-20-9].
50-20-3
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Dealer Copy -- Not for Resale
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OPERATOR SEAT
Seat Belt Removal And Installation (Retractable)
Removal And Installation
Figure 50-30-2
Figure 50-30-1
1
1
P-90355
P-85776
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the seat belt.
Remove the four seat mounting nuts (Item 1) [Figure 5030-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nut to 73 N•m (54 ftlb) torque.
Lower the operator cab. (See Lowering on Page 10-303.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.
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Remove the mounting nut (Item 1) [Figure 50-30-2].
OPERATOR SEAT (CONT’D)
Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation
(Standard)
Figure 50-30-4
Figure 50-30-3
3
1
1
2
P101250
Remove the lower mounting bolt, washer and nut (Item
1). Remove the upper mounting bolt and nut (Item 2)
[Figure 50-30-3].
Remove the seat belt.
Remove the bracket mounting bolts (Item 1) [Figure 5030-4].
Remove the bracket (Item 3) [Figure 50-30-3].
Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting bolts to 73 N•m (54 ftlb) torque.
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Raise the operator cab. (See Raising on Page 10-30-2.)
P101249
OPERATOR SEAT (SUSPENSION)
Slide Rail Removal And Installation
Removal And Installation
Figure 50-31-2
Figure 50-31-1
1
1
1
P-85769
P-85776
Remove the operator seat.
Installation on Page 50-31-1.)
(See
Removal
And
Remove the four seat mounting nuts (Item 1) [Figure 5031-1] and washers from the operator seat mounting
studs.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-2].
Figure 50-31-3
Lower the operator cab. (See Lowering on Page 10-303.)
2
Remove the seat.
NOTE: With the seat removed, the cab may raise.
1
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.
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Raise the operator cab. (See Raising on Page 10-30-2.)
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].
Dealer Copy -- Not for Resale
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.
Figure 50-31-5
1
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat
belt mount.
Remove the seat belt.
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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
Insert the tab (Item 1) into the slot (Item 2) [Figure 5031-7].
Remove the two screws (Item 1) [Figure 50-31-9] and tilt
the seat back to the upright position.
Figure 50-31-8
Remove the back cushion from the seat.
1
1
2
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.
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Dealer Copy -- Not for Resale
Tilt the seat all the way forward.
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation
Shock Removal And Installation
Remove the operator seat.
Installation on Page 50-31-1.)
(See
Removal
And
Figure 50-31-10
Figure 50-31-11
2
1
1
2
1
P-85777
P-85785
(See
Removal
And
Remove the mounting nut (Item 1) [Figure 50-31-11].
Remove the seat shock clips (Item 1) [Figure 50-31-10].
(Both ends.)
Remove the end release buckle (Item 2) [Figure 50-3111].
Remove the seat shock (Item 2) [Figure 50-31-10].
Figure 50-31-12
2
1
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-3112].
488 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the operator seat.
Installation on Page 50-31-1.)
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].
Dealer Copy -- Not for Resale
Remove the two mounting bolts (Item 1) [Figure 50-3113].
Figure 50-31-14
1
P-85787
Remove the shoulder harness retractor (Item 1) [Figure
50-31-14].
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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 BobTach.
Removal And Installation
1
Figure 50-40-1
P-31402
Remove the snap ring (Item 1) [Figure 50-40-3] from
both sides of the Bob-Tach pivot pin grease plug.
1
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.
Remove the bolt and nut (Item 1) [Figure 50-40-1] from
the rod end pivot pin.
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 50-40-2
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
1
P-85649
Remove the rod end pivot pin (Item 1) [Figure 50-40-2].
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Figure 50-40-4
S530 Service Manual
BOB-TACH (HAND LEVER) (CONT’D)
Figure 50-40-7
Removal And Installation (Cont’d)
Figure 50-40-5
1
P-31406
1
Remove the bolt (Item 1) [Figure 50-40-7] from the BobTach pin.
P-31405
Installation: Tighten the bolt and nut to 264 N•m (195 ftlb) torque.
Figure 50-40-6
Figure 50-40-8
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 50-40-5].
1
1
P-31403
P-31407
Remove the nut (Item 1) [Figure 50-40-6] from both of
the Bob-Tach pivot pin bolts.
With a 22 mm (0.875 in) punch (Item 1) [Figure 50-40-8]
and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.
NOTE: Use tapered ream MEL1734 to clean the
tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
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BOB-TACH (HAND LEVER) (CONT’D)
Figure 50-40-11
Lever And Wedge Disassembly And Assembly
Figure 50-40-9
1
1
2
P-85665
Remove the washer, spring (Item 1), and the lever
assembly (Item 2) [Figure 50-40-11].
P-85664
Figure 50-40-12
Figure 50-40-10
35,3 mm
(1.39 in)
1
2
P-85666
Remove the roll pin (Item 1) [Figure 50-40-12] from the
Bob-Tach wedge and spring clevis.
P127544
Installation: Tighten the lever mounting nut until the
spring is compressed to 35,3 mm (1.39 in) [Figure 5040-10].
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Remove the spring clevis assembly (Item 2) [Figure 5040-12].
50-40-3
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the nut (Item 1) [Figure 50-40-9].
BOB-TACH (HAND LEVER) (CONT’D)
Later Design
Lever And Wedge Disassembly And Assembly
(Cont'd)
Figure 50-40-15
4
Figure 50-40-13
1
1
3
2
P-85667
Remove the wedge (Item 1) [Figure 50-40-13] out the
bottom of the Bob-Tach.
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 50-40-15] and
replace the damaged parts as needed.
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54
N•m (35 - 40 ft-lb) torque.
Always replace bent or broken wedges.
Earlier Design
Figure 50-40-14
4
3
1
2
P19287
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
replace the damaged parts as needed.
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135
N•m (90 - 100 ft-lb) torque.
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P121303
BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-16
2
1
P-85669
Dealer Copy -- Not for Resale
Remove the Bob-Tach. (See Removal And Installation on
Page 50-40-1.)
Remove the seal (Item 1) [Figure 50-40-16] from the
Bob-Tach.
Remove the bushing (Item 2) [Figure 50-40-16] from the
Bob-Tach.
Figure 50-40-17
3
2
4
1
NA9243
Installation: The seal (Item 1) needs to be seated in the
Bob-Tach frame (Item 2) to a depth of 1,27 mm (0.050 in)
(Item 3) [Figure 50-40-17].
NOTE: To allow for the proper seal depth, it is
necessary to seat the bushing (Item 4) [Figure
50-40-17] fully into the Bob-Tach frame.
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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
lever assemblies by pressing a switch on the right switch
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.
1
2
2
The Power Bob-Tach block is located on the rear of the
gear pump.
P-85570
IMPORTANT
Lower the Bob-Tach onto the blocks.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Mark the hoses (Item 1) [Figure 50-41-1] for correct
installation.
Remove the hoses from the cylinder.
I-2003-0888
Remove the bolts (Item 2) [Figure 50-41-1], washers and
nuts.
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ftlb) torque.
Remove the cylinder from the Bob-Tach.
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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].
BOB-TACH (POWER) (CONT’D)
Figure 50-41-4
Removal And Installation (Cont’d)
Figure 50-41-2
1
1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] from
both sides of the Bob-Tach pivot pin grease plug.
P-85554
Figure 50-41-5
Installation: Tighten the bolt to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 50-41-3
1
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5].
P-85649
Remove the rod end pivot pin (Item 1) [Figure 50-41-3].
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Dealer Copy -- Not for Resale
Remove the bolt (Item 1) [Figure 50-41-2] and nut from
the rod end pivot pin.
BOB-TACH (POWER) (CONT’D)
Figure 50-41-8
Removal And Installation (Cont’d)
Figure 50-41-6
1
P-31406
1
Remove the bolt (Item 1) [Figure 50-41-8] from both of
the Bob-Tach pivot pin.
P-31405
Installation: Tighten the bolt to 264 N•m (195 ft-lb)
torque.
Figure 50-41-7
Figure 50-41-9
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 50-41-6].
1
1
P-31403
P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the BobTach pivot pin bolts.
With a 22 mm (0.875 in) punch (Item 1) [Figure 50-41-9]
and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.
NOTE: Use tapered ream MEL1734 to clean the
tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
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S530 Service Manual
BOB-TACH (POWER) (CONT’D)
Figure 50-41-12
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
spring is compressed to 35,3 mm (1.39 in) [Figure 5041-12].
Remove the bolts (Item 1) [Figure 50-41-10], washers,
and nuts.
Figure 50-41-13
Dealer Copy -- Not for Resale
P-85570
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ftlb) 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
Remove the nut (Item 1) [Figure 50-41-11].
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S530 Service Manual
BOB-TACH (POWER) (CONT’D)
Earlier Design
Lever And Wedge Disassembly And Assembly
(Cont'd)
Figure 50-41-16
Figure 50-41-14
4
3
1
1
2
2
P-85666
Remove the roll pin (Item 1) [Figure 50-41-14] from the
Bob-Tach wedge and spring clevis.
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 50-41-16] and
replace the damaged parts as needed.
Remove the spring clevis assembly (Item 2) [Figure 5041-14].
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
N•m (90 - 100 ft-lb) torque.
Figure 50-41-15
Later Design
Figure 50-41-17
4
1
1
3
P-85667
2
P121303
Remove the wedge (Item 1) [Figure 50-41-15] out the
bottom of the Bob-Tach.
Always replace bent or broken wedges.
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 50-41-17] and
replace the damaged parts as needed.
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-41-17], tighten to 48 - 54
N•m (35 - 40 ft-lb) torque.
501 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
P19287
BOB-TACH (POWER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Remove the Power Bob-Tach. (See Removal And
Installation on Page 50-41-1.)
Figure 50-41-18
2
1
Dealer Copy -- Not for Resale
P-85669
Remove the seal (Item 1) [Figure 50-41-18] from the
Bob-Tach.
Remove the bushing (Item 2) [Figure 50-41-18] from the
Bob-Tach.
Figure 50-41-19
3
2
4
1
NA9243
Installation: The seal (Item 1) needs to be seated in the
Bob-Tach frame (Item 2) to a depth of 1,27 mm (0.050 in)
(Item 3) [Figure 50-41-19].
NOTE: To allow for the proper seal depth, it is
necessary to seat the bushing (Item 4) [Figure
50-41-19] fully into the Bob-Tach frame.
502 of 1148
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S530 Service Manual
Figure 50-50-3
LIFT ARMS
Stabilizer Bar Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
1
P-90591
With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
2
Remove the stabilizer bar from the loader.
Dealer Copy -- Not for Resale
Figure 50-50-4
P106928
Remove the retainer bolt (Item 1) [Figure 50-50-1] and
nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 5050-1].
1
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the
stabilizer bar (both ends).
Inspect the bushings and replace as needed.
1
P-90593
Remove the retainer bolt (Item 1) [Figure 50-50-2] from
the stabilizer bar rear pivot pin at the lift arm.
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
503 of 1148
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S530 Service Manual
Figure 50-50-7
LIFT ARMS (CONT’D)
Link Removal And Installation
Figure 50-50-5
1
P106930
Remove the retainer bolt and nut (Item 1) [Figure 50-507] from the lift arm link pivot pin (both sides).
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Dealer Copy -- Not for Resale
P-90595
Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the retainer bolt and nut (Item 1) [Figure 50-506] from the lift arm pivot pin (both sides).
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]
(both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
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S530 Service Manual
LIFT ARMS (CONT’D)
Link Removal And Installation (Cont’d)
Figure 50-50-9
1
P-90610
Dealer Copy -- Not for Resale
Remove the lift arm link pivot pin (Item 1) [Figure 50-509] (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Remove the lift arm link from the loader.
505 of 1148
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S530 Service Manual
LIFT ARMS (CONT’D)
Figure 50-50-12
Removal And Installation
Put jackstands under the rear corners of the loader.
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
1
Figure 50-50-10
P114629
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
1
P106931
1
At the right side upright, disconnect the two tilt cylinder
hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90602
1
Remove the retaining bolt and nut (Item 1) [Figure 5050-13] from the pin on the rod end of the lift cylinder (both
sides).
1
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
P106932
At the left side upright, disconnect the three auxiliary
hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.
506 of 1148
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S530 Service Manual
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Figure 50-50-13
1
LIFT ARMS (CONT’D)
Figure 50-50-16
Removal And Installation (Cont’d)
Figure 50-50-14
1
1
2
P-90604
With a slide hammer, remove the pin (Item 1) [Figure 5050-14] from the rod end of the lift cylinder (both sides).
Disconnect the stabilizer bar from both sides of the lift
arms (Item 2) [Figure 50-50-16].
Figure 50-50-15
Figure 50-50-17
1
1
1
1
P-90606
P-90605
Install slings (Item 1) [Figure 50-50-15] on the lift arms
and connect to a chain hoist.
Position the front sling in the middle of the Bob-Tach as
shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.
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S530 Service Manual
Dealer Copy -- Not for Resale
NOTE: Be sure the slings on the lift arms are in a
position to balance the lift arms when being
removed. See (Item 1) [Figure 50-50-16].
P-90611
LIFT ARMS (CONT’D)
Removal And Installation (Cont’d)
Figure 50-50-18
1
2
P-90609
Dealer Copy -- Not for Resale
Remove the retaining bolt and nut (Item 1) and the pin
(Item 2) [Figure 50-50-18] (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Remove the lift arms from the loader.
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S530 Service Manual
REAR GRILLE
Installing
Removing
Figure 50-60-2
Stop the engine and open the rear door.
1
Figure 50-60-1
P107953A
Lift and pull the rear grille backward to remove from the
loader [Figure 50-60-1].
Dealer Copy -- Not for Resale
Align the edge of the rear grille under the shield (Item 1),
insert the tabs into the slots (Right Side Shown) (Inset)
[Figure 50-60-2], and lower.
P109623
509 of 1148
P107279
Close the rear door.
50-60-1
S530 Service Manual
REAR GRILLE (CONT’D)
Shield Removal And Installation
Figure 50-60-3
1
2
1
P114171
Dealer Copy -- Not for Resale
Remove the two bolts (Item 1) and remove the shield
(Item 2) [Figure 50-60-3].
510 of 1148
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S530 Service Manual
REAR DOOR (TAILGATE)
Figure 50-70-3
Removal And Installation
Figure 50-70-1
1
2
2
3
1
P-85695
Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the main frame harness.
NOTE: Install the door stop (Item 2) and the door stop
retainer (Item 3) [Figure 50-70-3] in the top
hinge as shown.
Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Installation: Tighten the bolts and nuts to 34 - 38 N•m
(25 - 28 ft-lb) torque.
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.
511 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the top and bottom door hinge bolts and nuts
(Item 1) [Figure 50-70-3].
P101519
REAR DOOR (TAILGATE) (CONT’D)
Striker Disassembly And Assembly
Striker Removal And Installation
Figure 50-70-5
Figure 50-70-4
5
1
3
2
4
1
P106584
1
P-85698B
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.
512 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the locknut (Item 1) [Figure 50-70-5].
REAR DOOR (TAILGATE) (CONT’D)
Striker Adjusting
WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
Dealer Copy -- Not for Resale
1
1
P-85698B
Loosen the striker assembly bolts (Item 1) [Figure 50-706].
Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the top striker assembly bolt only,
until it will hold the striker assembly in the
center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.
Tighten both bolts (Item 1) [Figure 50-70-6] to 125 - 135
N•m (90 - 100 ft-lb) torque.
Close the rear door.
513 of 1148
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REAR DOOR (TAILGATE) (CONT’D)
Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
2
1
P109094
Remove the door handle (Item 1) [Figure 50-70-9] from
the rear door.
P109092
Inspect the parts for wear and replace as needed.
Dealer Copy -- Not for Resale
Remove the bolt (Item 1) and nut (Item 2) [Figure 50-707] from the latch.
Installation: Tighten the bolt (Item 1) and nut (Item 2) to
34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-70-8
2
1
P109093
Remove the spacer (Item 1) [Figure 50-70-8] from the
latch.
Remove the spring (Item 2) [Figure 50-70-8] from the
latch.
514 of 1148
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S530 Service Manual
FUEL TANK
Figure 50-80-3
Removal And Installation
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-14.)
Figure 50-80-1
1
2
1
P106871
Remove the hose (Item 1) and fitting (Item 2) [Figure 5080-3].
P114311
2
Remove the fuel vent hose (Item 1) [Figure 50-80-1].
Figure 50-80-2
2
1
1
1
P106868
3
Remove the bolts (Item 1) and the bracket (Item 2)
[Figure 50-80-4].
P114312
Remove the bolt / nut (Item 1), two bolts (Item 2), and fuel
fill hose (Item 3) [Figure 50-80-2].
Drain the fuel into a container.
515 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-80-4
FUEL TANK (CONT’D)
Figure 50-80-7
Removal And Installation (Cont'd)
Figure 50-80-5
1
1
2
P106874
Remove the bolt (Item 1) [Figure 50-80-7] and tubeline
clamp.
P114187
Installation: Tighten the bolts to 122 - 135 N•m (90 - 100
ft-lb) torque.
Figure 50-80-6
P106875
Remove the tank [Figure 50-80-8].
1
P114186
At the left side of the loader, remove the two main frame
bolts and nuts (Item 1) [Figure 50-80-6].
Installation: Tighten the bolts to 122 - 135 N•m (90 - 100
ft-lb) torque.
516 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-80-8
At the right side of the loader, remove the two main frame
bolts and nuts (Item 1). Remove the bracket (Item 2)
[Figure 50-80-5].
FUEL TANK (CONT’D)
Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation
Figure 50-80-11
Figure 50-80-9
1
1
1
2
2
P114271
P106961
Remove the two bolts (Item 1) and remove the fuel fill
hose (Item 2) [Figure 50-80-11].
Figure 50-80-12
Dealer Copy -- Not for Resale
Disconnect the wire harness (Item 1) [Figure 50-80-9]
from the fuel level sender.
NOTE: Loosen and reposition the hoses (Item 2)
[Figure 50-80-9] as needed to access the
sender.
Figure 50-80-10
1
1
P114273
Remove the fuel fill screen (Item 1) [Figure 50-80-12].
P106963
Remove the fuel level sender (Item 1) [Figure 50-80-10].
Inspect the fuel level sender and replace if worn or
damaged.
517 of 1148
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518 of 1148
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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
W-2059-0598
Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as
needed.
Dealer Copy -- Not for Resale
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.
Figure 50-90-2
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
DANGER
1
P-85676
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
Remove the pedal assembly from the loader.
D-1009-0409
519 of 1148
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S530 Service Manual
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 50-905].
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.
Remove the crossbar from the pivot (Item 2) [Figure 5090-6].
Dealer Copy -- Not for Resale
P-85678
Figure 50-90-6
Figure 50-90-4
1
2
2
1
1
P-85681
P-85680
Remove the hairpin clips (Item 1) and cross-pins (Item 2)
[Figure 50-90-4] from the control valve lift spool.
Installation: Inspect the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed.
Disconnect the crossbar from the control valve.
520 of 1148
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S530 Service Manual
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
spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-90-7
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.
1
2
Figure 50-90-9
1
P-85675
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
2
P-85675A
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage.
Remove the linkage (Item 2) [Figure 50-90-8].
P-85675
Loosen the bolt (Item 1) [Figure 50-90-10] 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 50-90-10] on the pedal assembly to standard
torque.
521 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the bolt (Item 1) [Figure 50-90-7] and nut from
the pedal linkage.
CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation
Remove the control panel. (See 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.)
Dealer Copy -- Not for Resale
Figure 50-90-11
1
1
P-85859
P-85860
Figure 50-90-12
2
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].
522 of 1148
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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
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as
needed.
Dealer Copy -- Not for Resale
WARNING
Figure 50-91-2
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
DANGER
1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the
pedal mounting bracket.
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Remove the pedal assembly from the loader.
D-1009-0409
523 of 1148
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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
spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-91-3
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.
1
Figure 50-91-5
1
1
P-90979
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
2
P-90981
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.
524 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Remove the hairpin clip and the pin (Item 1) [Figure 5091-3] from the foot sensor.
CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation
Remove the control panel. (See 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.)
Dealer Copy -- Not for Resale
Figure 50-91-7
1
1
P-85859
P-85860
Figure 50-91-8
2
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].
525 of 1148
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526 of 1148
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CONTROL PANEL
Description
NA1034
The steering system consists of independent steering
levers the operator uses to provide steering input to the
loader.
The steering levers are attached to pivoting bellcranks
that pivot on a steering shaft and plastic bushings.
The forward travel is adjusted by drift adjustment bolts.
The bellcranks are attached to steering linkage bars with
torsion bushings pressed into the bellcranks. Bellcranks
mount to the control handle assembly and mount to the
control panel.
Steering linkage bars are a two-piece design. Steering
linkage bars are adjustable in length for “full travel
adjustment”.
Pintle arms are of a two-piece design that allow easy
adjustment of the neutral or “creep”.
The steering system returns the levers to their starting
position by means of the centering spring and the
returning force of the torsion bushings [Figure 50-100-1].
NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
made.
Sequence of steering adjustments:
1. Set neutral of pintle arms, “creep”
2. Set full travel at steering linkage bars
3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a
rubber torsion bushing is pressed into the pintle arms.
527 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-100-1
CONTROL PANEL (CONT’D)
Figure 50-100-2
Removal And Installation
2
DANGER
1
P106720
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Figure 50-100-3
2
D-1009-0409
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P106718
Disconnect the control harness connectors (Item 1) and
the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
528 of 1148
50-100-2
S530 Service Manual
Dealer Copy -- Not for Resale
•
CONTROL PANEL (CONT’D)
Removal And Installation (Cont'd)
Figure 50-100-4
2
1
2
P106716
Dealer Copy -- Not for Resale
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-4] which are connected to the
steering shaft on the control panel.
Remove the four steering linkage bolts, nuts, and rubber
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
N•m (35 - 40 ft-lb) torque.
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].
529 of 1148
50-100-3
S530 Service Manual
Figure 50-100-7
CONTROL PANEL (CONT’D)
Disassembly And Assembly
Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
2
2
Two Piece Shaft
Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
1
3
Figure 50-100-6
3
1
3
3
P-85865
Figure 50-100-8
1
1
1
1
P-85864
1
Remove the nuts (Item 1) and the steering stabilizers
(Item 2) [Figure 50-100-6].
P-85861
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50100-8].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8].
530 of 1148
50-100-4
S530 Service Manual
Dealer Copy -- Not for Resale
2
2
CONTROL PANEL (CONT'D)
Figure 50-100-11
Disassembly And Assembly (Cont’d)
Two Piece Shaft (Cont’d)
Figure 50-100-9
2
1
1
2
1
P-85872
Remove the two bolts (Item 1) from the bellcrank (Item 2)
[Figure 50-100-11].
Remove the four bolts (Item 1) [Figure 50-100-9] from
the control panel.
Dealer Copy -- Not for Resale
Remove the bellcrank from the bracket [Figure 50-10011].
P-85867
Figure 50-100-12
Remove the control handle assembly (Item 2) [Figure
50-100-9].
2
Figure 50-100-10
4
3
1
3
2
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.
1
P-85868
Repeat the procedure for the other control handle
assembly.
Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Remove the control handle (Item 4) [Figure 50-100-10].
531 of 1148
50-100-5
S530 Service Manual
Figure 50-100-15
CONTROL PANEL (CONT'D)
Disassembly And Assembly (Cont’d)
One Piece Shaft
Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Figure 50-100-13
1
P-85861
1
Remove the bolts and nuts (Item 1), steering link, (Item
2), and washers (Item 3) [Figure 50-100-14] and [Figure
50-100-15].
2
2
1
Installation: Verify correct orientation of components
[Figure 50-100-14] and [Figure 50-100-15].
1
P-85864
Figure 50-100-16
Remove the nuts (Item 1) and the steering stabilizers
(Item 2) [Figure 50-100-13].
1
2
2
Figure 50-100-14
2
2
1
1
3
3
1
3
1
1
1
P-85867
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].
532 of 1148
50-100-6
S530 Service Manual
Dealer Copy -- Not for Resale
1
Figure 50-100-19
CONTROL PANEL (CONT’D)
Disassembly And Assembly (Cont’d)
One Piece Shaft (Cont’d)
2
2
Figure 50-100-17
4
3
1
1
2
P126301
P126310
Remove the two bolts (Item 1) from the bellcrank (Item 2)
[Figure 50-100-18] and [Figure 50-100-19].
1
Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-17] on both sides.
Dealer Copy -- Not for Resale
Remove the bellcrank assembly (Item 2) [Figure 50-10018] and [Figure 50-100-19] from the bracket.
P-85868
Figure 50-100-20
4
Remove the control handles (Item 4) [Figure 50-100-17].
Figure 50-100-18
2
3
1
2
P126302
533 of 1148
1
1
P126303
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.
50-100-7
S530 Service Manual
CONTROL PANEL (CONT’D)
Figure 50-100-21
Linkage Removal And Installation
2
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
2
W-2059-0598
P106716
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
Lift and block the loader. (See Procedure on Page 10-101.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-21] which are connected to the
steering shaft on the control panel.
Remove the four steering linkage bolts and nuts (Item 2)
[Figure 50-100-21].
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage bolts to 47,5 - 54,2
N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,
the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-12.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 50-100-22
1
2
P-48631
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-22].
Remove the bolt / spring assembly.
Installation: Tighten the centering spring bolt and a
NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
534 of 1148
50-100-8
S530 Service Manual
Dealer Copy -- Not for Resale
WARNING
CONTROL PANEL (CONT’D)
Figure 50-100-25
Linkage Removal And Installation (Cont’d)
Figure 50-100-23
2
1
1
1
2
P-48629
Inspect for wear on the centering blocks (Item 1) [Figure
50-100-25].
Slide the centering plate (Item 1) [Figure 50-100-23] as
shown to remove it from the hydrostatic pumps.
NOTE: If the centering blocks are worn, the blocks
can be removed and rotated 180 degrees and
reinstalled.
Figure 50-100-24
7
3
1
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
8
6
4
If the centering blocks are worn, remove the bolts (Item
2) [Figure 50-100-25]. Remove the centering blocks.
NOTE: The washers go between the bolts and the
centering plate.
5
2
2
P-48630
The centering plate assembly consists of the following
parts: bolt (Item 1), bushing (Item 2), washer (Item 3),
spacer (Item 4), spring (Item 5), locknut (Item 6),
centering plate (Item 7), and guide bushings (Item 8)
[Figure 50-100-24].
535 of 1148
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S530 Service Manual
Dealer Copy -- Not for Resale
P-48632
CONTROL PANEL (CONT’D)
Figure 50-100-28
Linkage Removal And Installation (Cont’d)
Figure 50-100-26
2
1
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-28].
P-54617
Remove the pintle base (Item 2) [Figure 50-100-28].
Figure 50-100-29
Dealer Copy -- Not for Resale
Remove the bolts and washers (Item 1) [Figure 50-10026] from the pintle.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-26].
Figure 50-100-27
2
3
1
1
P-48659
2
4
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 ftlb) torque.
3
2
1
NOTE: After installing the linkage onto the
hydrostatic pumps, the linkage neutral
adjusting procedure must be performed. (See
Linkage Neutral (Adjusting) on Page 50-10012.)
P-48624
Remove the bolt and nut (Item 1) [Figure 50-100-27].
Inspect the washers (Item 2), pintle arm (Item 3), and the
steering control lever (Item 4) [Figure 50-100-27] for
damage and replace as needed.
NOTE: The washers (Item 2) [Figure 50-100-27] are
hardened and must be replaced with Bobcat
Parts.
536 of 1148
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S530 Service Manual
CONTROL PANEL (CONT’D)
Pintle Arm Disassembly And Assembly
NOTE: Anti-sieze should be used on the adjusting
screw to prevent corrosion and allow free
movement while adjusting.
Figure 50-100-30
Figure 50-100-32
2
4
2
3
1
2
3
P-48619
1
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-30].
Inspect the torsion bushing (Item 4) [Figure 50-100-30]
for damage and replace as needed.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
Figure 50-100-31
Using a bushing driver (Item 1), remove the torsion
bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-32].
Installation: Install the torsion bushing (Item 2) [Figure
50-100-32] into the pintle arm using the same procedure
as the removal.
NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
arm should be the same.
1
4
2
3
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.
537 of 1148
50-100-11
S530 Service Manual
Dealer Copy -- Not for Resale
P-54624
CONTROL PANEL (CONT’D)
Figure 50-100-34
Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following
procedure:
Kit - 7022042 Remote Start Tool (Service Tool) or
MEL1563 Remote Start Tool.
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.)
Lift and block the loader. (See Procedure on Page 10-101.)
P106719
Loosen the bolt / nut (Item 1) [Figure 50-100-34] only
until the tension is released from the torsion bushing.
Figure 50-100-33
3
1
2
1
2
P-48450A
Tool that may assist in the neutral adjustment [Figure 50100-33].
To make this tool, use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-33] to a small rounded edge.
A steering centering block (Item 3) [Figure 50-100-33] is
also needed. The centering block is placed as shown and
welded to the C-Clamp.
P-54613
Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-35].
NOTE: The bolt must be loose enough to allow the
torsion bushing (Item 2) [Figure 50-100-35] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
538 of 1148
50-100-12
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-100-35
CONTROL PANEL (CONT’D)
WARNING
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-36
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
1
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
Loosen the two bolts (Item 1) holding the right centering
block. Move the right hand centering block (Item 2)
[Figure 50-100-36] until both pintle cams contact the
centering block.
NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left
centering block will also become aligned
properly.
Figure 50-100-37
NOTE: When the engine is started, the wheels /
tracks may begin to move.
NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
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
2
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 50-10037] around both centering blocks.
Lock the C-Clamp in place.
539 of 1148
50-100-13
S530 Service Manual
Dealer Copy -- Not for Resale
Move the traction lock override switch so the traction
function is unlocked. On a standard loader the wedge
brake will unlock.
P-54614
CONTROL PANEL (CONT’D)
Figure 50-100-39
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
Turn the adjustment screw (Item 1) [Figure 50-100-39] to
a point between forward and reverse where there is zero
creep.
P-48632
Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-38].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
Stroke the left steering lever to forward and allow the
lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.
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.
540 of 1148
50-100-14
S530 Service Manual
Dealer Copy -- Not for Resale
Turn the adjustment screw (Item 1) [Figure 50-100-39]
counterclockwise until forward creep is seen.
CONTROL PANEL (CONT’D)
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-40
2
2
1
1
P-48632
Dealer Copy -- Not for Resale
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 50100-40] 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.)
541 of 1148
50-100-15
S530 Service Manual
Figure 50-100-41
CONTROL PANEL (CONT’D)
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
be sure the bushings are not binding or too
loose, which will affect the procedure.
1
WARNING
W-2059-0598
P106719
Loosen the bolt / nut (Item 1) [Figure 50-100-41] only
until the tension is released from the torsion bushing.
Figure 50-100-42
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
2
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-101.)
P-54613
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Preload tension in the torsion bushings must be removed
before adjusting the steering linkage.
542 of 1148
Loosen the nuts (Item 1) only until the tension is released
from the torsion bushings (Item 2) [Figure 50-100-42].
The bolts must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-42] to turn freely
between the torsion bushing and the linkage bar.
50-100-16
S530 Service Manual
Dealer Copy -- Not for Resale
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.
CONTROL PANEL (CONT’D)
Figure 50-100-45
Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-43
2
1
1
3
P-51132
Locate the control lever drift adjustment access hole in
the front of the control panel.
Turn the control lever drift adjustment bolts (Item 1)
[Figure 50-100-43] (one on each control lever) out until
they no longer contact the bellcrank.
Figure 50-100-44
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
speed.
Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-46
2
3
2
4
1
1
P-51131
P-51133
Move the right side steering lever to the rear and install a
10 mm (3/8 in) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3)
[Figure 50-100-44].
Before adjusting the linkage, verify the pintle base bolt
(Item 1) and both of the upper pintle bolts (Item 2) are
tightened to 48 - 54 N•m (35 - 40 ft-lb) torque. There must
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.
543 of 1148
50-100-17
S530 Service Manual
Dealer Copy -- Not for Resale
Move the right side steering lever forward and install a 24
mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50100-45].
P-85878
CONTROL PANEL (CONT’D)
Figure 50-100-49
Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-47
1
1
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 50-10047] on each steering linkage bar.
Figure 50-100-48
1
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
is rotated to the front as far as possible [Figure 50-10048]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2
N•m (35 - 40 ft-lb) torque.
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.
544 of 1148
50-100-18
S530 Service Manual
Dealer Copy -- Not for Resale
2
CONTROL PANEL (CONT’D)
Figure 50-100-53
Linkage Travel (Adjusting) (Cont'd)
WARNING
1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 50-100-51
P-85878
Push the control lever to full stroke and turn drift
adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in until it contacts the bellcrank.
1
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,0 m (10
ft) of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right
adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in.
P106719
Tighten the two bolts and nuts (Item 1) [Figure 50-10051] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering
bellcranks.
If the drift is excessive to the right, turn the left
adjustment bolt in.
Installation: After removal, installation and adjusting of
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.)
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 overcorrection
and excessive reduction in travel speed.
Figure 50-100-52
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after
adjustment.
1
P-85877
545 of 1148
50-100-19
S530 Service Manual
Dealer Copy -- Not for Resale
Repeat steps on the other control lever.
CONTROL PANEL (CONT’D)
Shock Removal And Installation
Figure 50-100-54
1
2
1
P106721
Dealer Copy -- Not for Resale
Remove the nuts (Item 1) [Figure 50-100-54] from the
end of the shocks connected to the steering linkages.
Remove the nuts (Item 2) [Figure 50-100-54] from the
other end of the shocks connected to the brackets on the
control panel.
Installation: Tighten the nuts to torque.
546 of 1148
50-100-20
S530 Service Manual
CONTROL PANEL (SJC)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Description
Raise the operator cab. (See Raising on Page 10-30-2.)
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.
Figure 50-101-1
1
Removal And Installation
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
1
W-2017-0286
Remove the three bolts (Item 1) [Figure 50-101-1] that
secure the controller.
DANGER
Figure 50-101-2
1
1
1
2
1
P-90328
•
•
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
1
3
1
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].
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
547 of 1148
50-101-1
S530 Service Manual
Dealer Copy -- Not for Resale
P-85879
Dealer Copy -- Not for Resale
548 of 1148
50-101-2
S530 Service Manual
CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the
forward and reverse travel.
The control handles / levers are mounted to the control
panel assembly.
Lever Removal And Installation
Figure 50-110-1
2
3
4
Dealer Copy -- Not for Resale
1
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.
549 of 1148
50-110-1
S530 Service Manual
CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal
And Installation on Page 50-110-1.)
Figure 50-110-2
1
Dealer Copy -- Not for Resale
P-85883A
Remove the rubber boot (Item 1) [Figure 50-110-2].
550 of 1148
50-110-2
S530 Service Manual
CONTROL HANDLE / LEVER (ACS)
Handle Sensor Removal And Installation
Description
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See Lift
And Tilt Calibration (ACS) on Page 60-160-11.)
Figure 50-111-1
Figure 50-111-2
1
1
P-21879
The control handles / levers are mounted to the control
panel.
551 of 1148
P-85882
Loosen the nuts (Item 1) [Figure 50-111-2].
Installation: Tighten the nuts until the lever cannot be
moved either right or left when seated in the operator
seat.
50-111-1
S530 Service Manual
Dealer Copy -- Not for Resale
The control handles / levers are used to control the
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 located in the
base of the control handle / levers.
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1
1
P-21860
Remove the handle lock solenoid connector (Item 1)
[Figure 50-111-5] from the clip.
P-21836
Disconnect the harness connector (Item 1) from the
handle sensor connector [Figure 50-111-3].
NOTE: Pry out with a small screwdriver and push the
connector down.
Dealer Copy -- Not for Resale
2
Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50111-3] from the handle lock solenoid connector.
1
Figure 50-111-4
5
1
2
4
3
1
Remove one of the two screws (Item 1) [Figure 50-1116] from the handle sensor.
P-21861
Remove the handle sensor connector (Item 1) [Figure
50-111-4] from the clip.
NOTE: Pry out with a small screwdriver and push the
connector down.
552 of 1148
P-21862
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 inlb) torque.
While removing the mounting pin (Item 2) from the
handle sensor, remove the plastic spacer (Item 3), the
spring (Item 4) and washer (Item 5) [Figure 50-111-6].
50-111-2
S530 Service Manual
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Figure 50-111-9
Handle Sensor Removal And Installation (Cont'd)
3
Figure 50-111-7
2
1
P-21878
Figure 50-111-10
1
P-21880
2
3
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
3
Installation: When installing the handle sensor into the
control handle, route the switch handle wire harness
(Item 1) [Figure 50-111-9] and [Figure 50-111-10] for
proper return of the control handle to neutral and
minimize harness movement.
4
7
6
2
NOTE: Route wires (Item 2) [Figure 50-111-9] and
[Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50111-10] to avoid wire damage.
5
P-21882
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.
553 of 1148
50-111-3
S530 Service Manual
Dealer Copy -- Not for Resale
Remove one of the two screws (Item 1) [Figure 50-1117] from the handle sensor.
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Figure 50-111-13
Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber boot (Item 1) [Figure 50-111-13]
from the handle.
P-21879
Figure 50-111-12
1
1
2
2
N-17385
Using a small screwdriver, hold the handle spacer (Item
1) and remove the screws (Item 2) [Figure 50-111-14]
from the handle assembly.
P16534
Remove the switch handle (Item 1) [Figure 50-111-12].
(See Switch Handle Removal on Page 60-130-2.)
554 of 1148
Installation: Tighten the screws to 4 N•m (35 in-lb)
torque.
50-111-4
S530 Service Manual
Dealer Copy -- Not for Resale
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.)
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Lever Removal And Installation
Handle Disassembly And Assembly
Figure 50-111-17
2
Figure 50-111-15
3
4
2
1
2
P-85882
1
N-17394
Remove the four nuts (Item 2) and the plate (Item 3)
[Figure 50-111-17].
Inspect all parts for wear and replace as needed.
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.
1
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.
555 of 1148
50-111-5
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the handle sleeve (Item 1) and bushings (Item 2)
[Figure 50-111-15] from the handle.
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
lever.
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal
And Installation on Page 50-111-5.)
Figure 50-111-18
1
Dealer Copy -- Not for Resale
P-85883A
Remove the rubber boot (Item 1) [Figure 50-111-18].
556 of 1148
50-111-6
S530 Service Manual
CONTROL HANDLE / LEVER (SJC)
Description
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.
Joystick Testing
Dealer Copy -- Not for Resale
See Bobcat Advanced Troubleshooting System (B.A.T.S.)
or connect to service analyzer to check function.
557 of 1148
50-112-1
S530 Service Manual
CONTROL HANDLE / LEVER (SJC) (CONT’D)
Figure 50-112-3
Joystick Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
1
Figure 50-112-1
P-85891
1
Disconnect the joystick connector (Item 1) [Figure 50112-3] from the harness connector.
Dealer Copy -- Not for Resale
P-85890
Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
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.
558 of 1148
50-112-2
S530 Service Manual
ACCESS PANEL (INSIDE)
Removal And Installation (Right)
Removal And Installation (Left)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Figure 50-120-2
Figure 50-120-1
1
1
1
1
2
2
3
3
P-85677A
Remove the four bolts, (Item 1), washer (Item 2), and
remove the left access panel (Item 3) [Figure 50-120-1].
559 of 1148
Remove the four bolts (Item 1), washer (Item 2), and
remove the right access panel (Item 3) [Figure 50-1202].
50-120-1
S530 Service Manual
Dealer Copy -- Not for Resale
P-85677
Dealer Copy -- Not for Resale
560 of 1148
50-120-2
S530 Service Manual
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Right)
Removal And Installation (Left)
Figure 50-121-3
Figure 50-121-1
4
3
2
1
1
2
P101581
P100731
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-121-1].
Loosen the bolt (Item 3) and remove the engine speed
control pedal (Item 4) [Figure 50-121-3].
Figure 50-121-2
Figure 50-121-4
1
1
1
1
1
2
P100732
1
P101584
Remove the four bolts (Item 1), and remove the left
access panel (Item 2) [Figure 50-121-2].
561 of 1148
Remove the bolts (Item 1) [Figure 50-121-4] and remove
the right access panel.
50-121-1
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-121-3].
Dealer Copy -- Not for Resale
562 of 1148
50-121-2
S530 Service Manual
WINDOW (REAR)
Rear Window Identification
There are two different procedures for removing the rear
window from your machine:
Figure 50-130-1
Latches
1. This window is equipped with latches [Figure 50-1301].
Rubber Cord
2. This window is equipped with a rubber cord and tag
[Figure 50-130-1].
2
NOTE: Use these procedures to remove the rear
window only under emergency conditions.
Damage to machine may occur.
1
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
disengage from the window frame.
Pull on the tag on the top of the rear window to remove
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 50-1303].
563 of 1148
Exit through the rear of the operator cab [Figure 50-1305].
50-130-1
S530 Service Manual
Dealer Copy -- Not for Resale
1
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 50-130-6
Figure 50-130-8
1
1
P-90669A
The rear window can be removed from outside the loader
using a T40 TORX® Drive tool. Turn both screws (Item 1)
[Figure 50-130-6] counterclockwise until the latches
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
Pull both handles (Item 1) [Figure 50-130-8] up and out
to remove the rear window.
OR
Figure 50-130-7
1
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 50-130-7]
counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.
564 of 1148
50-130-2
S530 Service Manual
Dealer Copy -- Not for Resale
P13982
Figure 50-130-10
WINDOW (REAR) (CONT’D)
Disassembly And Assembly (Latches)
8
Figure 50-130-9
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 50-130-10].
Remove the screw (Item 1) from the latch [Figure 50130-9].
1. Latch
Installation: Tighten the screw to 21 - 23 N•m (180 - 200
in-lb) torque.
3. Bushing
Dealer Copy -- Not for Resale
2. Spacer
4. O-ring
5. Washer
6. Screw
7. Rear Window
8. Seal
565 of 1148
50-130-3
S530 Service Manual
Dealer Copy -- Not for Resale
566 of 1148
50-130-4
S530 Service Manual
WINDOW (TOP)
Figure 50-131-3
Removal And Installation
Figure 50-131-1
1
1
1
P107298A
1
P-85808
From inside the operator cab, remove the four nuts (Item
1) [Figure 50-131-1].
To help control the amount of adhesive compression
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
and cab.
Figure 50-131-4
Figure 50-131-2
1
1
1
1
2
P-85807
P-85807
Remove the bolts (Item 1). Separate the window
adhesive (Item 2) [Figure 50-131-2] from the cab.
Align the window and cab holes prior to placing window.
Install the bolts (Item 1) [Figure 50-131-4] through the
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.
567 of 1148
50-131-1
S530 Service Manual
Dealer Copy -- Not for Resale
1
WINDOW (TOP) (CONT’D)
Removal And Installation (Cont’d)
Figure 50-131-5
1
1
1
1
P-85808
Dealer Copy -- Not for Resale
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.
568 of 1148
50-131-2
S530 Service Manual
Figure 50-132-3
WINDOW (SIDE)
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Figure 50-132-1
1
2
1
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
Remove the plastic cap (Item 1) [Figure 50-132-1].
1
Figure 50-132-2
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 inlb) 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.
569 of 1148
50-132-1
S530 Service Manual
Dealer Copy -- Not for Resale
P-85314A
Dealer Copy -- Not for Resale
570 of 1148
50-132-2
S530 Service Manual
CAB DOOR
Figure 50-140-3
Description
The standard cab door is available as an option or dealer
installed kit.
1
Removal And Installation
Open the cab door.
Figure 50-140-1
2
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
Dealer Copy -- Not for Resale
1
2
1
P-85781A
Disconnect the wire harness (Item 1) and washer fluid
hose (Item 2) [Figure 50-140-1].
Figure 50-140-2
3
2
1
2
1
P-85837
P-85588A
P-85589A
Rotate and pull the clip (Item 1) out of the gas spring
socket. Pull the gas spring socket (Item 2) straight off the
ball stud fitting (Item 3) [Figure 50-140-2].
Remove the bolts (Item 1) [Figure 50-140-4] and nuts
from the cab.
Remove the hinges (Item 2) [Figure 50-140-4] from the
cab.
Installation: Tighten the bolts to 9,6 - 10,7 N•m (85 - 90
in-lb) torque.
571 of 1148
50-140-1
S530 Service Manual
CAB DOOR (CONT’D)
Figure 50-140-7
Disassembly And Assembly
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
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
(80 - 97 in-lb) torque.
1
Remove the wiper motor shaft nut (Item 4) [Figure 50140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88
- 124 in-lb) torque.
4
3
Remove the door from the loader. (See Removal And
Installation on Page 50-140-1.)
4
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 50-1408].
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].
572 of 1148
50-140-2
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].
CAB DOOR (CONT’D)
Aligning
Disassembly And Assembly (Cont’d)
Figure 50-140-11
Figure 50-140-9
WRONG
WRONG
2
1
1
1
4
3
P106481
4
P-85836
Adjust as needed. (See Adjusting on Page 50-140-4.)
Remove the two nuts and bolts (Item 4) [Figure 50-1409].
Figure 50-140-12
Installation: Tighten the nuts to 31 - 34 N•m (270 - 300
in-lb) torque.
CORRECT
CORRECT
Figure 50-140-10
3
1
1
1
P106482
2
When the striker or latch is adjusted properly there will be
no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
2
P106380
Disconnect the wire harness (Item 1) [Figure 50-14010].
After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.
573 of 1148
50-140-3
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the bolt (Item 1), latch (Item 2), and spring (Item
3) [Figure 50-140-9].
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
CAB DOOR (CONT’D)
Checking Operation
Adjusting
Figure 50-140-15
Figure 50-140-13
2
1
1
1
P-85413F
P-85830
Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Figure 50-140-14
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.
1
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.)
574 of 1148
50-140-4
S530 Service Manual
Dealer Copy -- Not for Resale
Loosen the two bolts (Item 1) [Figure 50-140-13] and
adjust the latch as needed.
Sit in operator’s seat. Turn the key ON, lower the seat bar
and close the door. Press the PRESS TO OPERATE
LOADER button (Item 1) [Figure 50-140-15].
ARMREST
Description
The armrests are located on each side of the seat. They
are adjustable for comfort.
Figure 50-150-1
1
Dealer Copy -- Not for Resale
P-90837
Adjustable armrests (Item 1) [Figure 50-150-1].
575 of 1148
50-150-1
S530 Service Manual
ARMREST (CONT’D)
Figure 50-150-4
Removal And Installation
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Installation on Page 50-31-2.)
Figure 50-150-2
2
P-90845
Remove the top spacer (Item 1) and the bottom spacer
(Item 2) [Figure 50-150-4] from the seat.
1
Dealer Copy -- Not for Resale
Repeat for the other side.
P-90835
Remove the two nuts and bolts (Item 1) [Figure 50-1502].
Figure 50-150-3
1
2
3
4
P-90836
Remove the tie strap (Item 1) and disconnect the wire
harness (Item 2) [Figure 50-150-3].
Remove the nut (Item 3) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the
seat.
576 of 1148
50-150-2
S530 Service Manual
ARMREST (CONT’D)
Figure 50-150-7
Disassembly And Assembly
Remove the joystick. (See Joystick Removal And
Installation on Page 50-112-2.)
Remove the armrest. (See Removal And Installation on
Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
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
2
1
P-90841
Remove the two nuts, bolts (Item 1), and the support tube
(Item 2) [Figure 50-150-8].
1
P-90839
Remove the two bolts, washers (Item 1), and the armrest
shell (Item 2) [Figure 50-150-6].
577 of 1148
50-150-3
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-150-8
Figure 50-150-11
ARMREST (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 50-150-9
3
1
1
2
2
P-90844
1
Remove the two nuts, bolts (Item 1), and the side rail
(Item 2) [Figure 50-150-11] from the armrest mount.
P100825
Repeat for the other side.
7
Dealer Copy -- Not for Resale
Figure 50-150-10
4
3
6
2
5
1
P100824
Remove the nut (Item 1), washer (Item 2), spring (Item 3)
[Figure 50-150-9] and [Figure 50-150-10].
Remove the spacer (Item 4), washer (Item 5), plastic
washer (Item 6), and the bolt (Item 7) [Figure 50-15010].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 inlb) torque.
578 of 1148
50-150-4
S530 Service Manual
LEFT SIDE LOWER PANEL
Figure 50-160-3
Removal And Installation
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 5031-4.)
Raise the operator cab.
1
Figure 50-160-1
1
P-90856
P-90863
1
Disconnect the wiper washer pump (Item 1) (if equipped)
[Figure 50-160-3] from the left side lower panel.
1
1
1
1
P-90897
1
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
1
Lower the operator cab.
NOTE: With the seat removed, the cab may raise.
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.
1
P-90867
Remove the storage compartment (Item 1) (if equipped)
[Figure 50-160-2] from the left side lower panel.
579 of 1148
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Dealer Copy -- Not for Resale
Figure 50-160-4
1
LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-7
Removal And Installation (Cont’d)
Figure 50-160-5
2
2
1
1
1
P-90858
Disconnect the hose (if equipped) (Item 1) and remove
the hose (Item 2) [Figure 50-160-7] from the panel.
1
P-90855
Figure 50-160-8
Figure 50-160-6
1
2
1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]
rear out and away from the side of the cab.
P-90857
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-160-6].
580 of 1148
NOTE: Pull the left side lower panel away from the
side of the cab far enough to access the wire
harness.
50-160-2
S530 Service Manual
Dealer Copy -- Not for Resale
Remove the three plastic rivets, anchors (Item 1), and the
screw (Item 2) [Figure 50-160-5].
LEFT SIDE LOWER PANEL (CONT’D)
Removal And Installation (Cont’d)
Figure 50-160-9
1
1
1
1
P-90859
Dealer Copy -- Not for Resale
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped).
581 of 1148
50-160-3
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LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
Disassembly And Assembly
Figure 50-160-10
1
1
1
1
1
1
1
1
P-90866
1
Remove the four screws (Item 1) [Figure 50-160-12] and
remove the speaker from the left side lower panel.
P-90860
Figure 50-160-13
Figure 50-160-11
1
1
P-90864
Remove the three screws (Item 1) [Figure 50-160-13]
and remove the washer tank from the left side lower
panel.
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are
removed the cup holder will need to be
replaced.
582 of 1148
50-160-4
S530 Service Manual
Dealer Copy -- Not for Resale
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Figure 50-170-3
RIGHT SIDE LOWER PANEL
Removal And Installation
2
Remove the seat. (See Removal And Installation on
Page 50-31-1.)
1
1
Raise the operator cab.
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
P-90897
Remove the five plastic rivets (Item 1) [Figure 50-170-1].
1
Lower the operator cab.
2
NOTE: With the seat removed, the cab may raise.
1
Figure 50-170-2
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.
583 of 1148
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Dealer Copy -- Not for Resale
1
RIGHT SIDE LOWER PANEL (CONT’D)
Removal And Installation (Cont’d)
Figure 50-170-5
1
P-90872
Dealer Copy -- Not for Resale
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
1
2
1
1
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.
584 of 1148
50-170-2
S530 Service Manual
RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
Disassembly And Assembly
Figure 50-170-7
1
1
P-90875
Remove the nut, washer and cover (Item 1) [Figure 50170-9] from the headphone jack.
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port. Remove the power
port from the right side lower panel.
Remove the headphone jack from the right side lower
panel.
Dealer Copy -- Not for Resale
P-90879
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
1
2
1
1
P-90877
1
1
P-90876
Remove the four screws (Item 1) [Figure 50-170-10] and
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.
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Dealer Copy -- Not for Resale
586 of 1148
50-170-4
S530 Service Manual
HEADLINER
Figure 50-180-3
Removal And Installation
Remove the cab light (if equipped). (See Cab Light
Removal And Installation (Earlier Models) on Page 6060-2.) or (See Cab Light Removal And Installation (Later
Models) on Page 60-60-3.)
Figure 50-180-1
1
1
1
P-90895
Remove the air duct (Item 1) [Figure 50-180-3] (if
equipped).
P-90893
1
Remove the two screws (Item 1) and the rear shelf (Item
2) [Figure 50-180-1] (if equipped).
NOTE: The rear shelf has two panel clips on the
bottom. Lift vertically to remove the shelf.
1
1
1
Installation: Tighten the screws to 2,3 N•m (20 in-lb)
torque.
2
Figure 50-180-2
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
groove on the topside of the headliner (if equipped with
HVAC).
1
P-90894
Remove the air duct (Item 1) [Figure 50-180-2] (if
equipped).
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50-180-1
S530 Service Manual
Dealer Copy -- Not for Resale
Figure 50-180-4
2
Dealer Copy -- Not for Resale
588 of 1148
50-180-2
S530 Service Manual
FAN DUCT PANELS
Figure 50-190-3
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the fan duct. (See Fan Duct Removal And
Installation on Page 70-40-4.)
1
Figure 50-190-1
P106816
Remove the hose (Item 1) [Figure 50-190-3].
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P106665
Figure 50-190-4
Figure 50-190-2
1
1
3
1
2
P106666
P106664
Remove the bolts (Item 1) [Figure 50-190-1] and (Item 1)
[Figure 50-190-2] and remove the plate (Item 2) [Figure
50-190-2].
Remove the bolts (Item 1) [Figure 50-190-4].
Remove the hose (Item 3) [Figure 50-190-2].
589 of 1148
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Dealer Copy -- Not for Resale
IMPORTANT
FAN DUCT PANELS (CONT’D)
Removal And Installation (Cont’d)
Figure 50-190-5
1
2
1
P106668
Dealer Copy -- Not for Resale
Remove the bolts (Item 1) [Figure 50-190-5] and remove
the plate (Item 2).
590 of 1148
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S530 Service Manual
ELECTRICAL SYSTEM AND ANALYSIS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-20-1
60-20-1
60-20-2
60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-30-1
60-30-1
60-30-2
60-30-3
60-30-4
60-30-4
60-30-5
60-30-6
60-30-8
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-40-1
60-40-1
60-40-1
60-40-2
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
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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
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-15
60-60-1
60-60-1
60-60-2
60-60-2
60-60-3
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-70-1
60-70-1
60-70-2
60-70-8
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-71-1
60-71-1
60-71-2
60-71-3
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-72-1
60-72-1
60-72-2
60-72-4
ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-80-1
60-80-1
60-80-2
60-80-3
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . .
Inspecting Deactivation Of The Auxiliary Hydraulics System 
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . .
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . .
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-100-2
60-100-2
60-100-2
60-100-2
60-100-2
60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . .
60-110-1
60-110-1
60-110-1
60-110-2
60-110-3
60-110-5
60-110-6
592 of 1148
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60-100-1
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LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Light Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . .
Cab Light Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . .
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-120-1
60-120-1
60-120-2
60-120-3
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-140-1
60-140-1
60-140-2
60-140-3
60-140-4
60-140-5
60-140-6
ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-141-1
60-141-1
60-141-2
60-141-3
60-141-4
60-141-5
60-141-6
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-142-1
60-142-1
60-142-2
60-142-3
60-142-4
60-142-5
60-142-6
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
593 of 1148
60-03
S530 Service Manual
Dealer Copy -- Not for Resale
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-1
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-5
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-8
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-11
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . .
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-190-1
60-190-1
60-190-1
60-190-2
60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-191-1
60-191-1
60-191-1
60-191-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-200-1
60-200-1
60-200-2
60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-210-1
60-210-1
60-210-1
60-210-2
60-210-3
60-210-4
60-210-5
60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-220-1
60-220-1
60-220-2
60-220-3
ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
594 of 1148
60-04
S530 Service Manual
Dealer Copy -- Not for Resale
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-231-1
60-231-1
60-231-2
60-231-4
Dealer Copy -- Not for Resale
CAMSHAFT AND CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . 60-240-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-1
595 of 1148
60-05
S530 Service Manual
Dealer Copy -- Not for Resale
596 of 1148
60-06
S530 Service Manual
Dealer Copy -- Not for Resale
Printable Version Click Here
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Dealer Copy -- Not for Resale
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CONNECTOR ASSIGNMENTS
CONN
DESCRIPTION
NUM OF
PINS
C100
C103
C105
WATER IN FUEL SENDER
TAILGATE HARNESS
HYD CHARGE PRESSURE SENSOR
2
8
3
Sheet
CONN
DESCRIPTION
NUM OF
PINS
Sheet
CONN
DESCRIPTION
NUM OF
PINS
Sheet
8
6,12,13,15
9
C434-1
C434-2
C435-1
LEFT FRONT WORKLIGHT (37W)
LEFT FRONT WORKLIGHT (50W)
RIGHT FRONT WORKLIGHT (37W)
2
2
2
13
13
13
FRC1
FUSE RELAY CENTER
112
4,5,8,9,13,14
J1A
GATEWAY CONTROLLER
34
5,8,9,10,12,13,14,15
C435-2
RIGHT FRONT WORKLIGHT (50W)
2
13
J1B
GATEWAY CONTROLLER
26
4,6,7,8,9,10,11,12,15
C438
CAB-MFR HARN CONN(DK GRY)
14
11,13,14,15
J2A
J2B
AUX CONTROLLER
AUX CONTROLLER
34
26
9,12,15
4,5,6,7,9,12,15
C441
C446
C449
C450
C479
C480
C482
C483
TWO SPEED SOLENOID
HYDRAULIC FAN
LEFT JOYSTICK(CAB HARN)
RIGHT JOYSTICK(CAB HARN)
LEFT PANEL(BLACK)
LEFT PANEL(GRAY)
SEATBAR SENSOR
TEMP CONTROL SWITCH
2
2
4
4
12
12
3
3
15
9
7
7
7,10
10
11
14
J7A
ENG ECU CONTROLLER(BCT)
58
5,6,7,8
SW1
SW2
SW3
SW4
BRAKE SWITCH
BEACON SWITCH
HAZARD SWITCH
HAND/FOOT, H/ISO SWITCH
6
6
6
6
10
15
15
11
C486
C489
AC COMPRESSOR
MFR ACCESSORY
2
2
14
5,6
SW5
SW6
POWER BOBTACH SWITCH
BUCKET POSITION SWITCH
6
6
15
15
C108
C110
C111
C112
HYD TEMPERATURE SENDER
ALTERNATOR
HARNESS ENGINE START CONN
HYD OIL FILTER SWITCH
2
2
3
2
9
8
8
9
C114
HAND THROTTLE
6
8
C118
ENG-CROSSOVER
4
8
C126
C129
C169
HORN
CAB ACCESSORY
ENGINE CAN (Diagnostic)
2
3
6
15
11
7
POWER SOCKET
2
11
SW9
TRAVEL CONTROL SWITCH
6
10
WASHER ADAPTER INTMD
WASHER PUMP
AIR RIDE SEAT
RIGHT SPEAKER
2
2
6
2
11
11
15
15
C499
C500
C503
PTOL
RH KEY SWITCH
RH DLX PANEL
4
6
6
10
10
7,10
SW10
SW11
SW12
BLOWER SWITCH
AC SWITCH
DPF SWITCH
6
3
10
14
14
10
C279
C308
C350
C355
LEFT SPEAKER
BRAKE SOLENOID
AC EVAPORATOR SWITCH
FUEL HARNESS
2
2
2
6
15
9
14
8,15
C602
C603
C606
C607
LEFT REAR TAIL LIGHT
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
POWER BOBTACH CLOSE
2
2
2
2
13
13
15
15
T1
T2
T3
T6
BATT GROUND
BUZZER GROUND
FLASHER
BATT GROUND
1
1
2
1
6
10
15
C404
BU ALARM-MFR HARN
2
5,12
C610
HVAC DUCT FAN
14
T8
BATT GROUND
1
6
C405
AIR FILTER SWITCH
BLOWER MOTOR
FUEL SENDER
CAB-MFR HARN CONN(BLK)
C630
C635
THERMOSTAT
HEATER VALVE
3
6
14
14
14
T10
T13
ENGINE SYSTEM GROUND
BUZZER POWER
1
1
6
10
T14
PRE HEATER
1
8
C409
RIGHT HANDLE (MAN/ACS)
10
8
8
4,6,7,10,
11,13,15
12
C611
C406
C408
2
2
14
2
4
C410
C411
C412
C415
C418
C419
C420
C421
C422
C423
C425
LEFT HANDLE (MAN/ACS)
LEFT HANDLE 5 WAY
LEFT HANDLE 2 WAY
HIGH FLOW SOLENOID
FRONT ROD
FRONT BASE
HYD LOCK
TILT SPOOL LOCK
LIFT SPOOL LOCK
BUCKET POSITION SOLENOID
BRAKE SOLENOID
10
5
2
2
12
15
15
15
T15
T16
T17
T18
RIGHT REAR WORK LIGHT(+)
RIGHT REAR WORK LIGHT(-)
LEFT REAR WORK LIGHT(+)
LEFT REAR WORK LIGHT(-)
1
1
13
13
9
9
9
12
12
15
9
BACKUP ALARM
BACKUP ALARM(GND)
ECU CASE GROUND
13
13
12
2
2
2
3
3
2
3
T19
T20
T32
1
1
1
1
1
12
6
C426
CAN(Remote Start Tool, ACD)
C428
CAB-MFR HARN CONN(LT GRY)
7
14
7
5,6,8,11,15
Dealer Copy -- Not for Resale
C212
C252
C253
C277
C278
C667
DOOR HARNESS
6
11
C670
C676
EXTERIOR BEACON HARNESS
RADIO
6
6
15
15
6
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 1 of 16
Printed In U.S.A.
613 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
FUNCTION
HYDRAULIC LOCK RETURN
LIFT SPOOL LOCK RETURN
HVAC RELAY - B
SWITCHED PWR RELAY - A
FRONT LIGHT RELAY - J
STARTER RELAY - M
TRACTION PULL RELAY - D
TILT SPOOL LOCK RETURN
AC SENSE
SPARE DIGITAL, ECU SOURCES
TRACTION LOCK FDBK RELAY - D
AIR FILTER SWITCH
REAR LIGHT RELAY - E
HYD FAN RETURN
PTOL LED
PTOL SWITCH
SWITCHED PWR FDBK RELAY - A
STARTER FDBK RELAY - M
START ENGINE
TWO SPEED RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
HYD CHARGE PRESS
UNSW BATT
UNSW BATT
RUN SIG ENG ECU
LIFT SPOOL LOCK
TRACTION LOCK HOLD
TILT SPOOL LOCK
CAN LO 1
CAN HI 1
HAND THROTTLE
SEAT BAR
FUEL LEVEL
BICS HYD LOCK HOLD
CAN HI 2
GROUND P1
GROUND P2
GROUND P3, SENSOR
HYD FAN
CAN LO 2
REMOTE RUN KEY
RUN/ENTER
SENSOR SUPPLY 8V
SENSOR SUPPLY 5V
TWO SPEED COIL
REAR LIGHT FDBK RELAY - E
HVAC FDBK RELAY - B
LIGHT FDBK RELAY - K
HYD OIL TEMP (8 VOLT)
FOOT THROTTLE
HYD OIL FILTER SW1
Dealer Copy -- Not for Resale
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
HARNESS PART NUMBER
MF MFR MAN
7223849
EXMF MFR MAN
7265268
7253375
DLX CAB
STD CAB
7227905
STD FUEL
7149219
614 of 1148
Printed In U.S.A.
DLX FUEL
7266824
BCT ENG START
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
BRAKE ADAPTER
WHL 2 SPD ADP
TRK 2 SPD
7220812
7217484
7217483
7163706
7165061
7159366
7214626
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
FUNCTION
PIN
FUNCTION
FRONT BASE RETURN
B-1
B-2
UNSW BATT
LEFT BLINKER RELAY
B-3
UNSW BATT
RIGHT BLINKER RELAY
B-4
B-5
HORN RELAY
B-6
B-7
B-8
CAN LO 1
B-9
CAN HI 1
B-10
B-11
LH PADDLE RIGHT
LH PADDLE LEFT
B-12
RH RIGHT ROCKER UP
B-13
FRONT BASE SOLENOID
B-14
CAN HI 2
B-15
GROUND
B-16
GROUND
B-17
RH PWM LOW
FRONT ROD RETURN
B-18
RH PWM SIGNAL
B-19
FRONT ROD
B-20
LH SW-FLOAT (ACS)
CAN LOW 2
B-21
RH TRIGGER
B-22
LH RIGHT ROCKER DOWN
SWITCHED POWER
B-23
RH PWM HIGH
B-24
B-25
HIGH FLOW RETURN
B-26
HIGH FLOW
LH RIGHT ROCKER UP
RH LEFT ROCKER UP
RH LEFT ROCKER DOWN
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 2 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
GROUP DESCRIPTION
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
WHITE
WHT
OTHER FUNCTIONS
7000 THROUGH 7999
TAN
TAN
ENGINE
8000 THROUGH 8999
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
ENGINE CONTROLLER
PIN
CONNECTOR J7
FUNCTION
1
SW POWER
2
GND
3
SW POWER
4
GND
5
SW POWER
6
GND
9
WATER FUEL SENSOR
13
14
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
15
19
IGN SW INPUT
21
24
25
B
28
MAF FREQ
29
PEDAL POS 2
35
MAF TEMP
34
WATER FUEL SENSOR GND
45
ECU RELAY GND
47
CAN 1 LO
48
CAN 1 HI
56
GLOW PLUG SIGNAL
E
J
Dealer Copy -- Not for Resale
A
26
D
C
F
G
H
K
L
M
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 3 of 16
Printed In U.S.A.
615 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
UNSWITCHED BATT POWER
1240 RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1450 RED/WHT
6
1110 RED/WHT
1130 RED/WHT
2
3
1400 RED/WHT
1450 RED/WHT
FRC1 FUSE RELAY CENTER
1070 RED
+12V
BATTERY
1025 RED
MEGAFUSE
100.0 Amps
FUSE 11 25 A
FUSE 13 25 A
1120 RED/WHT
1160 RED/WHT
SP2
SP36
J1B
GWY CTRLR
1150 RED/WHT
3
1180 RED/WHT
2
SHEET 10
C503 RH DLX PANEL
SHEET 11
C667 DOOR HARNESS
SP7
1420 RED/WHT
SHEET 10
C500 RH KEY SWITCH
1440 RED/WHT
SHEET 10
C479 LH PANEL (BLACK)
J2B
AUX CTRLR
FUSE 15 OPEN
T4 1
FUSE 17 OPEN
SHEET 8
STARTER
1140 RED/WHT
FUSE 3 30 A
1310 RED
1360 RED/WHT
FUSE 1 15 A
1340 RED
SP26
FUSE 2 20 A
1320 RED/WHT
1350 RED/WHT
1330 RED/WHT
1060 RED
1335 RED
1325 RED
SP1
1300 RED
FUSE 9 50 A
FUSE 20 5 A
FUSE 16 25 A
1065 RED/WHT
1345 RED/WHT
1035 RED/WHT
1445 RED/WHT
1190 RED
1040 RED
1290 RED
FUSE 18 25 A
FUSE 22 25 A
FUSE 24 25 A
1165 RED/WHT
1490 RED/WHT
1370 RED/WHT
SHEET 14
FRC1 HVAC RELAY
Dealer Copy -- Not for Resale
FUSE 4 25 A
1010 RED
SHEET 9
FRC 1 TRACTION LOCK RELAY
SHEET 13
FRC1 REAR LIGHT RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 5
FRC1 ENGINE ECU RELAY
SHEET 5
FRC 1 ENGINE ECU RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 7
C426 REMOTE RUN, ACD
1460 RED/WHT
SP24
1410 RED/WHT
SHEET 15 C412 LH HANDLE HORN
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60
1050 RED
1030 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
SHEET 8
FRC1 STARTER RELAY
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 4 of 16
Printed In U.S.A.
616 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
SWITCHED POWER
FRC1
ENGINE ECU
+12V RELAY - G
SHEET 4
1035 RED/WHT
PWR
30
1504 RNG/WHT
87
85
86
SP54
1509 RNG/WHT
J7A ENGINE ECU
1506 RNG/WHT
1
1507 RNG/WHT
3
1508 RNG/WHT
5
45
8005 TAN
FRC1 FUSE RELAY CENTER
SHEET 4
1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT
SHEET 8 ENG-CROSSOVER
1720 RNG/WHT
1760 RNG/WHT
1790 RNG/WHT
FUSE 6 25 A
FUSE 12 15 A
C489
A MFR ACCESSORY
1750 RNG/WHT
1780 RNG/WHT
SP50
1850 RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1550 RNG/WHT
Dealer Copy -- Not for Resale
FUSE 5 25 A
1530 RNG/WHT
FUSE 14 5 A
1570 RNG/WHT
1560 RNG/WHT
SP11
1660 RNG/WHT
1765 RNG/WHT
1795 RNG/WHT
SP25
FUSE 7 25 A
SHEET 4
SHEET 6
1050 RED
+12V
PWR
30
87
2055 BLK
GND 85
86
1815 RNG/WHT
3450 LBL
21
3380 LBL
4
J1A
GWY CTRLR
FUSE 23 15 A
1730 RNG/WHT
SP65
SHEET 12 C409 RIGHT HANDLE
22
C428
J2B
(LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
2
1735 RNG/WHT
1580 RNG/WHT
1800 RNG/WHT
9
1920 RNG/WHT
SP37
1660 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 C479 LH PANEL (BLACK)
SHEET 10 T13 LH PANEL BUZZER
SHEET 10 C499 RH PANEL PTOL
SHEET 10 SW1 BRAKE SWITCH
SHEET 10 SW9 TRAVEL CONTROL SWITCH
SHEET 11 SW4 H/ISO SWITCH
SHEET 10 C500 RH PANEL KEY SWITCH
SHEET 10 C503 RH DELUXE PANEL
SP42
SHEET 7 C169 ENGINE CAN
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 8 C110 ALT EXCITATION
C428
(LT GRAY)
CAB-MFR HARN CONN 2
1920 RNG/WHT
1620 RNG/WHT
1940 RNG/WHT
1930 RNG/WHT
1775 RNG/WHT
1960 RNG/WHT
1785 RNG/WHT
1950 RNG/WHT
1590 RNG/WHT
SHEET 12 C410 LEFT HANDLE
1725 RNG/WHT
FUSE 8 25 A
FRC1
SWITCHED
POWER RELAY - A
1700 RNG/WHT
1705 RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION)
1520 RNG/WHT
1805 RNG/WHT
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
B
1840 RNG/WHT
1830 RNG/WHT
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
SHEET 7
C449 LH JOYSTICK
Printable Version Click Here
SHEET 7
C450 RH JOYSTICK
sheet 5 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
Printed In U.S.A.
617 of 1148
GROUND
2
J7A
ENG ECU CTRLR
2002 BLK
6
SP53
2810 BLK
2003 BLK
T32
ECU CASE GND
2320 BRN
2370 BRN
SHEET 11
C408 CAB-MFR CONN (SEATBAR SENSOR)
SHEET 9
C108 HYD TEMP SENDER
J1B
GWY CTRLR
2220 BRN
2230 BRN
17
SP12
2190 BRN
SHEET 9
C105 HYD CHG PRESSURE SENDER
2180 BRN
SHEET 8
C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 8
C405 AIR FILTER SWITCH
2690 BRN
SHEET 8
2001 BLK
4
SHEET 9
C112 HYD OIL FILTER SWITCH
2004 BLK
C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C479 LH PANEL
SHEET 10
C499 PTOL
SHEET 10
C500 RH PANEL KEY SWITCH
2080 BLK
2070 BLK
2920 BLK
2940 BLK
T6
BATT GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SP4
2950 BLK
10
2960 BLK
J1B
GWY CTRLR
2250 BLK
SHEET 10
C503 RH DELUXE PANEL
2065 BLK
SHEET 10
SW12 DPF SWITCH
2930 BLK
SHEET 10
SW1 BRAKE SWITCH
2830 BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700 BLK
SHEET 10
SW9 TRAVEL CONTROL SWITCH
2785 BLK
SHEET 15
C126 HORN
2620 BLK
SHEET 13
T16 RH REAR LIGHT
2650 BLK
SHEET 12
T20 BU ALARM
2640 BLK
SHEET 13
C602 LH REAR LIGHT
2610 BLK
SHEET 13
C603 RH REAR LIGHT
SHEET 13
T18 LH REAR LIGHT
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SP47
2900 BLK
2500 BLK
15
SHEET 15
C355 FUEL HARN (PWR BOB/AC)
SHEET 9
C425 BRAKE
SP51 2600 BLK
2540 BLK
2550 BLK
2900 BLK
C489
MFR ACCESSORY
B
2630 BLK
Printed In U.S.A.
2510 BLK
15
16
J2B
AUX CTRLR
2045 BLK
SHEET 13
FRC1 REAR LIGHT RELAY
2035 BLK
SHEET 9
FRC1 TRACTION LOCK RELAY
2115 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY
2030 BLK
SHEET 14
FRC1 HVAC RELAY
2005 BLK
SHEET 8
FRC1 STARTER RELAY
2120 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY
618 of 1148
16
1
C103
TAILGATE HARN
2765 BLK
SHEET 13
C408 CAB-MFR CONN (FR LIGHTS)
2745 BLK
SHEET 14
C408 CAB-MFR CONN (HVAC)
2790 BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES)
2780 BLK
SHEET 15
C408 CAB-MFR CONN (OPTIONS)
2730 BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2950 BLK
B
2770 BLK
2200 BLK
2720 BLK
2600 BLK
2455 BLK
SHEET 15
C423 BKT POSITION SOLENOID
2710 BLK
SHEET 7
C426 REMOTE RUN, ACD
2715 BLK
SHEET 7
C169 ENGINE CAN
2290 BLK
SHEET 14
D4 COMPRESSOR DIODE
SP55
Dealer Copy -- Not for Resale
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
2110 BLK
SP3
2090 BLK
SP28
2390 BLK
SP6
T1
BATT GND
SHEET 8
ALTERNATOR GROUND
T8
BATT GND
2015 BLK
T10
ENGINE
GROUND
2300 BLK
SP27
2105 BLK
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 6 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
CAN BUS
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7207731)
J7A
ECU CNTRLR
47
CAN LO
48
CAN HI
9200 PUR
9100 PUR/WHT
9215 PUR
9115 PUR/WHT
J1B
GWY CTRLR
SP90
9210 PUR
9110 PUR/WHT
SP91
RE018
120 OHM
0.5 W
RESISTOR
20
14
9205 PUR
9105 PUR/WHT
RE021
120 OHM
0.5W
RESISTOR
C169
ENGINE CAN
SHEET 5
SHEET 6
1
2
1725 RNG/WHT
2715 BLK
3
4
9155 PUR/WHT
9255 PUR
J1B
GWY CTRLR
9260 PUR
9160 PUR/WHT
8
9
SP31
9230 PUR
9130 PUR/WHT
RE014
120 OHM
O.5W
RESISTOR
Dealer Copy -- Not for Resale
5
6
SP30
C408
(BLACK)
CAB-MFR HARN CONN 1
9220 PUR
9120 PUR/WHT
4
3
SP39 9430 PUR
SP35 9450 PUR
9220 PUR SP18
9460 PUR
9410 PUR
9310 PUR/WHT 9330 PUR/WHT
9350 PUR/WHT 9360 PUR/WHT
9120 PUR/WHT
SP17
SP38 SP34
RE019
120 OHM
0.5 W
RESISTOR
9440 PUR
9340 PUR/WHT
J2B
AUX CTRLR
9280 PUR
9180 PUR/WHT
8
9
SHEET 5
SHEET 6
9320 PUR/WHT
9420 PUR
9300 PUR/WHT
9400 PUR
J2B
AUX CTRLR
CAN HI
CAN LO
C479
LEFT PANEL (BLACK)
4
2
C503
RIGHT DELUXE PANEL
1830 RNG/WHT
2070 BLK
1
2
3
4
1840 RNG/WHT
2080 BLK
1
2
3
4
*
C450
RIGHT JOYSTICK
*
C449
LEFT JOYSTICK
C426
Remote Run Tool, ACD
14
9500 PUR/WHT
A
20
9600 PUR
B
J1B
GWY CTRLR
21
3090 LBL
SHEET 5
SHEET 4
SHEET 6
Printed In U.S.A.
619 of 1148
SHEET 5
SHEET 6
4
3
1735 RNG/WHT
1165 RED/WHT
2710 BLK
D
C
E
F
G
REMOTE RUN KEY
SWITCHED POWER
UNSWITCHED POWER
GROUND
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 7 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
ENGINE
FRC1
STARTER RELAY - M
1030 RED
SHEET 4
2005 BLK
SHEET 6
7
8210 TAN
22
3560 LBL
+12V
PWR 30
85
86
8210 TAN
SHEET 5
FUSE 12
3560 LBL
1800 RNG/WHT
A
B
C
8220 TAN
3560 LBL
S
R
M
B
SHEET 4
1015 RED
C110
B
ALTERNATOR
J1A
GWY CTRLR
G
S
L
1020 RED
1800 RNG/WHT
EXCITATION
C405
2150 BRN
3150 LBL
SHEET 6
16
J1B
GWY CTRLR
B
A
GND
10
3690 LBL
4
8007 TAN
SHEET 6
C406
3180 LBL
2180 BRN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 11
J7A
ENG ECU CTRLR
C
D
SHEET 6
ENGINE GROUND TERMINAL
Dealer Copy -- Not for Resale
3180 LBL
2180 BRN
2015 BLK
AIR FILTER
SWITCH (NC)
SIG
C355
FUEL HARN
12
19
STARTER
8200 TAN
87
GND
C111
HARN ENG START CONN
A
B
SIG
GND
FUEL SENDER
(30 - 270 OHM)
C114
HAND THROTTLE
5690 YEL
7
5690 YEL
3690 LBL
6
3690 LBL
2690 BRN
8
2690 BRN
SHEET 6
8007 TAN
C
A
B
+5V PWR
SIG
GND
D
E
F
C100
9
34
1
2
3865 LBL
2865 BRN
SIG
GND
WATER IN FUEL SENDER
(FUEL FILTER)
C118
ENG-CROSSOVER
SHEET 5
MAF FREQ
MAF TEMP
1511 RNG/WHT
1
28
8013 TAN
8013 TAN
2
35
8014 TAN
8014 TAN
3
+12V
PWR
SHEET 4
56
1065 RED/WHT
8510 TAN
3420 LBL
30
85
87
86
PREHEATER
RELAY - C
Printed In U.S.A.
8525 TAN
8500 TAN
SP93
1445 RED/WHT
SHEET 4
4
PRE-HEATER
To C154 - PIN1 and
C155 - PIN 3
MAF Sensor - PIN 1
MAF Sensor - PIN 4
TO J7B - PIN 79
Sheet 16 of 16
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 8 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
620 of 1148
1360 RED/WHT
SHEET 4
2035 BLK
SHEET 6
FRC1
TRACTION LOCK
+12V RELAY - D
PWR 30
87
GND
85
HYDRAULICS
4100 LGN
SHEET 6
86
4200 LGN
2200 BLK
C425
B
A
C
C308
4200 LGN
2200 BLK
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061
8
4110 LGN
13
3430 LBL
SHEET 6
32
C108
2220 BRN
3220 LBL
B
A
GND
SIG
C112
J1A
GWY CTRLR
34
SHEET 6
3320 LBL
2320 BRN
A
B
SIG
GND
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
(8 VOLT)
HYDRAULIC OIL
FILTER SWITCH (NC)
C446
2910 BRN
4010 LGN
1
2410 BRN
4410 LGN
2
1
GND
SIG
C420
B
A
GND
SIG
C105
SHEET 6
2190 BRN
3190 LBL
5190 YEL
B
C
A
GND
SIG
+8V PWR
4200 LGN
19 13
HYDRAULIC
FAN SOLENOID
7.2 OHM 12 V
Dealer Copy -- Not for Resale
18
HYDRAULIC LOCK
SOLENOID
9.8 OHM 12 V
HYDRAULIC CHARGE
PRESSURE SENSOR
0.5-7.5V
1 23 6
+8V
J1B
GWY CTRLR
C418
J2A
AUX CTRLR
18
2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
3.3 OHM PWM
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
C419
1
2340 BRN
4340 LGN
2
1
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
19 13
J2B
AUX CTRLR
Printed In U.S.A.
621 of 1148
sheet 9 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
1940 RNG/WHT
CAB DISPLAY
LEFT PANEL
BUZZER
7040 WHT
C479
LEFT PANEL (BLACK)
T2
BUZZER (-)
SHEET 6
SHEET 5
1960 RNG/WHT
SHEET 4
SW9
TRAVEL CONTROL
SWITCH (OPTIONAL)
SHEET 6
2700 BLK
SHEET 5
SHEET 15
5 6
4
2 3
1
SHEET 5
SHEET 6
SHEET 15
3610 LBL
1775 RNG/WHT
2930 BLK
3
1
4
7040 WHT
10
2920 BLK
2
1440 RED/WHT
1
1620 RNG/WHT
5
3400 LBL
11
3500 LBL
8
3650 LBL
7
3600 LBL
9
6
SW1
2 BRAKE SWITCH
UNSWITCHED POWER
SWITCHED POWER
1700 RNG/WHT
2065 BLK
3620 LBL
7 9
2
1930 RNG/WHT
2940 BLK
1
3
20
3030 LBL
1
3030 LBL
2
19
2380 BRN
12
2380 BRN
4
J1A
GWY CTRLR
LEFT BLINKER INPUT
24
TRAVEL CONTROL INPUT
SWITCHED POWER
GROUND
PTOL OUTPUT
PTOL LED
C500
RIGHT PANEL - KEY SWITCH
RIGHT BLINKER INPUT
8130 TAN
2
8130 TAN
PARK BRAKE INPUT
C480
LEFT PANEL (GRAY)
SW12
DIESEL PARTICULATE
FILTER SWITCH
SHEET 6
GROUND
6
3610 LBL
SHEET 5
BUZZER
5
1705 RNG/WHT 10
C408
(BLACK)
CAB-MFR HARN CONN 1
C499
Press To Operate Loader
(PTOL)
2
START
6
12
SHEET 11
SHEET 5
SHEET 5
SHEET 6
8050 TAN
12
11
10
3
2
8
7
6
4
8
8055 TAN
5
3
8060 TAN
1
1
4
8070 TAN
9
DOOR SIGNAL
PARK BRAKE OUTPUT
DPF LAMP
DPF INHIBIT LAMP
Dealer Copy -- Not for Resale
SHEET 5
T13
BUZZER (+)
J1B
GWY CTRLR
22
3040 LBL
14
3040 LBL
SHEET 5
SHEET 4
SHEET 6
1950 RNG/WHT
1420 RED/WHT
2960 BLK
4
5
1
3
RUN/ENTER SWITCH
SWITCHED POWER
UNSWITCHED POWER
GROUND
C503
RIGHT PANEL DELUXE DISPLAY
SHEET 5
SHEET 4
DPF OVERRIDE
SHEET 6
1590 RNG/WHT
5
1240 RED/WHT
1
2250 BLK
3
6
DPF INHIBIT REGEN
SWITCHED POWER
UNSWITCHED POWER
GROUND
NOT USED
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Printed In U.S.A.
sheet 10 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
622 of 1148
*
SHEET 5
C438
SHEET 11
(DK GRAY)
CAB-MFR HARN CONN 3
1850 RNG/WHT
SHEET 5
7
4235 LGN
8
4275 LGN
9
4550 LGN
2
1850 RNG/WHT
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT
2 1
3
6
2060 BLK
5
4
CAB
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
*
C212
POWER
SOCKET
2795 BLK
1375 RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT
SHEET 4
7
*
SP45
1370 RED/WHT
1580 RNG/WHT
5
1865 RNG/WHT
2800 BLK
A
B
C
1510 RNG/WHT
SP44
SHEET 6
11
2730 BLK
GND
2790 BLK
14
SHEET 6
11
+5V
24
5100 YEL
SHEET 8
2370 BRN
4
2370 BRN
A
SEATBAR
SENSOR
GND
3370 LBL
5
3370 LBL
B
SIG
3
5370 YEL
C
+5V PWR
SP13 5370 YEL
*
2210 BLK
SHEET 15
2885 BLK
2060 BLK
SHEET 15
SHEET 11
2790 BLK
C482
J1B
GWY CTRLR
*
1850 RNG/WHT
SHEET 10
SHEET 4
3620 LBL
1400 RED/WHT
1
4
5
6
2840 BLK
2
7310 WHT
3
WIPER SWITCH, MOTOR SWITCHED POWER
DOOR SIGNAL
DOOR UNSW PWR
WIPER MOTOR GROUND
WASHER SIGNAL
5690 YEL
*
2845 BLK
Printed In U.S.A.
T38
DOME LIGHT (-)
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
HARNESS WASHER PUMP
7253378
623 of 1148
DOME
LIGHT
2010 BLK
+12V BATT PWR
+12V SW PWR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 6
T37
DOME LIGHT (+)
SHEET 15
SHEET 15
1885 RNG/WHT
2730 BLK
SP41
Dealer Copy -- Not for Resale
1210 RED/WHT
SHEET 5
GND
+12V PWR
1390 RED/WHT
C129
CAB ACCESSORY
1580 RNG/WHT SP8
1
2
C253
C252
A
7310 WHT
1
B
2845 BLK
2
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
PWR
WASHER
MOTOR
GND
sheet 11 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
MANUAL CONTROLS
J2A
AUX CTRLR
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS Sheet)
A
C103
TAILGATE HARN
C
7100 WHT
SHEET 6
30
31
T19 TERMINAL (+)
7100 WHT
BACK UP
ALARM
2650 BLK
SHEET 5
13
C421
2980 BRN
4980 LGN
10
3
1
2
GND
SIG
TILT SPOOL LOCK
17.8 OHM 12V
C422
2990 BRN
4990 LGN
2
7
3
1
2
GND
SIG
LIFT SPOOL LOCK
17.8 OHM 12V
Dealer Copy -- Not for Resale
T20 TERMINAL (-)
J1A
GWY CTRLR
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
1530 RNG/WHT
4940 LGN
4930 LGN
4920 LGN
4910 LGN
4310 LGN
4320 LGN
4300 LGN
21 17 18 23
J2B
AUX CTRLR
20
28
22
12
11
SHEET 5
K
G
A
H
J
E
F
C
D
B
SKI CTRL
DETENT FLOW
TWO SPD
PWM
C410
LEFT HANDLE
(MANUAL/ACS ONLY)
4640 LGN
4840 LGN
4830 LGN
4820 LGN
4810 LGN
1520 RNG/WHT
K
D
C
B
G
F
A
J
H
E
SKI CTRL
SIDE SHIFT
5
J1B
GWY CTRLR
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 12 of 16
Printed In U.S.A.
624 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
C434-1
LIGHTS
2735 BLK
6100 PNK
C408
(BLACK)
CAB-MFR HARN CONN 1
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
37.00 Watts
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
50.00 Watts
C434-2
SHEET 6
2765 BLK
9
2765 BLK
SP14
2750 BLK
6110 PNK
6000 PNK
8
6000 PNK
SP15
6120 PNK
2760 BLK
B
A
C435-1
FRC1
FRONT WORK
LIGHTS RELAY - J
SHEET 6
1350 RED/WHT
30
2120 BLK
85
87
6610 PNK
13
86
SHEET 4
SHEET 6
5
31
J1A
17
GWY CTRLR
28
1330 RED/WHT
+12V
PWR
30
87
2115 BLK
GND 85
86
6320 PNK
3460 LBL
6210 PNK
3440 LBL
FRC1
REAR LIGHT
RELAY - E
SHEET 4
SHEET 6
1320 RED/WHT
6610 PNK
6310 PNK
A
6310 PNK
GND 85
86
A
B
SP64
C103
TAILGATE HARN
SP10
6340 PNK
C435-2
6130 PNK
2705 BLK
C603
2610 BLK
6320 PNK
SHEET 6
2
1
GND
SIG
SP49
RIGHT REAR
TAIL LIGHT
C602
6330 PNK
2640 BLK
SHEET 6
2620 BLK
SHEET 6
6210 PNK
1
2
SIG
GND
T16 TERMINAL (-)
GND
SIG
LEFT REAR
TAIL LIGHT
RIGHT REAR
WORK LIGHT
T15 TERMINAL (+)
+12V
PWR 30
87
2045 BLK
6630 PNK
FRC1
FRONT WORK
LIGHTS RELAY - K
Dealer Copy -- Not for Resale
SHEET 4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
A
B
6200 PNK
H
6200 PNK
SHEET 6
SP5
6200 PNK
2630 BLK
T17 TERMINAL (+)
SIG
GND
LEFT REAR
WORK LIGHT
T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 13 of 16
Printed In U.S.A.
625 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
2440 BLK
7440 WHT
HVAC
*
2560 BLK
7420 WHT
7425 WHT
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
*
*
C610
2
1
C
A
B
SHEET 6
3
30
+12V
PWR 30
2030 BLK
AC EVAPORATOR
SWITCH
GND 85
86
3050 LBL
SHEET 6
2745 BLK
SP40
7021 WHT
7020 WHT
11
12
C350
B
A
SWITCH
7410 WHT
C486
7025 WHT
SHEET 6
2290 BLK
2280 BLK
D4
1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
OFF
5 2
1
4
6
3
SW11
AC SWITCH
*
2745 BLK
7530 WHT
7520 WHT
7510 WHT
2580 BLK
*
C611
1
2
3
4
14.00 Amps
7.50 Amps
5.00 Amps
High
Med
Low
3
2100 BLK
7015 WHT
C
7400 WHT
1
*
C630
3
2
1
THERMOSTAT
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 14 of 16
Printed In U.S.A.
626 of 1148
BLOWER
MOTOR
SP16
2570 BLK
7020 WHT
7023 WHT
7024 WHT
HEATER
VALVE
SW10
*BLOWER
10 1500 RNG/WHT
7050 WHT
J1A
GWY CTRLR
11
1500 RNG/WHT
87
POTENTIOMETER
(TEMP CONTROL
SWITCH)
D
SIG
C
GND
A +12V PWR
B
E
F
C438
(DK GRAY)
CAB-MFR HARN CONN 3
Dealer Copy -- Not for Resale
1140 RED/WHT
BLK
DBL
WHT
C635
SP48
FRC1
HVAC RELAY - B
HVAC DUCT
FAN
C483
2130 BLK
7430 WHT
SHEET 4
GND
SIG
(PRINTED NOVEMBER 2016)
7254941 (0)
OPTIONS
#
POWER BOB
CLOSE
SIG
GND
#
POWER BOB
OPEN
GND
SIG
C607
1
2
4470 LGN
2470 BLK
E
B
2770 BLK
#
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C355
FUEL HARN
11
4470 LGN
2770 BLK
4470 LGN
4480 LGN
SHEET 6
SW5
*POWER
BOBTACH
SWITCH
C606
2
1
2480 BLK
4480 LGN
F
4480 LGN
C411
13
1550 RNG/WHT
12
6010 PNK
1550 RNG/WHT
1410 RED/WHT
SHEET 4
1
6515 PNK
6500 PNK
6
6500 PNK
6415 PNK
6400 PNK
3
6400 PNK
E
D
6410 PNK
6510 PNK
2780 BLK
SHEET 6
C423
BUCKET
POSITION
SOLENOID
6.13 OHM
SIG
A
4450 LGN
GND
B
2450 BLK
D3
4455 LGN
2455 BLK
B
A
4
5
2780 BLK
4455 LGN
SHEET 6
SHEET 6
7210 WHT
1460 RED/WHT
13
X
1430 RED/WHT
2830 BLK
C408
(BLACK)
CAB-MFR HARN CONN 1 SHEET 6
C412
LEFT HANDLE
HORN SIGNAL
(HORN) 2 WAY
PWR
(SEE ADDITIONAL
OPTIONS DWG)
1200 RED/WHT
SHEET 10 3500 LBL
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
1410 RED/WHT
Dealer Copy -- Not for Resale
LEFT
5
3
4
6
2785 BLK
7210 WHT
L
D1
D2
3400 LBL
SHEET 10
6430 PNK
SW3
*HAZARD
SWITCH
(PINS 3 & 6
INTERNALLY
INSULATED)
2
5
6
2
5
1
3
4
2725 BLK
6700 PNK
2850 BLK
6
*
SW6
BUCKET
POSITION
SWITCH
GND
SIG
HORN
LEFT
SPEAKER
*+
2420 BLK
D
F
B
C
A
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
C676
RADIO CONN
C279
1
2
SWITCH
6
5
4
1
2
3
* C670E
6440 PNK
6540 PNK
C126
B
A
CONN
SW2
*BEACON
2780 BLK
3
1
4
T3
* FLASHER
6530 PNK
6570 PNK
RIGHT
(SEE ADDITIONAL
OPTIONS DWG)
B
C
A
E
D
1
1380 RED/WHT
6010 PNK
C438
(DK GRAY)
CAB-MFR HARN CONN 3
FLASHER PWR
LEFT HANDLE
(FLASHER) 5 WAY
2
10
SHEET 5
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219 )
7820 WHT
7830 WHT
3
4
*
-
SHEET 4
RIGHT
SPEAKER
*+
C278
SHEET 11
SHEET 11
2
1
7810 WHT
7800 WHT
1885 RNG/WHT
2885 BLK
6
5
1
2
SHEET 11
SHEET 11
1510 RNG/WHT
2210 BLK
C277
1
2
3
4
5
6
AIR RIDE
SEAT
PWR
GND
C415
J2A
AUX CTRLR
26
J2B
AUX CTRLR
26
2460 BRN
4460 LGN
B
A
GND
SIG
HIGH FLOW
SOLENOID
7.5 OHM 12 V
C441
J1A
GWY CTRLR
26
J1B
GWY CTRLR
26
2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
5.1 OHM 12 V
TRACK 2 SPEED
ADAPTER
(SEE ADDITIONAL
OPTIONS DWG)
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 15 of 16
Printed In U.S.A.
627 of 1148
(PRINTED NOVEMBER 2016)
7254941 (0)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PRE HEATER
TO C118 - PIN 4
See Sheet 8 of 16
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
ENGINE
HARNESS
SHEET #
179
J7B
ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
106
TEMP SENSOR 2
2
123
SENSOR RETURN 2
1
C151
EGR VALVE
DC MOTOR
5
3
EGR VREF3
POSITION SIGNAL
POSITION RETURN
TO C113 PIN 3
See Sheet 5 of 14
164
116
120
172
137
6
H BRIDGE POS
192
2
H BRIDGE NEG
193
3
1
109
COOLANT RETURN
145
165
VREF3 OIL PRESSURE
3
1
FUEL TEMP SENSOR
110
111
OIL PRESSURE SENSOR
4
2
FUEL RETURN
146
148
104
2
SENSOR SIGNAL
131
1
SENSOR RETURN
SHIELD
130
128
2
1
169
194
SENSOR SIGNAL
SENSOR RETURN
SHIELD
RETURN GND
OIL TEMPERATURE SENSOR
MAF
SENSOR
2
COOLANT TEMP SENSOR
C146
ENGINE BLOCK
ACCELEROMETER 2
4
1
C147
ENGINE BLOCK
ACCELEROMETER 1
C136
2
C148
FUEL TEMP
SENSOR
5V
TO C113 PIN 2
See Sheet 5 of 14
C149
COOLANT TEMP
SENSOR
SENSOR GROUND
Dealer Copy -- Not for Resale
1
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
1
OIL PRESSURE &
TEMPERATURE
SENSOR
2
RETURN
1
SENSOR
2
132
INTAKE
MANIFOLD
TEMPERATURE
133
129
C145
CRANKSHAFT
POSITION
SENSOR
1
CRANK SENSOR POS
160
2
CRANK SENSOR NEG
136
3
SENSOR RETURN
147
2
POS SENSOR
159
C144
CAM SHAFT
SENSOR
1
C143
1
RAIL
PRESSURE
SENSOR
CYL 3
CYL 4
VREF1 CAM
TO C118 - PIN 1|
See Sheet 8 of 16
RAIL PRESSURE SENSOR
NOTE: ON EARLY MODELS, WIRE
TO PIN 161 WAS TO PIN 141
INTAKE PRESS SENSOR
. 161
112
167
INTAKE PRESS SENSOR
INTAKE PRESS RETURN
628 of 1148
B
1
A
3
2
D
INTAKE MANIFOLD
PRESSURE
SENSOR
135
2
SENSOR RETURN
119
3
VREF1 SENSOR
138
FUEL INJECTOR HSDB
151
FUEL INJECTOR LSD1B
175
FUEL INJECTOR HSDA
103
FUEL INJECTOR LSD2A
125
Printable Version Click Here
C139
127
FUEL INJECTOR HSDA
1
126
FUEL INJECTOR LSD1A
2
150
FUEL INJECTOR HSDB
2
174
FUEL INJECTOR LSD2B
1
CYL 1
C140
CYL 2
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR812541 - ALR814313)
C154
177
PWM
TO C118 - PIN 1
SEE Sheet 8 of 16
Printed In U.S.A.
C138
2
1
INLET METERING
VALVE
sheet 16 of 16
(PRINTED NOVEMBER 2016)
7254941 (0)
CONNECTOR ASSIGNMENTS
CONN
DESCRIPTION
NUM OF
PINS
Sheet
CONN
DESCRIPTION
NUM OF
PINS
Sheet
CONN
DESCRIPTION
NUM OF
PINS
Sheet
C100
C103
C105
WATER IN FUEL SENDER
TAILGATE HARNESS
HYD CHARGE PRESSURE SENSOR
2
8
3
8
6,12,13,15
9
C434-1
C434-2
C435-1
LEFT FRONT WORKLIGHT (37W)
LEFT FRONT WORKLIGHT (50W)
RIGHT FRONT WORKLIGHT (37W)
2
2
2
13
13
13
FRC1
FUSE RELAY CENTER
112
4,5,8,9,13,14
J1A
GATEWAY CONTROLLER
34
5,8,9,10,12,13,14,15
C108
HYD TEMPERATURE SENDER
2
9
C435-2
RIGHT FRONT WORKLIGHT (50W)
2
13
J1B
GATEWAY CONTROLLER
26
4,6,7,8,9,10,11,12,15
C110
C111
C112
C114
C118
C126
C129
C169
C212
C252
ALTERNATOR
HARNESS ENGINE START CONN
HYD OIL FILTER SWITCH
HAND THROTTLE
ENG-CROSSOVER
HORN
CAB ACCESSORY
ENGINE CAN (Diagnostic)
POWER SOCKET
WASHER ADAPTER INTMD
2
3
2
6
4
2
3
6
2
2
8
8
9
8
8
15
11
7
11
11
C438
CAB-MFR HARN CONN(DK GRY)
14
11,13,14,15
C441
C446
C449
C450
C479
C480
C482
C483
C486
TWO SPEED SOLENOID
HYDRAULIC FAN
LEFT JOYSTICK(CAB HARN)
RIGHT JOYSTICK(CAB HARN)
LEFT PANEL(BLACK)
LEFT PANEL(GRAY)
SEATBAR SENSOR
TEMP CONTROL SWITCH
AC COMPRESSOR
2
2
4
4
12
12
3
3
2
15
9
7
7
7,10
10
11
14
14
J2A
J2B
AUX CONTROLLER
AUX CONTROLLER
34
26
9,12,15
4,5,6,7,9,12,15
J7A
SW1
SW2
SW3
SW4
SW5
SW6
ENG ECU CONTROLLER(BCT)
BRAKE SWITCH
BEACON SWITCH
HAZARD SWITCH
HAND/FOOT, H/ISO SWITCH
POWER BOBTACH SWITCH
BUCKET POSITION SWITCH
58
6
6
6
6
6
6
5,6,7,8
10
15
15
11
15
15
C253
C277
C278
WASHER PUMP
AIR RIDE SEAT
RIGHT SPEAKER
2
6
2
11
15
15
C489
C499
C500
MFR ACCESSORY
PTOL
RH KEY SWITCH
2
4
6
5,6
10
10
SW9
SW10
SW11
TRAVEL CONTROL SWITCH
BLOWER SWITCH
AC SWITCH
6
6
3
10
14
14
10
LEFT SPEAKER
2
15
C503
RH DLX PANEL
6
7,10
SW12
DPF SWITCH
10
BRAKE SOLENOID
2
9
C602
LEFT REAR TAIL LIGHT
2
13
T1
BATT GROUND
1
6
C350
C355
C404
C405
AC EVAPORATOR SWITCH
FUEL HARNESS
BU ALARM-MFR HARN
AIR FILTER SWITCH
2
6
14
8,15
13
15
T2
T3
10
15
2
2
15
14
T4
T6
BUZZER GROUND
FLASHER
MEGAFUSE LOAD SIDE
BATT GROUND
1
2
5,12
8
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
POWER BOBTACH CLOSE
HVAC DUCT FAN
2
2
2
2
C603
C606
C607
C610
1
1
6
C406
C408
FUEL SENDER
CAB-MFR HARN CONN(BLK)
2
14
C611
C630
BLOWER MOTOR
THERMOSTAT
4
3
14
14
T8
BATT GROUND
1
6
T10
ENGINE SYSTEM GROUND
1
6
C409
C410
RIGHT HANDLE (MAN/ACS)
LEFT HANDLE (MAN/ACS)
10
10
8
4,6,7,10,
11,13,15
12
12
C635
C667
HEATER VALVE
DOOR HARNESS
6
6
14
11
T13
T14
1
10
C411
LEFT HANDLE 5 WAY
5
15
C670
EXTERIOR BEACON HARNESS
6
15
T15
BUZZER POWER
PRE HEATER
RIGHT REAR WORK LIGHT(+)
C412
LEFT HANDLE 2 WAY
2
15
C676
RADIO
6
15
T16
C415
C418
HIGH FLOW SOLENOID
FRONT ROD
2
2
15
9
C419
FRONT BASE
2
9
C420
C421
C422
C423
HYD LOCK
TILT SPOOL LOCK
LIFT SPOOL LOCK
BUCKET POSITION SOLENOID
2
3
3
2
9
12
12
15
C425
C426
C428
BRAKE SOLENOID
CAN(Remote Start Tool, ACD)
CAB-MFR HARN CONN(LT GRY)
3
7
14
9
7
5,6,8,11,15
Dealer Copy -- Not for Resale
C279
C308
T17
T18
T19
T20
T32
T37
T38
RIGHT REAR WORK LIGHT(-)
LEFT REAR WORK LIGHT(+)
LEFT REAR WORK LIGHT(-)
BACKUP ALARM
BACKUP ALARM(GND)
ECU CASE GROUND
DOMELIGHT (+)
DOMELIGHT (-)
4
1
8
1
1
13
13
1
1
13
13
1
12
1
1
1
1
12
6
11
11
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 1 of 16
Printed In U.S.A.
629 of 1148
(PRINTED NOVEMBER 2016)
7279776 (A)
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
FUNCTION
HYDRAULIC LOCK RETURN
LIFT SPOOL LOCK RETURN
HVAC RELAY - B
SWITCHED PWR RELAY - A
FRONT LIGHT RELAY - J
STARTER RELAY - M
TRACTION PULL RELAY - D
TILT SPOOL LOCK RETURN
AC SENSE
SPARE DIGITAL, ECU SOURCES
TRACTION LOCK FDBK RELAY - D
AIR FILTER SWITCH
REAR LIGHT RELAY - E
HYD FAN RETURN
PTOL LED
PTOL SWITCH
SWITCHED PWR FDBK RELAY - A
STARTER FDBK RELAY - M
START ENGINE
TWO SPEED RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
HYD CHARGE PRESS
UNSW BATT
UNSW BATT
RUN SIG ENG ECU
LIFT SPOOL LOCK
TRACTION LOCK HOLD
TILT SPOOL LOCK
CAN LO 1
CAN HI 1
HAND THROTTLE
SEAT BAR
FUEL LEVEL
BICS HYD LOCK HOLD
CAN HI 2
GROUND P1
GROUND P2
GROUND P3, SENSOR
HYD FAN
CAN LO 2
REMOTE RUN KEY
RUN/ENTER
SENSOR SUPPLY 8V
SENSOR SUPPLY 5V
TWO SPEED COIL
REAR LIGHT FDBK RELAY - E
HVAC FDBK RELAY - B
LIGHT FDBK RELAY - K
HYD OIL TEMP (8 VOLT)
FOOT THROTTLE
HYD OIL FILTER SW1
HARNESS PART NUMBER
MF MFR MAN
7276760
EXMF MFR MAN
7276758
DLX CAB
7253375
7227905
STD CAB
STD FUEL
7149219
Printed In U.S.A.
630 of 1148
DLX FUEL
7266824
BCT ENG START
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
BRAKE ADAPTER
WHL 2 SPD ADP
TRK 2 SPD
7220812
7217484
7217483
7266829
7165061
7159366
7214626
Dealer Copy -- Not for Resale
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
FUNCTION
FRONT BASE RETURN
LEFT BLINKER RELAY
RIGHT BLINKER RELAY
HORN RELAY
LH PADDLE RIGHT
LH PADDLE LEFT
RH RIGHT ROCKER UP
FRONT ROD RETURN
LH SW-FLOAT (ACS)
LH RIGHT ROCKER DOWN
HIGH FLOW RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
UNSW BATT
UNSW BATT
CAN LO 1
CAN HI 1
FRONT BASE SOLENOID
CAN HI 2
GROUND
GROUND
RH PWM LOW
RH PWM SIGNAL
FRONT ROD
CAN LOW 2
RH TRIGGER
SWITCHED POWER
RH PWM HIGH
HIGH FLOW
LH RIGHT ROCKER UP
RH LEFT ROCKER UP
RH LEFT ROCKER DOWN
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 2 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BLK
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
PNK
WHITE
WHT
OTHER FUNCTIONS
7000 THROUGH 7999
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PIN
CONNECTOR J7
FUNCTION
1
SW POWER
2
GND
3
SW POWER
4
GND
5
SW POWER
6
GND
9
WATER FUEL SENSOR
19
IGN SW INPUT
28
MAF FREQ
34
35
WATER IN FUEL SENSOR
GND
MAF TEMP
45
ECU RELAY GND
47
CAN 1 LO
48
CAN 1 HI
56
GLOW PLUG SIGNAL
B
A
E
F
J
K
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PARTIAL CONNECTOR
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
D
C
Dealer Copy -- Not for Resale
ENGINE CONTROLLER
G
H
L
M
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 3 of 16
Printed In U.S.A.
631 of 1148
(PRINTED NOVEMBER 2016)
7279776 (A)
UNSWITCHED BATT POWER
1240/RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1450/RED/WHT
6
1110/RED/WHT
1130/RED/WHT
2
3
1400/RED/WHT
1450/RED/WHT
FRC1 FUSE RELAY CENTER
1070/RED
+12V
BATTERY
1025/RED
MEGAFUSE
100.0 Amps
1 1
FUSE 11 25 A
FUSE 13 25 A
1120/RED/WHT
1160/RED/WHT
SP2
SP36
J1B
GWY CTRLR
1150/RED/WHT
3
1180/RED/WHT
2
SHEET 10
C503 RH DLX PANEL
SHEET 11
C667 DOOR HARNESS
SP7
1420/RED/WHT
SHEET 10
C500 RH KEY SWITCH
1440/RED/WHT
SHEET 10
C479 LH PANEL (BLACK)
J2B
AUX CTRLR
FUSE 15 OPEN
FUSE 17 OPEN
FUSE 4 25 A
1010/RED
1310/RED
FUSE 3 30 A
FUSE 1 15 A
1340/RED
SP26
FUSE 2 20 A
1140/RED/WHT
Dealer Copy -- Not for Resale
SHEET 8
STARTER
1360/RED/WHT
1320/RED/WHT
1350/RED/WHT
1335/RED
1325/RED
SP1
1300/RED
FUSE 9 50 A
SHEET 13
FRC1 REAR LIGHT RELAY
FUSE 20 5 A
FUSE 16 25 A
1065/RED/WHT
SHEET 8
FRC1 PRE HEATER RELAY
1345/RED/WHT
SHEET 5
FRC1 ENGINE ECU RELAY
1035/RED/WHT
SHEET 5
FRC 1 ENGINE ECU RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 7
C426 REMOTE RUN, ACD
1460/RED/WHT
SP24
1410/RED/WHT
1445/RED/WHT
1190/RED
1040/RED
1290/RED
1055/RED
SP60
1050/RED
1030/RED
632 of 1148
SHEET 9
FRC 1 TRACTION LOCK RELAY
1330/RED/WHT
1060/RED
Printed In U.S.A.
SHEET 14
FRC1 HVAC RELAY
FUSE 18 25 A
FUSE 22 25 A
FUSE 24 25 A
1165/RED/WHT
1490/RED/WHT
1370/RED/WHT
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 15 C412 LH HANDLE HORN
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
SHEET 5
(S/N B42T11001 - B42T11009)
FRC1 SWITCHED PWR RELAY
SHEET 8
Sheet 4 of 16
FRC1 STARTER RELAY
(PRINTED NOVEMBER 2016)
7279776 (A)
SWITCHED POWER
FRC1
ENGINE ECU
+12V RELAY - G
SHEET 4
1035/RED/WHT
PWR
30
85
86
1
1506/RNG/WHT
SP54
1504/RNG/WHT
87
1509/RNG/WHT
1507/RNG/WHT
3
1508/RNG/WHT
5
45
8005/TAN
SHEET 4
J7A ENGINE ECU
FRC1 FUSE RELAY CENTER
1345/RED/WHT
FUSE 21 15 A
1511/RNG/WHT
SHEET 8 ENG-CROSSOVER
C404
FUSE 5 25 A
1760/RNG/WHT
1790/RNG/WHT
FUSE 6 25 A
FUSE 12 15 A
Dealer Copy -- Not for Resale
1720/RNG/WHT
C489
1550/RNG/WHT
1700/RNG/WHT
1705/RNG/WHT
1570/RNG/WHT
1560/RNG/WHT
SP11
1660/RNG/WHT
1765/RNG/WHT
1795/RNG/WHT
SP25
FUSE 7 25 A
FRC1
SWITCHED
POWER RELAY - A
SHEET 4
SHEET 6
1050/RED
+12V
PWR 30
87
2055/BLK
GND 85
86
1815/RNG/WHT
3450/LBL
21
3380/LBL
4
J1A
GWY CTRLR
1730/RNG/WHT
SP65
C428
J2B
(LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
2
1735/RNG/WHT
FUSE 23 15 A
1580/RNG/WHT
1800/RNG/WHT
9
SP37
1920/RNG/WHT
1660/RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
SHEET 8 C110 ALT EXCITATION
1840/RNG/WHT
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 C479 LH PANEL (BLACK)
SHEET 10 T13 LH PANEL BUZZER
SHEET 10 C499 RH PANEL PTOL
SHEET 10 SW1 BRAKE SWITCH
SHEET 10 SW9 TRAVEL CONTROL SWITCH
SHEET 11 SW4 H/ISO SWITCH
SHEET 10 C500 RH PANEL KEY SWITCH
SHEET 10 C503 RH DELUXE PANEL
SP42
SHEET 7 C169 ENGINE CAN
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
1830/RNG/WHT
633 of 1148
22
C428
(LT GRAY)
CAB-MFR HARN CONN 2
1920/RNG/WHT
Printed In U.S.A.
SHEET 12 C410 LEFT HANDLE
SHEET 12 C409 RIGHT HANDLE
1725/RNG/WHT
FUSE 8 25 A
1620/RNG/WHT
1940/RNG/WHT
1930/RNG/WHT
1775/RNG/WHT
1960/RNG/WHT
1785/RNG/WHT
1950/RNG/WHT
1590/RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION)
1530/RNG/WHT
FUSE 14 5 A
(SEE ADDITIONAL
OPTIONS DWG)
A MFR ACCESSORY
1750/RNG/WHT 1780/RNG/WHT
SP50
1850/RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1520/RNG/WHT
1805/RNG/WHT
B BU ALARM-MFR HARN
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 5 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
2
J7A
ENG ECU CTRLR
4
6
T32
ECU CASE GND
SHEET 9
C112 HYD OIL FILTER SWITCH
GROUND
2001/BLK
2002/BLK
SP53
2320/BRN
2370/BRN
SHEET 11
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220/BRN
SHEET 9
C108 HYD TEMP SENDER
2190/BRN
SHEET 9
C105 HYD CHG PRESSURE SENDER
2180/BRN
SHEET 8
C355 FUEL HARN (FUEL SENDER)
2150/BRN
SHEET 8
C405 AIR FILTER SWITCH
2690/BRN
SHEET 8
2810/BLK
2003/BLK
2004/BLK
J1B
GWY CTRLR
2230/BRN
17
SP12
C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C479 LH PANEL
SHEET 10
C499 PTOL
SHEET 10
C500 RH PANEL KEY SWITCH
2080/BLK
2070/BLK
2920/BLK
2940/BLK
T6
BATT GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SP4
2950/BLK
2960/BLK
16
J1B
GWY CTRLR 15
2250/BLK
SHEET 10
C503 RH DELUXE PANEL
2065/BLK
SHEET 10
SW12 DPF SWITCH
2930/BLK
SHEET 10
SW1 BRAKE SWITCH
2830/BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700/BLK
SHEET 10
SW9 TRAVEL CONTROL SWITCH
2785/BLK
SHEET 15
C126 HORN
2620/BLK
SHEET 13
T16 RH REAR LIGHT
2650/BLK
SHEET 12
T20 BU ALARM
2640/BLK
SHEET 13
C602 LH REAR LIGHT
2610/BLK
SHEET 13
C603 RH REAR LIGHT
2630/BLK
SHEET 13
T18 LH REAR LIGHT
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SP47
2900/BLK
16
J2B
AUX CTRLR
1
SHEET 9
C425 BRAKE
C103
TAILGATE HARN
C489
MFR ACCESSORY
B
634 of 1148
2500/BLK
2540/BLK
2550/BLK
B
2770/BLK
2200/BLK
2720/BLK
2600/BLK
FRC1 STARTER RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
2510/BLK
2900/BLK
2045/BLK
SHEET 13
FRC1 REAR LIGHT RELAY
2035/BLK
SHEET 9
FRC1 TRACTION LOCK RELAY
2115/BLK
SHEET 13
FRC1 FRONT LIGHT RELAY
2055/BLK
SHEET 5
FRC1 SWITCHED POWER RELAY
2030/BLK
SHEET 14
FRC1 HVAC RELAY
2005/BLK
SHEET 8
Printed In U.S.A.
15
SHEET 15
C355 FUEL HARN (PWR BOB/AC)
SP51 2600/BLK
2765/BLK
SHEET 13
C408 CAB-MFR CONN (FR LIGHTS)
2745/BLK
SHEET 14
C408 CAB-MFR CONN (HVAC)
2790/BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES)
2780/BLK
SHEET 15
C408 CAB-MFR CONN (OPTIONS)
2730/BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2950/BLK
10
Dealer Copy -- Not for Resale
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
2120/BLK
2455/BLK
SHEET 15
C423 BKT POSITION SOLENOID
2710/BLK
SHEET 7
C426 REMOTE RUN, ACD
2715/BLK
SHEET 7
C169 ENGINE CAN
2290/BLK
SHEET 14
D4 COMPRESSOR DIODE
SP55
2110/BLK
SP3
2090/BLK
SP28
2390/BLK
SP6
2300/BLK
SP27
2105/BLK
T1
BATT GND
SHEET 8
ALTERNATOR GROUND
T8
BATT GND
2015/BLK
T10
ENGINE
GROUND
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 6 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
CAN BUS
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
J7A
ECU CNTRLR
47
9200/PUR
9100/PUR/WHT
CAN LO
48
CAN HI
9215/PUR
9115/PUR/WHT
J1B
GWY CTRLR
SP90
9210/PUR
9110/PUR/WHT
SP91
RE018
120 OHM
0.5 W
RESISTOR
20
14
9205/PUR
9105/PUR/WHT
RE021
120 OHM
0.5W
RESISTOR
SHEET 5
SHEET 6
C169
ENGINE CAN
1725/RNG/WHT
2715/BLK
3
4
9155/PUR/WHT
9255/PUR
SP31
9230/PUR
9130/PUR/WHT
RE014
120 OHM
O.5W
RESISTOR
SP30
Dealer Copy -- Not for Resale
9260/PUR
9160/PUR/WHT
8
9
9220/PUR
9120/PUR/WHT
9280/PUR
9180/PUR/WHT
J2B
AUX CTRLR
CAN HI
CAN LO
5
6
C408
(BLACK)
CAB-MFR HARN CONN 1
J1B
GWY CTRLR
4
3
SP18
SP35 9450/PUR
9220/PUR
9460/PUR
9410/PUR SP39 9430/PUR
9310/PUR/WHT 9330/PUR/WHT
9350/PUR/WHT 9360/PUR/WHT
9120/PUR/WHT
SP17
SP38 SP34
RE019
120 OHM
0.5 W
RESISTOR
9440/PUR
9340/PUR/WHT
J2B
AUX CTRLR
8
9
SHEET 5
SHEET 6
9320/PUR/WHT
9420/PUR
C426
Remote Run Tool, ACD
14
9500/PUR/WHT
A
20
9600/PUR
B
1
2
9300/PUR/WHT
9400/PUR
SHEET 5
SHEET 6
4
3
C479
LEFT PANEL (BLACK)
4
2
C503
RIGHT DELUXE PANEL
1830/RNG/WHT
2070/BLK
1
2
3
4
1840/RNG/WHT
2080/BLK
1
2
3
4
*
C450
RIGHT JOYSTICK
*
C449
LEFT JOYSTICK
Printable Version Click Here
J1B
GWY CTRLR
21
3090/LBL
SHEET 5
SHEET 4
SHEET 6
Printed In U.S.A.
1735/RNG/WHT
1165/RED/WHT
2710/BLK
D
C
E
F
G
REMOTE RUN KEY
SWITCHED POWER
UNSWITCHED POWER
GROUND
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 7 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
635 of 1148
ENGINE
FRC1
STARTER RELAY - M
1030/RED
SHEET 4
2005/BLK
SHEET 6
7
8210/TAN
22
3560/LBL
J1A
GWY CTRLR
C111
HARN ENG START CONN
+12V
PWR 30
8200/TAN
87
GND
85
86
8210/TAN
STARTER
8220/TAN
3560/LBL
S
R
M
B
SHEET 4
1015/RED
C110
B
ALTERNATOR
G
S
L
SHEET 6
J1B
GWY CTRLR
B
A
GND
SIG
C355
FUEL HARN
3180/LBL
2180/BRN
12
10
3690/LBL
4
8007/TAN
SHEET 6
C406
A
B
3180/LBL
2180/BRN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 11
J7A
ENG ECU CTRLR
C
D
2015/BLK
SHEET 6
ENGINE GROUND TERMINAL
AIR FILTER
SWITCH (NC)
Dealer Copy -- Not for Resale
2150/BRN
3150/LBL
1020/RED
1800/RNG/WHT
EXCITATION
C405
16
19
SHEET 5
FUSE 12
3560/LBL
1800/RNG/WHT
A
B
C
SIG
GND
FUEL SENDER
(30 - 270 OHM)
C114
HAND THROTTLE
5690/YEL
7
5690/YEL
3690/LBL
6
3690/LBL
2690/BRN
8
2690/BRN
C
A
B
SHEET 6
+5V PWR
SIG
GND
D
E
F
8007/TAN
C100
9
34
1
2
3865/LBL
2865/BRN
SIG
GND
WATER IN FUEL SENDER
(FUEL FILTER)
Printable Version Click Here
C118
ENG-CROSSOVER
MAF FREQ
MAF TEMP
SHEET 5
28
8013/TAN
35
8014/TAN
+12V
PWR
SHEET 4
56
Printed In U.S.A.
636 of 1148
1065/RED/WHT
8510/TAN
30
85
1511/RNG/WHT
1
8013/TAN
2
8014/TAN
3
3420/LBL
87
86
PREHEATER
RELAY - C
8525/TAN
8500/TAN
SP93
1445/RED/WHT
SHEET 4
4
PRE-HEATER
To C154 - PIN 1, &
To C114, Pin 3, Sheet 16 of 16
MAF Sensor - PIN 1, Sheet 16 of 16
MAF Sensor - PIN 4, Sheet 16 of 16
TO GLOW PLUG, J7B - PIN 79,
Sheet 16 of 16
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 8 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
1360/RED/WHT
SHEET 4
2035/BLK
SHEET 6
HYDRAULICS
FRC1
TRACTION LOCK
+12V RELAY - D
PWR 30
87
GND
85
C425
4100/LGN
SHEET 6
86
4200/LGN
2200/BLK
B
A
C
C308
4200/LGN
2200/BLK
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061
4110/LGN
13
3430/LBL
SHEET 6
32
C108
2220/BRN
3220/LBL
B
A
GND
SIG
C112
J1A
GWY CTRLR
34
SHEET 6
3320/LBL
2320/BRN
A
B
SIG
GND
C446
18
2910/BRN
4010/LGN
1
2410/BRN
4410/LGN
2
1
GND
SIG
C420
B
A
GND
SIG
C105
SHEET 6
2190/BRN
3190/LBL
5190/YEL
B
C
A
GND
SIG
+8V PWR
4200/LGN
19 13
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
(8 VOLT)
HYDRAULIC OIL
FILTER SWITCH (NC)
Dealer Copy -- Not for Resale
8
HYDRAULIC
FAN SOLENOID
7.2 OHM 12 V
HYDRAULIC LOCK
SOLENOID
9.8 OHM 12 V
HYDRAULIC CHARGE
PRESSURE SENSOR
0.5-7.5V
1 23 6
+8V
J1B
GWY CTRLR
Printable Version Click Here
C418
J2A
AUX CTRLR
18
2330/BRN
4330/LGN
1
2340/BRN
4340/LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
3.3 OHM PWM
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
C419
19 13
Printed In U.S.A.
637 of 1148
J2B
AUX CTRLR
2
1
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 9 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
1940/RNG/WHT
CAB DISPLAY
LEFT PANEL
BUZZER
7040/WHT
SHEET 6
1960/RNG/WHT
SHEET 5
SHEET 6
SHEET 4
SW9
TRAVEL CONTROL
SWITCH (OPTIONAL)
2700/BLK
SHEET 5
SHEET 15
5 6
4
2 3
1
SHEET 5
SHEET 6
SHEET 15
3610/LBL
1775/RNG/WHT
2930/BLK
3
1
4
7040/WHT
10
2920/BLK
2
1440/RED/WHT
1
1620/RNG/WHT
5
3400/LBL
11
3500/LBL
8
3650/LBL
7
3600/LBL
9
6
SW1
BRAKE
SWITCH
2
3620/LBL
3610/LBL
SW12
DIESEL PARTICULATE
FILTER SWITCH
SHEET 5
SHEET 6
1700/RNG/WHT
7 9
1705/RNG/WHT 10
2065/BLK
2
8050/TAN
8
8055/TAN
5
3
8060/TAN
1
1
4
8070/TAN
9
NOT USED
Printed In U.S.A.
UNSWITCHED POWER
SWITCHED POWER
1
3
20
3030/LBL
1
3030/LBL
2
19
2380/BRN
12
2380/BRN
4
24
TRAVEL CONTROL INPUT
PARK BRAKE INPUT
DOOR SIGNAL
PARK BRAKE OUTPUT
8130/TAN
DPF OVERRIDE
DPF INHIBIT REGEN
PTOL OUTPUT
PTOL LED
2
8130/TAN
2
START
6
J1B
GWY CTRLR
22
3040/LBL
14
3040/LBL
SHEET 5
SHEET 4
SHEET 6
1950/RNG/WHT
1420/RED/WHT
2960/BLK
4
5
1
3
RUN/ENTER SWITCH
SWITCHED POWER
UNSWITCHED POWER
GROUND
C503
RIGHT PANEL DELUXE DISPLAY
DPF LAMP
DPF INHIBIT LAMP
SWITCHED POWER
GROUND
C500
RIGHT PANEL - KEY SWITCH
RIGHT BLINKER INPUT
Printable Version Click Here
SHEET 5
SHEET 4
WIRING SCHEMATIC SHEET 6
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 10 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
638 of 1148
1930/RNG/WHT
2940/BLK
J1A
GWY CTRLR
LEFT BLINKER INPUT
C480
LEFT PANEL (GRAY)
12
11
10
3
2
8
7
6
4
C408
(BLACK)
CAB-MFR HARN CONN 1
GROUND
5
6
SHEET 5
SHEET 6
BUZZER
12
SHEET 11
SHEET 5
C499
Press To Operate Loader
(PTOL)
C479
LEFT PANEL (BLACK)
T2
BUZZER (-)
Dealer Copy -- Not for Resale
SHEET 5
T13
BUZZER (+)
1590/RNG/WHT
5
1240/RED/WHT
1
2250/BLK
3
6
SWITCHED POWER
UNSWITCHED POWER
GROUND
*
SHEET 5
C438
SHEET 11
(DK GRAY)
CAB-MFR HARN CONN 3
1850/RNG/WHT
SHEET 5
7
4235/LGN
8
4275/LGN
9
4550/LGN
2
1850/RNG/WHT
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785/RNG/WHT
2 1
3
6
2060/BLK
5
4
CAB
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
*
C212
POWER
SOCKET
2795/BLK
1375/RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1370/RED/WHT
SHEET 4
7
*
SP45
1370/RED/WHT
1390/RED/WHT
C129
CAB ACCESSORY
5
1210/RED/WHT
1865/RNG/WHT
2800/BLK
A
B
C
1510/RNG/WHT
1885/RNG/WHT
SP44
2730/BLK
SHEET 6
11
2730/BLK
GND
2790/BLK
14
2210/BLK
SHEET 15
2885/BLK
2060/BLK
SHEET 15
SHEET 11
2790/BLK
C482
SHEET 6
11
+5V
24
5100/YEL
SHEET 8
4
2370/BRN
A
GND
3370/LBL
5
3370/LBL
B
SIG
3
5370/YEL
C
+5V PWR
SP13 5370/YEL
2845/BLK
639 of 1148
T38
DOME LIGHT (-)
*
3620/LBL
1400/RED/WHT
1
4
5
6
2840/BLK
2
7310/WHT
3
WIPER SWITCH, MOTOR SWITCHED POWER
DOOR SIGNAL
DOOR UNSW PWR
WIPER MOTOR GROUND
WASHER SIGNAL
Printable Version Click Here
HARNESS WASHER PUMP
7253378
Printed In U.S.A.
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
5690/YEL
*
DOME
LIGHT
1850/RNG/WHT
SEATBAR
SENSOR
2370/BRN
T37
DOME LIGHT (+)
SHEET 15
SHEET 15
SHEET 10
SHEET 4
J1B
GWY CTRLR
GND
+12V PWR
2010/BLK
+12V BATT PWR
+12V SW PWR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 6
Dealer Copy -- Not for Resale
1580/RNG/WHT
SHEET 5
1580/RNG/WHT SP8
SP41
1
2
C253
C252
A
7310/WHT
1
B
2845/BLK
2
PWR
GND
WASHER
MOTOR
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 11 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
MANUAL
CONTROLS
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS Sheet)
A
C103
TAILGATE HARN
C
7100/WHT
SHEET 6
J2A
AUX CTRLR
30
31
T19 TERMINAL (+)
7100/WHT
BACK UP
ALARM
2650/BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
SHEET 5
13
C421
J1A
GWY CTRLR
2980/BRN
4980/LGN
10
3
1
2
GND
SIG
TILT SPOOL LOCK
17.8 OHM 12V
C422
2990/BRN
4990/LGN
2
3
1
2
GND
SIG
LIFT SPOOL LOCK
17.8 OHM 12V
Dealer Copy -- Not for Resale
T20 TERMINAL (-)
1530/RNG/WHT
4940/LGN
4930/LGN
4920/LGN
4910/LGN
4310/LGN
4320/LGN
4300/LGN
21 17 18 23
J2B
AUX CTRLR
20
28
22
12
11
SHEET 5
7
5
J1B
GWY CTRLR
Printed In U.S.A.
640 of 1148
K
D
C
B
G
F
A
J
H
E
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 12 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
SKI CTRL
DETENT FLOW
TWO SPD
PWM
C410
LEFT HANDLE
(MANUAL/ACS ONLY)
4640/LGN
4840/LGN
4830/LGN
4820/LGN
4810/LGN
1520/RNG/WHT
Printable Version Click Here
K
G
A
H
J
E
F
C
D
B
SKI CTRL
SIDE SHIFT
LIGHTS
C434-1
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 6
30
2120/BLK
85
87
6620/PNK
5
31
J1A
17
GWY CTRLR
28
2115/BLK
30
GND 85
87
6340/PNK
6310/PNK
6320/PNK
3460/LBL
6210/PNK
3440/LBL
FRC1
REAR LIGHT
RELAY - E
SHEET 4
SHEET 6
1320/RED/WHT
2045/BLK
87
GND 85
86
SP14
2750/BLK
6110/PNK
8
6000/PNK
SP15
6120/PNK
2760/BLK
LEFT FRONT
WORK LIGHT
37.00 Watts
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
50.00 Watts
C435-1
A
B
C435-2
6130/PNK
2705/BLK
A
B
6610/PNK SP64
C103
TAILGATE HARN
86
+12V
PWR 30
GND
SIG
6000/PNK
SHEET 6
1330/RED/WHT
2765/BLK
13
6630/PNK
SHEET 4
9
C438
(DK GRAY)
CAB-MFR HARN CONN 3
86
RC1
FRONT WORK
LIGHTS RELAY 2
+12V
PWR
6610/PNK
Dealer Copy -- Not for Resale
SHEET 6
1350/RED/WHT
B
A
C434-2
2765/BLK
RC1
FRONT WORK
LIGHTS RELAY 1
SHEET 4
2735/BLK
6100/PNK
A
6310/PNK
C603
2610/BLK
6320/PNK
SHEET 6
2
1
GND
SIG
SP49
RIGHT REAR
TAIL LIGHT
C602
6330/PNK
2640/BLK
SHEET 6
2620/BLK
SHEET 6
6210/PNK
1
2
SIG
GND
T16 TERMINAL (-)
GND
SIG
LEFT REAR
TAIL LIGHT
RIGHT REAR
WORK LIGHT
T15 TERMINAL (+)
6200/PNK
H
6200/PNK
SHEET 6
SP5
6200/PNK
2630/BLK
T17 TERMINAL (+)
SIG
GND
LEFT REAR
WORK LIGHT
T18 TERMINAL (-)
Printable Version Click Here
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 13 of 16
Printed In U.S.A.
641 of 1148
(PRINTED NOVEMBER 2016)
7279776 (A)
HVAC
2440/BLK
7440/WHT
*
2560/BLK
7420/WHT
7425/WHT
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
*
*
C610
2
1
C
A
B
SHEET 6
3
30
+12V
PWR 30
2030/BLK
AC EVAPORATOR
SWITCH
GND 85
86
3050/LBL
SHEET 6
2745/BLK
SP40
7021/WHT
7020/WHT
11
12
C350
B
A
C486
7025/WHT
SHEET 6
Printed In U.S.A.
SWITCH
7410/WHT
2290/BLK
2280/BLK
D4
1
2
OFF
5 2
1
4
6
3
7530/WHT
7520/WHT
7510/WHT
2580/BLK
*
SW11
AC SWITCH
2745/BLK
SP16
3
2100/BLK
7015/WHT
C
1
*
2570/BLK
7020/WHT
7023/WHT
7024/WHT
HEATER
VALVE
SW10
*BLOWER
10 1500/RNG/WHT
7050/WHT
J1A
GWY CTRLR
11
1500/RNG/WHT
87
POTENTIOMETER
(TEMP CONTROL
SWITCH)
D
SIG
C
GND
A +12V PWR
B
E
F
C438
(DK GRAY)
CAB-MFR HARN CONN 3
Dealer Copy -- Not for Resale
1140/RED/WHT
BLK
DBL
WHT
C635
SP48
FRC1
HVAC RELAY - B
HVAC DUCT
FAN
C483
2130/BLK
7430/WHT
SHEET 4
GND
SIG
C630
3
2
1
*
C611
1
2
3
4
14.00 Amps
7.50 Amps
5.00 Amps
7400/WHT
THERMOSTAT
Printable Version Click Here
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 14 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
642 of 1148
High
Med
Low
BLOWER
MOTOR
#
POWER BOB
CLOSE
SIG
GND
#
POWER BOB
OPEN
GND
SIG
C607
1
2
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C355
FUEL HARN
4470/LGN
2470/BLK
E
B
2770/BLK
#
11
4470/LGN
2770/BLK
4470/LGN
4480/LGN
SHEET 6
*
SW5
POWER
BOBTACH
SWITCH
C606
2
1
2480/BLK
4480/LGN
F
4480/LGN
13
1550/RNG/WHT
12
6010/PNK
1550/RNG/WHT
LEFT
1
6515/PNK
6500/PNK
6
6500/PNK
6415/PNK
6400/PNK
3
6400/PNK
6410/PNK
6510/PNK
2780/BLK
SHEET 6
C423
BUCKET
POSITION
SOLENOID
6.13 OHM
SIG
A
4450/LGN
GND
B
2450/BLK
D3
4455/LGN
2455/BLK
B
A
4
5
2780/BLK
4455/LGN
SHEET 6
SHEET 6
7210/WHT
1460/RED/WHT
13
2785/BLK
7210/WHT
L
D1
D2
3400/LBL
SHEET 10
6430/PNK
SW3
*HAZARD
SWITCH
(PINS 3 & 6
INTERNALLY
INSULATED)
2
5
6
GND
SIG
HORN
LEFT
SPEAKER
SHEET 4
C415
J2B
AUX CTRLR
26
J1A
GWY CTRLR
26
J1B
GWY CTRLR
26
B
A
GND
SIG
Printed In U.S.A.
643 of 1148
2
1
GND
SIG
TWO SPEED
SOLENOID
5.1 OHM 12 V
2850/BLK
6
*
C670
2420/BLK
*
1
2
-
*
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
C676
RADIO CONN
C279
+
E
D
F
B
C
A
7820/WHT
7830/WHT
3
4
*
C277
C278
-
2
1
7810/WHT
7800/WHT
1885/RNG/WHT
2885/BLK
6
5
1
2
SHEET 11
SHEET 11
1510/RNG/WHT
2210/BLK
1
2
3
4
5
6
AIR RIDE
SEAT
PWR
GND
Printable Version Click Here
HIGH FLOW
SOLENOID
7.5 OHM 12 V
C441
2350/BRN
4350/LGN
6700/PNK
POSITION
SWITCH
SHEET 11
SHEET 11
2460/BRN
4460/LGN
5
1
3
4
SW6
*BUCKET
+
26
2
SWITCH
6
5
4
1
2
3
2725/BLK
6440/PNK
6540/PNK
C126
B
A
T3
FLASHER
CONN
SW2
*BEACON
2780/BLK
3
1
4
*
6530/PNK
RIGHT
SPEAKER
J2A
AUX CTRLR
X
1430/RED/WHT
2830/BLK
C408
(BLACK)
CAB-MFR HARN CONN 1 SHEET 6
C412
LEFT HANDLE
HORN SIGNAL
(HORN) 2 WAY
PWR
(SEE ADDITIONAL
OPTIONS DWG)
1200/RED/WHT
SHEET 10 3500/LBL
E
D
* DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN 7227905)
1410/RED/WHT
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
3
4
6
6570/PNK
RIGHT
(SEE ADDITIONAL
OPTIONS DWG)
1410/RED/WHT
SHEET 4
Dealer Copy -- Not for Resale
LEFT HANDLE
(FLASHER) 5 WAY
B
C
A
E
D
5
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219 )
1380/RED/WHT
6010/PNK
C438
(DK GRAY)
CAB-MFR HARN CONN 3
C411
1
10
SHEET 5
FLASHER PWR
2
OPTIONS
TRACK 2 SPEED
ADAPTER
(SEE ADDITIONAL
OPTIONS DWG)
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 15 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR COLOR CODE
RED
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BLK
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
TAN
TAN
ENGINE
8000 THROUGH 8999
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
EGR VALVE
DC MOTOR
5
3
EGR VREF3
POSITION SIGNAL
POSITION RETURN
TEMP SENSOR 2
2
123
SENSOR RETURN 2
1
TO C118 PIN 3
See Sheet 7 of 16
3
172
137
5V
2
192
H BRIDGE NEG
193
TO C118 PIN 2
See Sheet 7 of 16
COOLANT RETURN
109
145
C148
FUEL TEMP
SENSOR
1
2
ENGINE BLOCK
ACCELEROMETER 1
FUEL RETURN
148
SENSOR SIGNAL
131
1
SENSOR RETURN
SHIELD
130
128
CRANKSHAFT
POSITION
SENSOR
2
1
4
146
SENSOR SIGNAL
SENSOR RETURN
SHIELD
C145
RETURN GND
OIL TEMPERATURE SENSOR
169
RETURN
1
SENSOR
2
132
1
CRANK SENSOR POS
160
2
CRANK SENSOR NEG
136
SENSOR RETURN
147
POS SENSOR
159
3
2
1
C143
RAIL
PRESSURE
SENSOR
CYL 3
CYL 4
1
VREF1 CAM
TO C118 - PIN 1,
See Sheet 8 of 16
RAIL PRESSURE SENSOR
VREF INTAKE PRESS SENSOR
112
187
INTAKE PRESS SENSOR
INTAKE PRESS RETURN
644 of 1148
2
C133
INTAKE
MANIFOLD
TEMPERATURE
C138
B
1
A
3
2
D
INTAKE
PRESSURE
SENSOR
135
2
SENSOR RETURN
119
3
VREF1 SENSOR
138
FUEL INJECTOR HSDB
151
FUEL INJECTOR LSD1B
175
FUEL INJECTOR HSDA
103
FUEL INJECTOR LSD2A
125
Printable Version Click Here
C139
127
FUEL INJECTOR HSDA
1
126
FUEL INJECTOR LSD1A
2
150
FUEL INJECTOR HSDB
2
174
FUEL INJECTOR LSD2B
1
CYL 1
C140
CYL 2
C154
177
PWM
TO C118 - PIN 1
SEE Sheet 7 of 16
Printed In U.S.A.
OIL PRESSURE &
TEMPERATURE
SENSOR
133
129
C144
CAM SHAFT
SENSOR
1
104
194
C146
ENGINE BLOCK
ACCELEROMETER 2
3
OIL PRESSURE SENSOR
111
2
C136
VREF3 OIL PRESSURE
110
MAF
SENSOR
1
165
FUEL TEMP SENSOR
C147
FREQ
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
4
SENSOR GROUND
2
COOLANT TEMP SENSOR
TEMP
116
120
H BRIDGE POS
1
C131
106
164
6
2
SHEET #
J7B
ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C149
COOLANT TEMP
SENSOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
ENGINE
HARNESS
179
C151
1
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
Dealer Copy -- Not for Resale
PRE HEATER
TO C118 - PIN 4
See Sheet 7 of 16
SCHEMATIC INDEX
2
1
INLET METERING
VALVE
WIRING SCHEMATIC
(MANUAL MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 16 of 16
(PRINTED NOVEMBER 2016)
7279776 (A)
Index Diagram
1
SH01 - INDEX
2
SH02 - UNSWITCHED BATT POWER
3
SH03 - SWITCHED POWER
4
SH04 - GROUND
5
SH05 - CAN BUS
6
SH06 - ENGINE
7
SH07 - ENGINE CONTROL UNIT
8
SH08 - HYDRAULICS
9
SH09 - CAB DISPLAY
10
SH10 - CAB
11
SH11 - MANUAL CONTROLS
12
SH12 - LIGHTS
13
SH13 - HVAC
14
SH14 - OPTIONS 1
15
SH15 - OPTIONS 2
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
HARNESS PART NUMBER
B1
645 of 1148
REV
GROUP NUMBER RANGE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
COLOR CODE
WIRE COLOR
MF MFR MAN
7300817
HYDRAULIC
EXMF MFR MAN
7300650
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
DLX CAB
7301237
7303755
6000 THROUGH 6999
PINK
STD CAB
LIGHTS
PNK
STD FUEL
7149219
7000 THROUGH 7999
WHITE
WHT
DLX FUEL
7266824
ENGINE
8000 THROUGH 8999
TAN
TAN
OTHER FUNCTIONS
7220812
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
7267103
TAILGATE EUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
7217483
PUR/WHT
SUSP JSTK
7163706
WHL 2 SPD ADP
7159366
TRK 2 SPD
7243409
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
MOVED
"GND"
TEXT
FROM A5 TO A2
Click
Here
For
Interactive
PDF
9205 SWAPPED SIZE AND MATERIAL VALUES
DESCRIPTION
104399
AEW
3
104399
AEW
5
CHG NOTICE DWN
SHEET
Dealer Copy -- Not for Resale
BCT ENG
TAILGATE DOM
Wiring Schematic
Standard Machine
B2
GROUP DESCRIPTION
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
LEGEND
CONNECTOR
1
1
PARTIAL CONNECTOR
1
1
1
1
WIRE BREAK
SHT1/F2
SHT1/F2
ECN
WIRE BREAK
WIRE BREAK
SHT1/F2
SHT1/F2
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 1 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 1 / 15
7300816
UNSWITCHED
BATT POWER
1240 RED/WHT
C408
MFR HARN CONN 1 (BLACK)
1450 RED/WHT
6
6
1450 RED/WHT
1400 RED/WHT
1440 RED/WHT
1110 RED/WHT
FUSE 11 25 A
1070 RED
11A
11B
SP2
FUSE 13 25 A
1025 RED
13B
13A
1130 RED/WHT
1120 RED/WHT
1160 RED/WHT
SHT10/D3
SP7
1420 RED/WHT
FUSE RELAY CENTER
SHT9/E4
SHT9/E4
SHT9/G8
2
GATEWAY CTRLR
3
J1B
SP36
1150 RED/WHT
1180 RED/WHT
3
AUX CTRLR
2
J2B
+12V BATTERY
MEGAFUSE
1
HW11
100.0 Amps
T5
1
T4
1310 RED
1140 RED/WHT
4B
Dealer Copy -- Not for Resale
1010 RED
SHT6/G1
BUS BAR
FUSE 4 25 A
4A
SHT13/E8
FUSE 3 30 A
3A
1360 RED/WHT
3B
SHT8/H8
BUS BAR
FUSE 1 15 A
1340 RED
1A
1320 RED/WHT
1B
SHT12/B8
FUSE 2 20 A
2A
SP26
1330 RED/WHT
2B
SHT12/D8
1350 RED/WHT
SHT12/F8
FUSE 9 50 A
1325 RED
1055 RED
1060 RED
9A
1065 RED/WHT
9B
SHT6/D3
FUSE 20 5 A
1335 RED
20A
1345 RED/WHT
20B
SHT3/G8
FUSE 16 25 A
SP1
1300 RED
1035 RED/WHT
16B
16A
SHT3/H8
1445 RED/WHT
SHT6/D3
FUSE 18 25 A
1190 RED
18A
1165 RED/WHT
18B
SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
1040 RED
22A
22B
1490 RED/WHT
1410 RED/WHT
SHT14/F7
SP24
FUSE 24 25 A
SP60
1290 RED
24A
FRC1
24B
1370 RED/WHT
SHT10/F8
FRC1
1050 RED
SHT3/D8
1030 RED
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
646 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
SHT6/G8
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 2 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 2 / 15
7300816
FRC1 ENGINE
ECU RELAY - G
1506 RNG/WHT
SHT2/D1
1035 RED/WHT
+12V PWR
G1
G2
30
86
87
G4
85
SP54
1540 RNG/WHT
1507 RNG/WHT
1508 RNG/WHT
G5
3
5
ENG ECU CTRLR
45
ENG ECU SW SIG
SWITCHED
POWER
FRC1
FRC1
8005 TAN
SHT2/D1
1
1345 RED/WHT
J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT
1511 RNG/WHT
21B
21A
1720 RNG/WHT
B
C404
BU ALARM-MFR HARN
B
(SEE ADDITIONAL
OPTION DWG)
A
A
BUS BAR
FUSE 5 25 A
1760 RNG/WHT
1780 RNG/WHT
1750 RNG/WHT
5B
5A
SP50
SHT6/C7
C489
MFR ACCESSORY
FUSE 6 25 A
1850 RNG/WHT
6B
6A
SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
1790 RNG/WHT
1550 RNG/WHT
12B
12A
SHT14/G7
1700 RNG/WHT
1805 RNG/WHT
14A
FRC1
SWITCHED
POWER
RELAY - A
1050 RED
+12V PWR
A1
30
87
B2
A5
86
1765 RNG/WHT
A4
85
A2
FRC1
SP25
1795 RNG/WHT
GND
7A
BUS BAR
SHT2/B1
FRC1
Dealer Copy -- Not for Resale
1520 RNG/WHT
SHT11/D2
1530 RNG/WHT
SHT11/G2
1705 RNG/WHT
1620 RNG/WHT
1940 RNG/WHT
1930 RNG/WHT
FUSE 14 5 A
1560 RNG/WHT
1570 RNG/WHT
14B
SP11
22 AUX CTRLR
1960 RNG/WHT
J2B
C428
MFR HARN CONN 2
(LT GRAY)
1660 RNG/WHT
2
2
1775 RNG/WHT
1785 RNG/WHT
1950 RNG/WHT
SP42
1660 RNG/WHT
1590 RNG/WHT
1555 RNG/WHT
FUSE 7 25 A
SP65
1730 RNG/WHT
7B
1735 RNG/WHT
SHT9/C8
SHT9/B8
SHT9/G8
SHT9/H8
SHT9/H4
SHT9/D8
SHT9/F8
SHT10/H8
SHT9/F4
SHT9/E4
SHT15/F4
SHT5/B8
1725 RNG/WHT
SHT5/C2
FUSE 8 25 A
8A
8B
1580 RNG/WHT
23B
1800 RNG/WHT
SHT10/F8
FUSE 23 15 A
1815 RNG/WHT
23A
SHT6/G8
FRC1
FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
21
SWITCHED POWER RELAY FEEDBACK
4
SWITCHED POWER RELAY SIGNAL
J1A
C428
MFR HARN CONN 2 (LT GRAY)
1920 RNG/WHT
9
9
1920 RNG/WHT
SP37
1840 RNG/WHT
SHT5/E3
1830 RNG/WHT
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
647 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
SHT5/F3
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 3 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 3 / 15
7300816
GROUND
ENG ECU CTRLR
2
4
6
J7A
T32
ECU CASE GND
1
SHT15/G5
2001 BLK
2002 BLK
SP53
2810 BLK
2320 BRN
SHT8/F7
2003 BLK
2004 BLK
SHT8/D7
SHT9/G8
SHT9/G4
SHT9/E4
SHT9/D4
2920 BLK
1
C408
MFR HARN CONN 1 (BLACK)
SP4
2940 BLK
2950 BLK
T6
BATT GND
2950 BLK
10 10
2960 BLK
2250 BLK
2510 BLK
16
SP3
2110 BLK
2500 BLK
J1B
2765 BLK
SHT12/H8
2745 BLK
SHT13/D7
SHT9/E8
SHT14/D5
SHT9/F8
SHT14/B7
16
2860 BLK
AUX CTRLR
2890 BLK
2065 BLK
C428
MFR HARN CONN 2 (LT GRAY)
2930 BLK
2900 BLK
2830 BLK
2700 BLK
2550 BLK
15
1
SP47
SP28
J2B
2900 BLK
1
2785 BLK
2770 BLK
SHT14/H6
2200 BLK
SHT8/H4
SHT12/C4
SHT11/F8
SHT12/C4
C489
MFR ACCESSORY B
2620 BLK
2650 BLK
B
2720 BLK
C103
TAILGATE HARN
2600 BLK
2640 BLK
B
2600 BLK
B
SP51
SHT12/E4
SHT12/B4
2730 BLK
SHT10/E8
T1
2390 BLK
BATT GND
1
2610 BLK
2630 BLK
SHT14/D6
SHT5/B8
SHT5/C2
2455 BLK
2710 BLK
SP27
AUX CTRLR
2300 BLK
2185 BRN
SHT15/E7
2715 BLK
2195 BRN
SHT11/G2
SHT15/G4
SHT12/B8
SHT8/G8
SHT12/D8
SHT3/C1
SHT13/F8
SHT6/G7
SHT12/E8
2505 BLK
SHT13/B8
648 of 1148
REV
DESCRIPTION
2995 BRN
2290 BLK
17
SENSOR GND
J2B
2035 BLK
2115 BLK
SP55
2105 BLK
2055 BLK
2030 BLK
2005 BLK
2120 BLK
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
SEE SHEET 1
SP58
2045 BLK
Wiring Schematic
Standard Machine
B
T10
ENGINE GROUND
1
2015 BLK
SHT6/F3
SP6
T8
BATT GND
2780 BLK
SHT14/E7
2090 BLK
1
2790 BLK
SHT10/D8
2540 BLK
Dealer Copy -- Not for Resale
SHT9/C8
J1B
2180 BRN
2070 BLK
15
SHT15/H5
SENSOR GROUND
2080 BLK
GATEWAY CTRLR
SHT15/D4
17
2150 BRN
SHT6/F7
SHT5/E3
2230 BRN
2190 BRN
SHT6/E7
SHT5/E3
SP12
2220 BRN
SHT8/F7
2155 BLK
GATEWAY CTRLR
2370 BRN
SHT10/D8
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
(B)
Printable Version ClickSCHEM
Here ELEC7300816
MAN
Sheet 4 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 4 / 15
7300816
CAN BUS
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
*
RE016
120 OHM 0.5 W RESISTOR
R3-1
GATEWAY CTRLR
CAN LO
8
CAN HI
9
TP-09
TP-09 9260 PUR
TP-10
9230 PUR
9130 PUR/WHT
9160 PUR/WHT
TP-10
SP31
TP-16
TP-16
9220 PUR
SP30
R3-2
J1B
RE019
120 OHM 0.5 W RESISTOR
C408
MFR HARN CONN 1 (BLACK)
9120 PUR/WHT
4
4
3
3
TP-01
SP18
9220 PUR
TP-01
TP-03
SP17
9120 PUR/WHT
TP-11
9410 PUR
TP-03
SP39
TP-05
SP38
9310 PUR/WHT
9430 PUR
SP35 TP-07
TP-05
SP34
9330 PUR/WHT
TP-08 9460 PUR
TP-08
9360 PUR/WHT
9350 PUR/WHT
4
CAN LO
3
CAN HI
R2
TP-06
TP-04
TP-02
R1
TP-07
9450 PUR
C479
LEFT PANEL
(BLACK)
C479
C503
RH DLX PANEL
AUX CTRLR
TP-06
9440 PUR
TP-11
9280 PUR
8
CAN LO
9
CAN HI
9340 PUR/WHT
9180 PUR/WHT
J2B
*
SHT3/B1
CAN HI
CAN LO
1830 RNG/WHT
2070 BLK
9320 PUR/WHT
TP-04
9420 PUR
1
1
2
2
3
3
4
4
14
TP-12
9500 PUR/WHT
9600 PUR
20
24
A
B
2070 BLK
9560 PUR/WHT
9660 PUR
*
SHT3/B1
2080 BLK
SHT4/G8
9300 PUR/WHT TP-02
9400 PUR
1
1
2
2
3
3
4
4
A
R18
120 OHM 0.5W RESISTOR
R1-1
CAN HI
ENG ECU CTRLR
B
1
1
2
2
3
3
4
4
GND
CAN HI
CAN LO
C459
LEFT JOYSTICK
1840 RNG/WHT
2080 BLK
9540 PUR/WHT
9640 PUR
1
1
2
2
3
3
4
4
CAN LO
TP-17
ENG CAN LO
47
ENG CAN HI
48
9200 PUR
TP-17
TP-18
R21
120 OHM 0.5W RESISTOR
SP90
9215 PUR
3095 LBL
9100 PUR/WHT
9115 PUR/WHT
R1-2
TP-20
TP-18
SP91
R2-1
9210 PUR TP-20
GND
CAN HI
CAN LO
J7A
9105 PUR/WHT
21
3090 LBL
SHT3/D1
3085 LBL
D
SP93
D
ENG CAN LO
14
ENG CAN HI
J1B
1725 RNG/WHT
1
REMOTE RUN KEY
SHT4/C6
1735 RNG/WHT
2715 BLK
2
E
E
SWITCHED POWER
F
F
UNSWITCHED POWER
G
G
GROUND
9255 PUR
1165 RED/WHT
SHT2/C1
2710 BLK
SHT4/C6
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
Wiring Schematic
Standard Machine
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
3
ENG CAN HI
4
ENG CAN LO
C169
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
COPYRIGHT
DESCRIPTION
20
C169
ENGINE CAN
SHT3/D1
REV
GATEWAY CTRLR
B1
R2-2
9155 PUR/WHT TP-19
649 of 1148
LEFT JOYSTICK
+12V PWR
TP-21 9205 PUR TP-21
9110 PUR/WHT
TP-19
J1B
SEE SHEET 1
RIGHT JOYSTICK
+12V PWR
GATEWAY CTRLR
B
CAN HI
SUSP SEAT JOYSTICK HARNESS
J2A
REMOTE RUN
2
C460
RIGHT JOYSTICK
1830 RNG/WHT
C449
LEFT JOYSTICK CONN
1840 RNG/WHT
C426
Remote Run Tool, ACD
J2B
REMOTE RUN
Dealer Copy -- Not for Resale
SHT4/G8
TP-12
CAN LO
C503
C450
RIGHT JOYSTICK CONN
AUX CTRLR
4
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 5 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 5 / 15
7300816
ENGINE
1030 RED
SHT2/B1
M1
8210 TAN
M5
30
87
85
86
FRC1
C111
MFR-BCT HARN CONN
8200 TAN
M4
M2
A
A
B
B
C
C
R
S
T9
1
B
8220 TAN
3560 LBL
SHT2/E7
1800 RNG/WHT
1015 RED
2005 BLK
SHT4/B8
1
1
T21
FRC1
1800 RNG/WHT
SHT3/C1
STARTER
T7
FRC1 STARTER
RELAY - M
GATEWAY CTRLR
7
STARTER RELAY FEEDBACK
22
3560 LBL
2150 BRN
SHT4/G3
AIR FILTER SIGNAL
3150 LBL
16
A
GND
C110
AIR FILTER
SWITCH (NC)
1020 RED
SIG
C355
FUEL HARN
3180 LBL
12
SHT4/G3
2180 BRN
C
D
C
D
T11
3180 LBL
2180 BRN
A
FUEL SENDER
(30 - 270 OHM)
B
SHT10/C7
1
3690 LBL
6
6
SHT10/D5
4
IGN SW ON
8007 TAN
J1B
ENG ECU CTRLR
IGN SW ON
WATER IN FUEL RETURN
C100
19
2865 BRN
34
WIF SENSOR
9
PRE HEATER RELAY DRIVER
56
GND
HAND THROTTLE
3865 LBL
SIG
A
GND
B
2690 BRN
C114
FRC1
PREHEATER
RELAY - C
1065 RED/WHT
SHT2/D1
SHT2/C1
C1
1445 RED/WHT
C5
FRC1
C4
8525 TAN
SP77
8500 TAN
1
T14
C2
FRC1
1
C118
AIR INLET TEMP
C
SIG
8510 TAN
1511 RNG/WHT
SHT3/G1
MAFS FREQ SIGNAL
+5V PWR
3690 LBL
C100
WATER IN FUEL SENSOR
(FUEL FILTER)
2
T12
F
E
D
5690 YEL
C428
MFR HARN CONN 2 (LT GRAY)
10
1
2015 BLK
SHT4/E3
C406
THROTTLE PRIMARY SIGNAL
ALTERNATOR
S
L
C405
J1A
FUEL SIGNAL
B
Dealer Copy -- Not for Resale
STARTER RELAY SIGNAL
8013 TAN
28
8014 TAN
35
J7A
KL87
SHT7/B6
1
1
SHT7/C6
2
2
SHT7/G3
3
3
SHT7/F3
4
4
SHT7/H7
ENG-CROSSOVER
3420 LBL
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
650 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click SCHEM
Here ELEC MAN
Sheet 6 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 6 / 15
7300816
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK
79
GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EGR VALVE DC MOTOR
1
5
3
4
64
16
72
OPEN
EXHAUST GAS TEMP SENSOR 2 RETURN
23
EXHAUST GAS TEMP SENSOR 2
6
1
2
C131
VREF 3 EGR
EGR POSITION SENSOR SIGNAL
EGR SENSOR RETURN GND
MAF SENSOR
SHT6/C5
6
92
EGR H BRIDGE POSITIVE
2
93
EGR H BRIDGE NEGATIVE
T
SHT6/C5
MASS AIR FLOW SENSOR 5V
37
MASS AIR FLOW SENSOR GND
20
C151
MAF FREQ
1
2
3
SHT6/C5
MAF TEMP
4
C136
1
45
COOLANT TEMP SENSOR RETURN
2
9
COOLANT TEMP SENSOR
OIL PRESSURE & TEMPERATURE SENSOR
OIL TEMP SENSOR
4
2
VREF 3 OIL PRESSURE
65
3
OIL PRESSURE SENSOR
11
4
OIL PRESSURE & TEMP RETURN GND
48
C149
T
FUEL TEMP SENSOR
1
10
FUEL TEMP SENSOR
2
46
FUEL TEMP SENSOR RETURN GND
1
C137
INTAKE MANIFOLD TEMPERATURE
KNOCK SENSOR 1
SHIELD-01
SHIELD-01
30
ENGINE BLOCK ACCELEROMETER #1 RETURN
2
31
ENGINE BLOCK ACCELEROMETER #1
3
28
ENGINE BLOCK ACCELEROMETER #1 SHIELD
C147
KNOCK SENSOR 2
SHIELD-02
SHIELD-02
1
2
3
33
ENGINE BLOCK ACCELEROMETER #2 RETURN
32
ENGINE BLOCK ACCELEROMETER #2
29
ENGINE BLOCK ACCELEROMETER #2 SHIELD
C146
CRANKSHAFT POSITION SENSOR
SHIELD-03
SHIELD-03
36
CRANKSHAFT SENSOR NEG
2
60
CRANKSHAFT POSITION SENSOR
3
87
CRANKSHAFT SENSOR SHIELD
1
Dealer Copy -- Not for Resale
C148
1
T
P
AIR INTAKE TEMP SENSOR RETURN
69
AIR INTAKE TEMP SENSOR
94
1
2
T
T
COOLANT TEMP SENSOR
C150
INTAKE MANIFOLD PRESSURE SENSOR
VREF 2, INTAKE PRESSURE SENSOR
61
1
INTAKE MANIFOLD PRESSURE SENSOR
12
3
INTAKE MANIFOLD PRESSURE RETURN GND
67
2
C145
P
C138
INJECTOR #1
FUEL INJECTOR #1 HSDA
27
FUEL INJECTOR #1 LSD1A
26
1
2
C139
INJECTOR #2
FUEL INJECTOR #2 HSDB
50
FUEL INJECTOR #2 LSD2B
74
1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1
SHT6/C5
2
59
CAM SHAFT POSITION SENSOR
3
47
CAM SHAFT POSITION SENSOR RETURN
C144
2
C140
INJECTOR #3
FUEL INJECTOR #3 HSDB
51
FUEL INJECTOR #3 LSD1B
75
1
RAIL PRESSURE SENSOR
P
3
38
VREF 1 RAIL PRESSURE SENSOR
1
35
RAIL PRESSURE SENSOR
2
19
RAIL PRESSURE SENSOR RETURN
C143
INLET METERING VALVE
VREF 1 INLET METERING VALVE
1
2
C141
INJECTOR #4
FUEL INJECTOR #4 HSDA
3
FUEL INJECTOR #4 LSD2A
25
1
2
C142
SHT6/C5
77
2
C154
INLET METERING VALVE (PWM)
J7B
J7B
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
Wiring Schematic
Standard Machine
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
651 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 7 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 7 / 15
7300816
HYDRAULICS
FRC1
TRACTION LOCK RELAY - D
C425
+12V PWR
1360 RED/WHT
SHT2/E1
4100 LGN
D1
D5
30
87
85
86
D4
D2
B
B
A
A
C
C
C308
BRAKE
SOLENOID 9.8
OHM 12 V
A
GND
2200 BLK
SHT4/D6
2200 BLK
FRC1
FRC1
B
TRACK 2 SPEED ADAPTER
(SEE ADDITIONAL OPTIONS DWG)
C308
2035 BLK
SHT4/B8
4200 LGN
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
TRACTION LOCK SIGNAL
8
TRACTION LOCK FEEDBACK
13
4110 LGN
3430 LBL
2220 BRN
SHT4/H3
GND
B
T
HYD TEMP SIGNAL
3220 LBL
32
SIG
HYDRAULIC TEMPERATURE SENDER
500 - 3000 OHM (8 VOLT)
A
C108
HYD FILTER DIFF PRESS
34
SHT4/H3
3320 LBL
SIG
2320 BRN
GND
A
HYDRAULIC OIL FILTER SWITCH
(NC)
B
HYDRAULIC FAN GROUND
18
4010 LGN
SIG
2910 BRN
GND
1
HYDRAULIC FAN SOLENOID
7.2 OHM 12 V
2
C446
HYD LOCK VALVE GROUND
1
2410 BRN
GND
4410 LGN
SIG
2
HYDRAULIC LOCK SOLENOID
9.8 OHM 12 V
J1A
1
C420
SHT4/G3
2190 BRN
GND
3190 LBL
SIG
5190 YEL
+8 PWR
B
C
P
A
C105
HYDRAULIC CHARGE
PRESSURE 0.5-7.5V
19
13
1
23
6
HYDRAULIC
FAN
HYD LOCK
SOLENOID
HYD CHARGE
PRESS SENDER
HYD CHARGE PRESS
SENDER POWER
TRACTION SOLENOID
OUTPUT
J1B
4200 LGN
Dealer Copy -- Not for Resale
C112
4330 LGN
AUX CTRLR
FRONT ROD SOLENOID GROUND
2330 BRN
18
1
2
GND
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
SIG
C418
4340 LGN
1
GND
GATEWAY CTRLR
FRONT BASE SOLENOID GROUND
2340 BRN
1
2
FRONT BASE SOLENOID (FEMALE)
3.3 OHM PWM
SIG
C419
13
FRONT BASE
SOLENOID
J2B
19
FRONT ROD
SOLENOID
J2A
AUX CTRLR
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
652 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version ClickSCHEM
Here ELEC MAN
Sheet 8 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 8 / 15
7300816
CAB DISPLAY
LEFT PANEL BUZZER
1
1940 RNG/WHT
SHT3/E1
T13
1
7040 WHT
C499
PTOL CONN
T2
C479
LEFT PANEL (BLACK)
1930 RNG/WHT
SHT3/E1
2940 BLK
SHT4/F8
2920 BLK
SHT4/G8
1440 RED/WHT
SHT2/G1
1620 RNG/WHT
SHT3/E1
3400 LBL
SHT14/F4
3500 LBL
SHT14/F4
SHT3/E1
10
BUZZER
2
GROUND
1
UNSWITCHED POWER
5
SWITCHED POWER
11
LEFT BLINKER INPUT
8
RIGHT BLINKER INPUT
PTOL SWITCH
20
PTOL LED
19
3030 LBL
2380 BRN
1
3030 LBL
1
2380 BRN
12 12
GROUND
2
PTOL OUTPUT
4
PTOL LED
C500
RH KEY SWITCH CONNECTOR
START ENGINE
24
8130 TAN
2
8130 TAN
2
2
START
4
RUN/ENTER SWITCH
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
J1A
1960 RNG/WHT
2700 BLK
2
RUN/ENTER
3650 LBL
3
7
TRAVEL CONTROL INPUT
22
3040 LBL
3040 LBL
14 14
J1B
4
1950 RNG/WHT
SW9
SW9
9
PARK BRAKE INPUT
SW1
BRAKE SWITCH
2930 BLK
2
1
5
6
C479
SHT5/G1
4
SW1
1420 RED/WHT
SHT2/G1
3600 LBL
SW1
Dealer Copy -- Not for Resale
5
SHT3/E1
3
C499
SHT3/D1
SHT4/E8
SWITCHED POWER
C408
MFR HARN CONN 1 (BLACK)
GATEWAY CTRLR
SW9
TRAVEL CONTROL SWITCH(OPTIONAL)
SHT4/E8
1
C480
LEFT PANEL CONN (GRAY)
1775 RNG/WHT
3620 LBL
SHT10/D3
12
3610 LBL
DOOR SIGNAL
2
PARK BRAKE OUTPUT
9
DESOX INHIBIT
2960 BLK
SHT4/F8
C500
C503
RH DLX PANEL
1590 RNG/WHT
SHT3/D1
1240 RED/WHT
SHT2/H1
2250 BLK
SHT4/F8
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
C503
SHT5/F1
SW12
DESOX INHIBIT SWITCH(OPT KIT)
SHT4/E8
SHT3/E1
SHT3/E1
2065 BLK
1700 RNG/WHT
1705 RNG/WHT
2
4
7
9
10
8
3
8070 TAN
8050 TAN
8055 TAN
8060 TAN
SW12
SW12
4
DPF LAMP
5
DESOX INHIBIT LAMP
1
DPF FORCE REGEN
C480
NOT USED
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
653 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 9 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 9 / 15
7300816
*
1785 RNG/WHT
SHT3/E1
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
2
*
1
6
2060 BLK
SHT10/D1
5
SW4
CAB
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
4
SW4
C438
MFR HARN CONN 3 (DK GRAY)
1850 RNG/WHT
SHT3/F1
7
7
8
8
9
9
2
2
4235 LGN
4275 LGN
4550 LGN
GND
2795 BLK
1850 RNG/WHT
1375 RED/WHT
+12V PWR
*
1
C212
POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK)
1370 RED/WHT
SHT2/B1
7
DOME LIGHT
SP45
1370 RED/WHT
7
1390 RED/WHT
1
* T37
C129
CAB ACCESSORY
1210 RED/WHT
2730 BLK
SHT4/E3
5
5
2730 BLK
11 11
C428
MFR HARN CONN 2 (LT GRAY)
2790 BLK
SHT4/E3
14 14
2790 BLK
2690 BRN
2370 BRN
SHT4/H3
4
4
SEATBAR
SENSOR
SP56
GATEWAY CTRLR
SEATBAR SENSOR SIGNAL
SEATBAR/THROTTLE +5V
11
24
3370 LBL
5
5370 YEL
3
5
3
GND
A
SIG
B
+5V PWR
C
3370 LBL
5370 YEL
SP52
2800 BLK
A
A
+12V BATT PWR
B
B
+12V SW PWR
C
C
GND
2010 BLK
1
* T38
SP41
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SP44
SHT14/B4
2210 BLK
SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
SHT6/E5
2375 BRN
2370 BRN
1865 RNG/WHT
2845 BLK
SHT3/D1
SP8
1580 RNG/WHT
Dealer Copy -- Not for Resale
1580 RNG/WHT
3620 LBL
SHT9/D8
1400 RED/WHT
SHT2/G1
2840 BLK
7310 WHT
5375 YEL
C482
1
1
WIPER SWITCH, MOTOR SWITCHED POWER
4
4
DOOR SIGNAL
5
5
DOOR UNSW PWR
2
2
WIPER MOTOR GROUND
3
3
WASHER SIGNAL
J1B
SHT6/E5
5690 YEL
*
HARNESS WASHER PUMP
7253378
C252
B
A
2845 BLK
B
7310 WHT
A
GND
PWR
2
WASHER
MOTOR
1
C253
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
Wiring Schematic
Standard Machine
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
654 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300816 (B)
SCHEM ELEC MAN
Sheet 10 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 10 / 15
7300816
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
RIGHT HANDLE LEFT ROCKER DOWN
RIGHT HANDLE LEFT ROCKER UP
1530 RNG/WHT
SHT3/E3
A
4930 LGN
31
J
4940 LGN
30
H
2195 BRN
SHT4/C3
4320 LGN
D
4300 LGN
C404
BU ALARM-MFR HARN (SEE
ADDITIONAL OPTION DWG)
A
C103
TAILGATE HARN
7100 WHT
A
C
C
SHT4/D8
RIGHT HANDLE RIGHT ROCKER UP
7100 WHT
T19
2650 BLK
1
1
PADDLE
B
4910 LGN
13
LEFT POSITION SWITCH
C
F
4920 LGN
E
BACK UP ALARM
K
T20
RIGHT POSITION SWITCH
TRIGGER
HANDLE LOCK (ACS ONLY)
G
C409
4980 LGN
SIG
TILT SPOOL LOCK
7.8 OHM 12V
1
C421
LIFT SPOOL LOCK GROUND
2990 BRN
2
GND
3
LIFT SPOOL LOCK
7.8 OHM 12V
J1A
4990 LGN
SIG
5
LIFT SPOOL
LOCK SOLENOID
23
J2B
LIFT (ACS/AHC ONLY)
H
HANDLE LOCK (ACS ONLY)
E
FLOAT SIGNAL
4640 LGN
20
D
1520 RNG/WHT
SHT3/E3
LEFT HANDLE RIGHT ROCKER DOWN
J1B
7
LEFT HANDLE
AUX CTRLR
1
C422
TILT SPOOL
LOCK SOLENOID
18
3
RIGHT HANDLE
PWM HIGH
GND
RIGHT HANDLE
PWM SIGNAL
2980 BRN
10
21
TILT SPOOL LOCK GROUND
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
Dealer Copy -- Not for Resale
TILT (ACS/AHC ONLY)
4830 LGN
22
LEFT HANDLE RIGHT ROCKER UP
28
LEFT HANDLE PADDEL RIGHT
11
LEFT HANDLE PADDEL LEFT
12
B
4840 LGN
FLOAT (ACS/AHC ONLY)
A
RIGHT POSTION SWITCH
C
4810 LGN
F
4820 LGN
PADDLE
G
C410
J2A
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
655 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 11 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 11 / 15
7300816
LIGHTS
C434-1
6100 PNK
SIG
A
37 WATT
C408
MFR HARN CONN 1 (BLACK)
2765 BLK
SHT4/F3
9
9
2735 BLK
2765 BLK
GND
2750 BLK
GND
SP14
LEFT FRONT
WORKLIGHT
B
B
50 WATT
SIG
6110 PNK
A
C434-2
C435-1
6000 PNK
8
8
6120 PNK
6000 PNK
SIG
SP15
FRONT WORK LIGHTS
RELAY - RC1
SHT2/E1
1350 RED/WHT
30
37 WATT
C438
MFR HARN CONN 3 (DK GRAY)
6620 PNK
87
SP23
6610 PNK
13 13
GND
2760 BLK
6610 PNK
6130 PNK
SIG
SP64
86
GND
2705 BLK
RC1
30
87
86
6340 PNK
SP10
6310 PNK
A
RC2
2115 BLK
A
2610 BLK
SHT4/D8
GND
2
RIGHT REAR
TAIL LIGHT
C103
TAILGATE HARN
85
RC2
SHT4/B8
Dealer Copy -- Not for Resale
6320 PNK
FRONT WORK LIGHTS
RELAY-RC2
RED/WHT
B
C435-2
2120 BLK
1330
RIGHT FRONT
WORK LIGHT
A
50 WATT
6630 PNK
SHT2/E1
B
85
RC1
SHT4/A8
A
SP49
6310 PNK
6320 PNK
SIG
1
C603
6330 PNK
SIG
1
LEFT REAR
TAIL LIGHT
GATEWAY CTRLR
2640 BLK
SHT4/D8
MRKR LIGHT PWR SIGNAL
5
MRKR LIGHT PWR FEEDBACK
31
REAR LIGHT RELAY SIGNAL
17
REAR LIGHT RELAY FEEDBACK
3460 LBL
T16 TERMINAL (-)
28
GND
E1
30
87
85
86
6210 PNK
6200 PNK
E4
H
H
6200 PNK
1
T17 TERMINAL (+)
6220 PNK
SIG
SP96
1
LEFT REAR
WORK LIGHT
E2
GND
2630 BLK
FRC1
1
T18 TERMINAL (-)
2045 BLK
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
656 of 1148
SIG
T15 TERMINAL (+)
SHT4/C8
FRC1
1
RIGHT REAR
WORK LIGHT
FRC1
REAR LIGHT
RELAY - E
6210 PNK
1320 RED/WHT
2620 BLK
SHT4/D8
3440 LBL
E5
SHT4/B8
2
C602
J1A
SHT2/E1
GND
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300816 (B)
SCHEM ELEC MAN
Sheet 12 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 12 / 15
7300816
2440 BLK
GND
2
HVAC
*
HVAC DUCT FAN
M
7440 WHT
SIG
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
C610
2560 BLK
C
7420 WHT
*
POTENTIOMETER (TEMP
CONTROL SWITCH)
A
7425 WHT
B
C483
D
2130 BLK
*
HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
10 10
B4
85
B2
86
FRC1
FRC1
GATEWAY CTRLR
HVAC RELAY SIGNAL
3
HVAC RELAY FEEDBACK
30
3050 LBL
2745 BLK
SHT4/F3
11 11
2745 BLK
SP16
AC SIGNAL MONITOR
11
7021 WHT
SP40
7020 WHT
5
12 12
2580 BLK
2100 BLK
2570 BLK
1
*
THERMOSTAT
2
3
SW11
AC SWITCH
7023 WHT
7025 WHT
7024 WHT
C350
SHT4/C6
*
SIG
1
D4
A
4
C611
C630
B
M
SW10
7410 WHT
7015 WHT
AC EVAPORATOR
SWITCH
LOW
3
3
7020 WHT
J1A
2
7510 WHT
SW10
HIGH
MED
7520 WHT
SW11
87
2
1
4
1
7400 WHT
7050 WHT
B5
30
*
7530 WHT
C
B1
1500 RNG/WHT
SW10
BLOWER SWITCH
3
SHT2/F1
1500 RNG/WHT
*
Dealer Copy -- Not for Resale
1140 RED/WHT
C438
MFR HARN CONN 3
(DK GRAY)
1
FRC1
HVAC RELAY-B
2290 BLK
MAGNET CLUTCH
(COMPRESSOR)
2280 BLK
GND
2
C486
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
657 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 13 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 13 / 15
7300816
#
C428
MFR HARN CONN 2 (LT GRAY)
C355
FUEL HARN
4470 LGN
1 SIG
POWER BOB
CLOSE
2 GND
#
SP33
2470 BLK
2770 BLK
E
E
B
B
F
F
4470 LGN
2770 BLK
OPTIONS 1
4470 LGN
11 11
*
SHT4/E6
C607
4480 LGN
1 SIG
POWER BOB
OPEN
2
GND
4480 LGN
4480 LGN
10 10
SW5
POWER BOBTACH SWITCH
1380 RED/WHT
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
*
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
2
3
SW5
2480 BLK
#
SW5
C606
6010 PNK
LEFT HANDLE
LIFT (ACS/AHC ONLY)
LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG)
1550 RNG/WHT
SHT3/F1
6010 PNK
13 13
1550 RNG/WHT
12 12
1405 RED/WHT
C438
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY)
1410 RED/WHT
SHT2/C1
1
SP43
1410 RED/WHT
1
SHT15/D6
1430 RED/WHT
*
X
L
1200 RED/WHT
T3
FLASHER
FLOAT (ACS/AHC ONLY)
B
6415 PNK
D
6515 PNK
A
TRIGGER
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
C411
E
E
D
D
6400 PNK
2780 BLK
4450 LGN
3
4
4455 LGN
5
2780 BLK
4
*
B
2
3
2450 BLK
GND
1
2455 BLK
4
SHT4/C6
C423
6
5
SW6
LEFT HANDLE
*
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG)
4
6
SW3
6700 PNK
*
2810 BLK
2420 BLK
6440 PNK
SHT4/E8
6540 PNK
AUX CTRLR
*
*
RIGHT SPEAKER
HIGH FLOW SOLENOID GROUND
26
2460 BRN
GND
B
HIGH FLOW
SOLENOID
7.5 OHM 12 V
J2A
HIGH FLOW SOLENOID SIGNAL
PADDLE
26
4460 LGN
SIG
A
2
7820 WHT
7830 WHT
C676
RADIO CONN
3
LEFT SPEAKER (+)
4
LEFT SPEAKER (-)
E
E
D
D
F
F
B
B
C
C
A
A
C670
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
L010
AIR RIDE SEAT
A
1460 RED/WHT
B
SHT2/C1
7210 WHT
13 13
C126
HORN CONNECTOR
7210 WHT
A
A
TWO SPEED GROUND
_
C412
SHT4/E8
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
2785 BLK
B
B
GND
AEW
CHG NOTICE DWN
SHEET
1885 RNG/WHT
TWO SPEED SIGNAL
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
5
RIGHT SPEAKER (+)
GND
1
RADIO SWITCHED POWER
C277
2
RADIO GROUND
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
2210 BLK
5
PWR
GND
C676
2350 BRN
26
4350 LGN
26
GND
2
TWO SPEED
SOLENOID
5.1 OHM 12 V
SIG
1
TRACK 2 SPEED
(SEE ADDITIONAL
OPTIONS DWG)
C441
J1B
WARNING
COPYRIGHT
104399
+
RIGHT SPEAKER (-)
J1A
HORN
4
6
SHT10/E1
7800 WHT
GATEWAY CTRLR
SIG
1510 RNG/WHT
PWR
2885 BLK
SHT10/D1
C408
MFR HARN CONN 1
(BLACK)
SHT10/E1
7810 WHT
C278
SHT10/E1
LEFT POSITION SWITCH
*
1
C415
J2B
DESCRIPTION
2970 BLK
C279
RIGHT POSTION SWITCH
REV
2725 BLK
2905 BLK
SHT15/D4
1
FLOAT (ACS/AHC ONLY)
658 of 1148
SW2
(PINS 3 & 6
INTERNALLY INSULATED)
SHT15/F4
2
SEE SHEET 1
6
SP46
2850 BLK
1
SW3
SHT15/F6
HANDLE LOCK (ACS ONLY)
B
1
SW2
LEFT SPEAKER
TRIGGER
2
SW3
HAZARD SWITCH
2
SW6
2830 BLK
LIFT (ACS/AHC ONLY)
*
SW2
BEACON SWITCH
6430 PNK
3400 LBL
SW6
BUCKET POSITION SWITCH
4455 LGN
5
6530 PNK
D13
6400 PNK
D3
A SIG
3
D14
6500 PNK
SHT9/G8
SHT4/E3
BUCKET
POSITION
SOLENOID
9.8 OHM
6
6510 PNK
6410 PNK
SP22
6
T3
3500 LBL
6570 PNK
PADDLE
6500 PNK
Dealer Copy -- Not for Resale
RIGHT POSTION SWITCH
LEFT POSITION SWITCH
SHT9/F8
SP21
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 14 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 14 / 15
7300816
*
SW7
RIDE CONTROL
C438
MFR HARN CONN 3 (DK GRAY)
AUX CTRLR
RIDE CONTROL SW AUTO
23
RIDE CONTROL RELAY SIGNAL
7
RIDE CONTROL COIL SIGNAL
21
3410 LBL
3410 LBL
14 14
2890 BLK
2
1
SW7
SHT4/E8
SP9
1
3425 LBL
3435 LBL
3445 LBL
1
L5
RIDE CONTROL
COIL
2
2040 BLK
2020 BLK
SP32
C439
2155 BLK
3475 LBL
16
7
REVERSING FAN AUTO SIGNAL
29
8
FRC1
SW13
REVERSING FAN
3475 LBL
7
2905 BLK
3470 LBL
8
3
SHT4/G8
*
2970 BLK
2
1
1555 RNG/WHT
REVERSING
FAN COIL
25
1
C442
SHT4/C3
RIDE CONTROL PRESSURE SENSOR SIGNAL
RIDE CONTROL SENSOR +5V PWR
2185 BRN
3455 LBL
10
5105 YEL
24
A
C
RIDE CONTROL
PRESSURE SENSOR
B
J2B
*
SW8
SIDELIGHT
1405 RED/WHT
SHT14/G3
2
1
Dealer Copy -- Not for Resale
REVERSING FAN SIGNAL
SHT14/D3
6
SW8
Wiring Schematic
Standard Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
659 of 1148
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
*
C672
SIDELIGHT CONN
6710 PNK
2810 BLK
2860 BLK
1
1
2
2
SHT4/E8
SW8
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712015
B2LA11899
B2KZ13499
B3H112017
B3GZ12002
B3GY12002
WARNING
COPYRIGHT
B
SHT3/D1
SW13
2
J2A
3485 LBL
SHT14/D3
6
4
SW13
C443
2175 BRN
27
SHT4/C8
FRC1
5
REVERSING FAN RETURN SIGNAL
2505 BLK
SHT3/F1
C440
SHT14/D3
3470 LBL
L2
1575 RNG/WHT
2
C428
MFR HARN CONN 2 (LT GRAY)
REVERSING FAN MANUAL SIGNAL
L1
L4
RIDE CONTROL
COIL
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
SW7
3480 LBL
3415 LBL
*
OPTIONS 2
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300816 (B)
Printable Version Click Here
SCHEM ELEC MAN
Sheet 15 of 15
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 15 / 15
7300816
Index Diagram
1
SH01 - INDEX
2
SH02 - UNSWITCHED BATT POWER
3
SH03 - SWITCHED POWER
4
SH04 - GROUND
5
SH05 - CAN BUS
6
SH06 - ENGINE
7
SH07 - ENGINE CONTROL UNIT
8
SH08 - HYDRAULICS
9
SH09 - CAB DISPLAY
10
SH10 - CAB
11
SH11 - MANUAL CONTROLS
12
SH12 - LIGHTS
13
SH13 - HVAC
14
SH14 - OPTIONS 1
15
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SH15 - OPTIONS 2
HARNESS PART NUMBER
MF MFR MAN
7331093
DLX CAB
7301237
STD CAB
7303755
STD FUEL
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
7000 THROUGH 7999
WHITE
WHT
8000 THROUGH 8999
TAN
TAN
COLOR CODE
WIRE COLOR
7149219
7266824
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
7220812
7267103
TAILGATE EUR
7217483
SUSP JSTK
7163706
WHL 2 SPD ADP
7159366
TRK 2 SPD
7243409
S550
S570
S590
S510
S530
T590
DESCRIPTION
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
110295
0
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
Dealer Copy -- Not for Resale
DLX FUEL
BCT ENG
CONNECTOR
1
1
PARTIAL CONNECTOR
1
1
1
1
WIRE BREAK
ENGINE
TAILGATE DOM
LEGEND
SHT1/F2
Click Here For Interactive PDF
REV
GROUP NUMBER RANGE
OTHER FUNCTIONS
Wiring Schematic
Standard Machine
660 of 1148
GROUP DESCRIPTION
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
SHT1/F2
ECN
WIRE BREAK
WIRE BREAK
SHT1/F2
SHT1/F2
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 1 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 1 / 15
7331097
UNSWITCHED
BATT POWER
1240 RED/WHT
C408
MFR HARN CONN 1 (BLACK)
1450 RED/WHT
6
6
1450 RED/WHT
1400 RED/WHT
1440 RED/WHT
1110 RED/WHT
FUSE 11 25 A
1070 RED
11A
11B
SP2
FUSE 13 25 A
1025 RED
13B
13A
1130 RED/WHT
1120 RED/WHT
1160 RED/WHT
SHT10/D3
SP7
1420 RED/WHT
FUSE RELAY CENTER
SHT9/E4
SHT9/E4
SHT9/G8
2
GATEWAY CTRLR
3
J1B
SP36
1150 RED/WHT
1180 RED/WHT
3
AUX CTRLR
2
J2B
+12V BATTERY
MEGAFUSE
1
HW11
100.0 Amps
T5
1
T4
1310 RED
1140 RED/WHT
4B
Dealer Copy -- Not for Resale
1010 RED
SHT6/G1
BUS BAR
FUSE 4 25 A
4A
SHT13/E8
FUSE 3 30 A
3A
1360 RED/WHT
3B
SHT8/H8
BUS BAR
FUSE 1 15 A
1340 RED
1A
1320 RED/WHT
1B
SHT12/B8
FUSE 2 20 A
2A
SP26
1330 RED/WHT
2B
SHT12/D8
1350 RED/WHT
SHT12/F8
FUSE 9 50 A
1325 RED
1055 RED
1060 RED
9A
1065 RED/WHT
9B
SHT6/D3
FUSE 20 5 A
1335 RED
20A
1345 RED/WHT
20B
SHT3/G8
FUSE 16 25 A
SP1
1300 RED
1035 RED/WHT
16B
16A
SHT3/H8
1445 RED/WHT
SHT6/D3
FUSE 18 25 A
1190 RED
18A
1165 RED/WHT
18B
SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
1040 RED
22A
22B
1490 RED/WHT
1410 RED/WHT
SHT14/F7
SP24
FUSE 24 25 A
SP60
1290 RED
24B
24A
FRC1
1370 RED/WHT
SHT10/F8
FRC1
1050 RED
SHT3/D8
1030 RED
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
661 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
SHT6/G8
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 2 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 2 / 15
7331097
FRC1 ENGINE
ECU RELAY - G
1506 RNG/WHT
SHT2/D1
1035 RED/WHT
+12V PWR
G1
G2
30
86
87
G4
85
SP54
1540 RNG/WHT
1507 RNG/WHT
1508 RNG/WHT
G5
3
5
ENG ECU CTRLR
45
ENG ECU SW SIG
FRC1
FRC1
8005 TAN
SHT2/D1
SWITCHED
POWER
1
1345 RED/WHT
J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT
1511 RNG/WHT
21B
21A
1720 RNG/WHT
B
C404
BU ALARM-MFR HARN
B
(SEE ADDITIONAL
OPTION DWG)
A
A
BUS BAR
FUSE 5 25 A
1760 RNG/WHT
1780 RNG/WHT
1750 RNG/WHT
5B
5A
SP50
SHT6/C7
C489
MFR ACCESSORY
FUSE 6 25 A
1850 RNG/WHT
6B
6A
SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
1790 RNG/WHT
1550 RNG/WHT
12B
12A
SHT14/G7
1700 RNG/WHT
1805 RNG/WHT
14A
FRC1
SWITCHED
POWER
RELAY - A
1050 RED
+12V PWR
A1
30
87
B2
A5
86
1765 RNG/WHT
A4
85
A2
FRC1
SP25
1795 RNG/WHT
GND
7A
BUS BAR
SHT2/B1
FRC1
Dealer Copy -- Not for Resale
1520 RNG/WHT
SHT11/D2
1530 RNG/WHT
SHT11/G2
1705 RNG/WHT
1620 RNG/WHT
1940 RNG/WHT
1930 RNG/WHT
FUSE 14 5 A
1560 RNG/WHT
1570 RNG/WHT
14B
SP11
22 AUX CTRLR
1960 RNG/WHT
J2B
C428
MFR HARN CONN 2
(LT GRAY)
1660 RNG/WHT
2
2
1775 RNG/WHT
1785 RNG/WHT
1950 RNG/WHT
SP42
1660 RNG/WHT
1590 RNG/WHT
1555 RNG/WHT
FUSE 7 25 A
SP65
1730 RNG/WHT
7B
1735 RNG/WHT
SHT9/C8
SHT9/B8
SHT9/G8
SHT9/H8
SHT9/H4
SHT9/D8
SHT9/F8
SHT10/H8
SHT9/F4
SHT9/E4
SHT15/F4
SHT5/B8
1725 RNG/WHT
SHT5/C2
FUSE 8 25 A
8A
8B
1580 RNG/WHT
23B
1800 RNG/WHT
SHT10/F8
FUSE 23 15 A
1815 RNG/WHT
23A
SHT6/G8
FRC1
FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
21
SWITCHED POWER RELAY FEEDBACK
4
SWITCHED POWER RELAY SIGNAL
J1A
C428
MFR HARN CONN 2 (LT GRAY)
1920 RNG/WHT
9
9
1920 RNG/WHT
SP37
1840 RNG/WHT
SHT5/E3
1830 RNG/WHT
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
662 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
SHT5/F3
Printed On August 2018
Printable Version Click Here
7331097
SCHEM ELEC MAN
Sheet 3 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 3 / 15
7331097
GROUND
ENG ECU CTRLR
2
4
6
J7A
T32
ECU CASE GND
1
SHT15/G5
2001 BLK
2002 BLK
SP53
2810 BLK
2320 BRN
SHT8/F7
2003 BLK
2004 BLK
SHT8/D7
SHT9/G8
SHT9/G4
SHT9/E4
SHT9/D4
2920 BLK
1
C408
MFR HARN CONN 1 (BLACK)
SP4
2940 BLK
2950 BLK
T6
BATT GND
2950 BLK
10 10
2960 BLK
2250 BLK
2510 BLK
16
SP3
2110 BLK
2500 BLK
J1B
2765 BLK
SHT12/H8
2745 BLK
SHT13/D7
SHT9/E8
SHT14/D5
SHT9/F8
SHT14/B7
16
2860 BLK
AUX CTRLR
2890 BLK
2065 BLK
C428
MFR HARN CONN 2 (LT GRAY)
2930 BLK
2900 BLK
2830 BLK
2700 BLK
2550 BLK
15
1
SP47
SP28
J2B
2900 BLK
1
2785 BLK
2770 BLK
SHT14/H6
2200 BLK
SHT8/H4
SHT12/C4
SHT11/F8
SHT12/C4
C489
MFR ACCESSORY B
2620 BLK
2650 BLK
B
2720 BLK
C103
TAILGATE HARN
2600 BLK
2640 BLK
B
2600 BLK
B
SP51
SHT12/E4
SHT12/B4
2730 BLK
SHT10/E8
T1
2390 BLK
BATT GND
1
2610 BLK
2630 BLK
SHT14/D6
SHT5/B8
SHT5/C2
2455 BLK
2710 BLK
SP27
AUX CTRLR
2300 BLK
2185 BRN
SHT15/E7
2715 BLK
SHT12/B8
SHT8/G8
SHT12/D8
SHT3/C1
SHT13/F8
SHT6/G7
SHT12/E8
2505 BLK
SHT13/B8
663 of 1148
REV
DESCRIPTION
2290 BLK
17
SENSOR GND
J2B
2035 BLK
2115 BLK
SP55
2105 BLK
2055 BLK
2030 BLK
2005 BLK
2120 BLK
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
SEE SHEET 1
2995 BRN
2045 BLK
Wiring Schematic
Standard Machine
0
SP58
2195 BRN
SHT11/G2
SHT15/G4
T10
ENGINE GROUND
1
2015 BLK
SHT6/F3
SP6
T8
BATT GND
2780 BLK
SHT14/E7
2090 BLK
1
2790 BLK
SHT10/D8
2540 BLK
Dealer Copy -- Not for Resale
SHT9/C8
J1B
2180 BRN
2070 BLK
15
SHT15/H5
SENSOR GROUND
2080 BLK
GATEWAY CTRLR
SHT15/D4
17
2150 BRN
SHT6/F7
SHT5/E3
2230 BRN
2190 BRN
SHT6/E7
SHT5/E3
SP12
2220 BRN
SHT8/F7
2155 BLK
GATEWAY CTRLR
2370 BRN
SHT10/D8
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 4 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 4 / 15
7331097
CAN BUS
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
*
RE016
120 OHM 0.5 W RESISTOR
R3-1
GATEWAY CTRLR
CAN LO
8
CAN HI
9
TP-09
TP-09 9260 PUR
TP-10
9230 PUR
9130 PUR/WHT
9160 PUR/WHT
TP-10
SP31
TP-16
TP-16
9220 PUR
SP30
R3-2
J1B
RE019
120 OHM 0.5 W RESISTOR
C408
MFR HARN CONN 1 (BLACK)
9120 PUR/WHT
4
4
3
3
TP-01
SP18
9220 PUR
TP-01
TP-03
SP17
9120 PUR/WHT
TP-11
9410 PUR
TP-03
SP39
TP-05
SP38
9310 PUR/WHT
9430 PUR
SP35 TP-07
TP-05
SP34
9330 PUR/WHT
TP-08 9460 PUR
TP-08
9360 PUR/WHT
9350 PUR/WHT
4
CAN LO
3
CAN HI
R2
TP-06
TP-04
TP-02
R1
TP-07
9450 PUR
C479
LEFT PANEL
(BLACK)
C479
C503
RH DLX PANEL
AUX CTRLR
TP-06
9440 PUR
TP-11
9280 PUR
8
CAN LO
9
CAN HI
9340 PUR/WHT
9180 PUR/WHT
J2B
*
SHT3/B1
CAN HI
CAN LO
1830 RNG/WHT
2070 BLK
9320 PUR/WHT
TP-04
9420 PUR
1
1
2
2
3
3
4
4
14
TP-12
9500 PUR/WHT
9600 PUR
20
24
A
B
2070 BLK
9560 PUR/WHT
9660 PUR
*
SHT3/B1
2080 BLK
SHT4/G8
9300 PUR/WHT TP-02
9400 PUR
1
1
2
2
3
3
4
4
A
R18
120 OHM 0.5W RESISTOR
R1-1
CAN HI
ENG ECU CTRLR
B
1
1
2
2
3
3
4
4
GND
CAN HI
CAN LO
C459
LEFT JOYSTICK
1840 RNG/WHT
2080 BLK
9540 PUR/WHT
9640 PUR
1
1
2
2
3
3
4
4
CAN LO
TP-17
ENG CAN LO
47
ENG CAN HI
48
9200 PUR
TP-17
TP-18
R21
120 OHM 0.5W RESISTOR
SP90
9215 PUR
3095 LBL
9100 PUR/WHT
9115 PUR/WHT
R1-2
TP-20
TP-18
SP91
R2-1
9210 PUR TP-20
GND
CAN HI
CAN LO
J7A
9105 PUR/WHT
21
3090 LBL
SHT3/D1
3085 LBL
D
SP93
D
ENG CAN LO
14
ENG CAN HI
J1B
1725 RNG/WHT
1
REMOTE RUN KEY
SHT4/C6
1735 RNG/WHT
2715 BLK
2
E
E
SWITCHED POWER
F
F
UNSWITCHED POWER
G
G
GROUND
9255 PUR
1165 RED/WHT
SHT2/C1
2710 BLK
SHT4/C6
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
DESCRIPTION
20
C169
ENGINE CAN
SHT3/D1
REV
GATEWAY CTRLR
B1
R2-2
9155 PUR/WHT TP-19
664 of 1148
LEFT JOYSTICK
+12V PWR
TP-21 9205 PUR TP-21
9110 PUR/WHT
TP-19
J1B
SEE SHEET 1
RIGHT JOYSTICK
+12V PWR
GATEWAY CTRLR
0
CAN HI
SUSP SEAT JOYSTICK HARNESS
J2A
REMOTE RUN
2
C460
RIGHT JOYSTICK
1830 RNG/WHT
C449
LEFT JOYSTICK CONN
1840 RNG/WHT
C426
Remote Run Tool, ACD
J2B
REMOTE RUN
Dealer Copy -- Not for Resale
SHT4/G8
TP-12
CAN LO
C503
C450
RIGHT JOYSTICK CONN
AUX CTRLR
4
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
3
ENG CAN HI
4
ENG CAN LO
C169
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 5 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 5 / 15
7331097
ENGINE
1030 RED
SHT2/B1
M1
8210 TAN
M5
30
87
85
86
FRC1
C111
MFR-BCT HARN CONN
8200 TAN
M4
M2
A
A
B
B
C
C
R
S
T9
1
B
8220 TAN
3560 LBL
SHT2/E7
1800 RNG/WHT
1015 RED
2005 BLK
SHT4/B8
1
1
T21
FRC1
1800 RNG/WHT
SHT3/C1
STARTER
T7
FRC1 STARTER
RELAY - M
GATEWAY CTRLR
7
STARTER RELAY FEEDBACK
22
3560 LBL
2150 BRN
SHT4/G3
AIR FILTER SIGNAL
3150 LBL
16
A
GND
C110
AIR FILTER
SWITCH (NC)
1020 RED
SIG
C355
FUEL HARN
3180 LBL
12
SHT4/G3
2180 BRN
C
D
C
D
T11
3180 LBL
2180 BRN
A
FUEL SENDER
(30 - 270 OHM)
B
SHT10/C7
1
3690 LBL
6
6
SHT10/D5
4
IGN SW ON
8007 TAN
J1B
ENG ECU CTRLR
IGN SW ON
WATER IN FUEL RETURN
C100
19
2865 BRN
34
WIF SENSOR
9
PRE HEATER RELAY DRIVER
56
GND
HAND THROTTLE
3865 LBL
SIG
A
GND
B
2690 BRN
C114
FRC1
PREHEATER
RELAY - C
1065 RED/WHT
SHT2/D1
SHT2/C1
C1
1445 RED/WHT
C5
FRC1
C4
8525 TAN
SP77
8500 TAN
1
T14
C2
FRC1
1
C118
AIR INLET TEMP
C
SIG
8510 TAN
1511 RNG/WHT
SHT3/G1
MAFS FREQ SIGNAL
+5V PWR
3690 LBL
C100
WATER IN FUEL SENSOR
(FUEL FILTER)
2
T12
F
E
D
5690 YEL
C428
MFR HARN CONN 2 (LT GRAY)
10
1
2015 BLK
SHT4/E3
C406
THROTTLE PRIMARY SIGNAL
ALTERNATOR
S
L
C405
J1A
FUEL SIGNAL
B
Dealer Copy -- Not for Resale
STARTER RELAY SIGNAL
8013 TAN
28
8014 TAN
35
J7A
KL87
SHT7/B6
1
1
SHT7/C6
2
2
SHT7/G3
3
3
SHT7/F3
4
4
SHT7/H7
ENG-CROSSOVER
3420 LBL
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
665 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 6 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 6 / 15
7331097
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK
79
GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EGR VALVE DC MOTOR
1
5
3
4
64
16
72
OPEN
EXHAUST GAS TEMP SENSOR 2 RETURN
23
EXHAUST GAS TEMP SENSOR 2
6
1
2
C131
VREF 3 EGR
EGR POSITION SENSOR SIGNAL
EGR SENSOR RETURN GND
MAF SENSOR
SHT6/C5
6
92
EGR H BRIDGE POSITIVE
2
93
EGR H BRIDGE NEGATIVE
T
SHT6/C5
MASS AIR FLOW SENSOR 5V
37
MASS AIR FLOW SENSOR GND
20
C151
MAF FREQ
1
2
3
SHT6/C5
MAF TEMP
4
C136
1
45
COOLANT TEMP SENSOR RETURN
2
9
COOLANT TEMP SENSOR
OIL PRESSURE & TEMPERATURE SENSOR
OIL TEMP SENSOR
4
2
VREF 3 OIL PRESSURE
65
3
OIL PRESSURE SENSOR
11
4
OIL PRESSURE & TEMP RETURN GND
48
C149
T
FUEL TEMP SENSOR
1
10
FUEL TEMP SENSOR
2
46
FUEL TEMP SENSOR RETURN GND
1
C137
INTAKE MANIFOLD TEMPERATURE
KNOCK SENSOR 1
SHIELD-01
SHIELD-01
30
ENGINE BLOCK ACCELEROMETER #1 RETURN
2
31
ENGINE BLOCK ACCELEROMETER #1
3
28
ENGINE BLOCK ACCELEROMETER #1 SHIELD
C147
KNOCK SENSOR 2
SHIELD-02
SHIELD-02
1
2
3
33
ENGINE BLOCK ACCELEROMETER #2 RETURN
32
ENGINE BLOCK ACCELEROMETER #2
29
ENGINE BLOCK ACCELEROMETER #2 SHIELD
C146
CRANKSHAFT POSITION SENSOR
SHIELD-03
SHIELD-03
36
CRANKSHAFT SENSOR NEG
2
60
CRANKSHAFT POSITION SENSOR
3
87
CRANKSHAFT SENSOR SHIELD
1
Dealer Copy -- Not for Resale
C148
1
T
P
AIR INTAKE TEMP SENSOR RETURN
69
AIR INTAKE TEMP SENSOR
94
1
2
T
T
COOLANT TEMP SENSOR
C150
INTAKE MANIFOLD PRESSURE SENSOR
VREF 2, INTAKE PRESSURE SENSOR
61
1
INTAKE MANIFOLD PRESSURE SENSOR
12
3
INTAKE MANIFOLD PRESSURE RETURN GND
67
2
C145
P
C138
INJECTOR #1
FUEL INJECTOR #1 HSDA
27
FUEL INJECTOR #1 LSD1A
26
1
2
C139
INJECTOR #2
FUEL INJECTOR #2 HSDB
50
FUEL INJECTOR #2 LSD2B
74
1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1
SHT6/C5
2
C140
2
59
CAM SHAFT POSITION SENSOR
3
47
CAM SHAFT POSITION SENSOR RETURN
C144
INJECTOR #3
FUEL INJECTOR #3 HSDB
51
FUEL INJECTOR #3 LSD1B
75
1
RAIL PRESSURE SENSOR
P
3
38
VREF 1 RAIL PRESSURE SENSOR
1
35
RAIL PRESSURE SENSOR
2
19
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
C143
INLET METERING VALVE
VREF 1 INLET METERING VALVE
1
2
C141
FUEL INJECTOR #4 HSDA
3
FUEL INJECTOR #4 LSD2A
25
1
2
C142
SHT6/C5
77
2
C154
INLET METERING VALVE (PWM)
J7B
J7B
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
666 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 7 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 7 / 15
7331097
FRC1
TRACTION LOCK RELAY - D
HYDRAULICS
C425
+12V PWR
1360 RED/WHT
SHT2/E1
4100 LGN
D1
D5
30
87
85
86
D4
D2
B
B
A
A
C
C
C308
BRAKE
SOLENOID 9.8
OHM 12 V
A
GND
2200 BLK
SHT4/D6
2200 BLK
FRC1
FRC1
B
TRACK 2 SPEED ADAPTER
(SEE ADDITIONAL OPTIONS DWG)
C308
2035 BLK
SHT4/B8
4200 LGN
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
TRACTION LOCK SIGNAL
8
TRACTION LOCK FEEDBACK
13
4110 LGN
3430 LBL
2220 BRN
SHT4/H3
GND
B
T
HYD TEMP SIGNAL
3220 LBL
32
SIG
HYDRAULIC TEMPERATURE SENDER
500 - 3000 OHM (8 VOLT)
A
C108
HYD FILTER DIFF PRESS
34
SHT4/H3
3320 LBL
SIG
2320 BRN
GND
A
HYDRAULIC OIL FILTER SWITCH
(NC)
B
C112
18
SIG
2910 BRN
GND
1
Dealer Copy -- Not for Resale
HYDRAULIC FAN GROUND
4010 LGN
HYDRAULIC FAN SOLENOID
7.2 OHM 12 V
2
C446
HYD LOCK VALVE GROUND
1
2410 BRN
GND
4410 LGN
SIG
2
HYDRAULIC LOCK SOLENOID
9.8 OHM 12 V
J1A
1
C420
SHT4/G3
SHT10/C8
2190 BRN
GND
3190 LBL
SIG
5190 YEL
+5 PWR
A
C
HYDRAULIC CHARGE
PRESSURE 0.5-4.5V
P
B
C105
19
13
1
6
HYDRAULIC
FAN
HYD LOCK
SOLENOID
HYD CHARGE
PRESS SENDER
TRACTION SOLENOID
OUTPUT
J1B
4200 LGN
4330 LGN
AUX CTRLR
FRONT ROD SOLENOID GROUND
2330 BRN
18
1
2
GND
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
SIG
C418
4340 LGN
1
GND
GATEWAY CTRLR
FRONT BASE SOLENOID GROUND
2340 BRN
1
2
FRONT BASE SOLENOID (FEMALE)
3.3 OHM PWM
SIG
C419
13
FRONT BASE
SOLENOID
J2B
19
FRONT ROD
SOLENOID
J2A
AUX CTRLR
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
667 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 8 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 8 / 15
7331097
CAB DISPLAY
LEFT PANEL BUZZER
1
1940 RNG/WHT
SHT3/E1
T13
1
7040 WHT
C499
PTOL CONN
T2
C479
LEFT PANEL (BLACK)
1930 RNG/WHT
SHT3/E1
2940 BLK
SHT4/F8
2920 BLK
SHT4/G8
1440 RED/WHT
SHT2/G1
1620 RNG/WHT
SHT3/E1
3400 LBL
SHT14/F4
3500 LBL
SHT14/F4
SHT3/E1
10
BUZZER
2
GROUND
1
UNSWITCHED POWER
5
SWITCHED POWER
11
LEFT BLINKER INPUT
8
RIGHT BLINKER INPUT
PTOL SWITCH
20
PTOL LED
19
3030 LBL
2380 BRN
1
3030 LBL
1
2380 BRN
12 12
GROUND
2
PTOL OUTPUT
4
PTOL LED
C500
RH KEY SWITCH CONNECTOR
START ENGINE
24
8130 TAN
2
8130 TAN
2
2
START
4
RUN/ENTER SWITCH
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
J1A
1960 RNG/WHT
2700 BLK
2
RUN/ENTER
3650 LBL
3
7
TRAVEL CONTROL INPUT
22
3040 LBL
3040 LBL
14 14
J1B
4
1950 RNG/WHT
SW9
SW9
9
PARK BRAKE INPUT
SW1
BRAKE SWITCH
2930 BLK
2
1
5
6
C479
SHT5/G1
4
SW1
1420 RED/WHT
SHT2/G1
3600 LBL
SW1
Dealer Copy -- Not for Resale
5
SHT3/E1
3
C499
SHT3/D1
SHT4/E8
SWITCHED POWER
C408
MFR HARN CONN 1 (BLACK)
GATEWAY CTRLR
SW9
TRAVEL CONTROL SWITCH(OPTIONAL)
SHT4/E8
1
C480
LEFT PANEL CONN (GRAY)
1775 RNG/WHT
3620 LBL
SHT10/D3
12
3610 LBL
DOOR SIGNAL
2
PARK BRAKE OUTPUT
9
DESOX INHIBIT
2960 BLK
SHT4/F8
C500
C503
RH DLX PANEL
1590 RNG/WHT
SHT3/D1
1240 RED/WHT
SHT2/H1
2250 BLK
SHT4/F8
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
C503
SHT5/F1
SW12
DESOX INHIBIT SWITCH(OPT KIT)
SHT4/E8
SHT3/E1
SHT3/E1
2065 BLK
1700 RNG/WHT
1705 RNG/WHT
2
4
7
9
10
8
3
8070 TAN
8050 TAN
8055 TAN
8060 TAN
SW12
SW12
4
DPF LAMP
5
DESOX INHIBIT LAMP
1
DPF FORCE REGEN
C480
NOT USED
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
668 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 9 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 9 / 15
7331097
*
1785 RNG/WHT
SHT3/E1
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
2
CAB
1
*
6
2060 BLK
SHT10/D1
5
SW4
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
4
SW4
C438
MFR HARN CONN 3 (DK GRAY)
1850 RNG/WHT
SHT3/F1
7
7
8
8
9
9
2
2
4235 LGN
4275 LGN
4550 LGN
GND
2795 BLK
1850 RNG/WHT
1375 RED/WHT
+12V PWR
1
*
C212
POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK)
1370 RED/WHT
SHT2/B1
7
DOME LIGHT
SP45
1370 RED/WHT
7
1390 RED/WHT
1
* T37
C129
CAB ACCESSORY
1210 RED/WHT
5
2730 BLK
SHT4/E3
5
1865 RNG/WHT
2730 BLK
11 11
C428
MFR HARN CONN 2 (LT GRAY)
2790 BLK
SHT4/E3
14 14
2790 BLK
2690 BRN
2370 BRN
SHT4/H3
4
4
SEATBAR
SENSOR
SP56
GATEWAY CTRLR
SEATBAR SENSOR SIGNAL
SEATBAR/THROTTLE +5V
3370 LBL
11
24
5100 YEL
5
SP13
5370 YEL
3
5
3
GND
A
SIG
B
+5V PWR
C
3370 LBL
5370 YEL
SP52
A
A
+12V BATT PWR
B
B
+12V SW PWR
C
C
GND
2010 BLK
SP41
1
* T38
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SP44
SHT14/B4
2210 BLK
SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
SHT6/E5
2375 BRN
2370 BRN
2800 BLK
2845 BLK
SHT3/D1
SP8
1580 RNG/WHT
Dealer Copy -- Not for Resale
1580 RNG/WHT
3620 LBL
SHT9/D8
1400 RED/WHT
SHT2/G1
2840 BLK
7310 WHT
5375 YEL
C482
1
1
WIPER SWITCH, MOTOR SWITCHED POWER
4
4
DOOR SIGNAL
5
5
DOOR UNSW PWR
2
2
WIPER MOTOR GROUND
3
3
WASHER SIGNAL
J1B
SHT8/D7
5190 YEL
SHT6/E5
5690 YEL
*
HARNESS WASHER PUMP
7253378
C252
B
A
2845 BLK
B
GND
7310 WHT
A
PWR
2
WASHER
MOTOR
1
C253
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
669 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 10 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 10 / 15
7331097
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
RIGHT HANDLE LEFT ROCKER DOWN
RIGHT HANDLE LEFT ROCKER UP
1530 RNG/WHT
SHT3/E3
A
4930 LGN
31
J
4940 LGN
30
H
2195 BRN
SHT4/C3
4320 LGN
D
4300 LGN
C404
BU ALARM-MFR HARN (SEE
ADDITIONAL OPTION DWG)
A
C103
TAILGATE HARN
7100 WHT
A
C
C
SHT4/D8
RIGHT HANDLE RIGHT ROCKER UP
7100 WHT
T19
2650 BLK
1
1
PADDLE
B
4910 LGN
13
LEFT POSITION SWITCH
C
F
4920 LGN
E
BACK UP ALARM
K
T20
RIGHT POSITION SWITCH
TRIGGER
HANDLE LOCK (ACS ONLY)
G
C409
4980 LGN
SIG
TILT SPOOL LOCK
7.8 OHM 12V
1
C421
LIFT SPOOL LOCK GROUND
2990 BRN
2
GND
3
LIFT SPOOL LOCK
7.8 OHM 12V
J1A
4990 LGN
SIG
5
LIFT SPOOL
LOCK SOLENOID
23
J2B
LIFT (ACS/AHC ONLY)
H
HANDLE LOCK (ACS ONLY)
E
FLOAT SIGNAL
4640 LGN
20
D
1520 RNG/WHT
SHT3/E3
LEFT HANDLE RIGHT ROCKER DOWN
J1B
7
LEFT HANDLE
AUX CTRLR
1
C422
TILT SPOOL
LOCK SOLENOID
18
3
RIGHT HANDLE
PWM HIGH
GND
RIGHT HANDLE
PWM SIGNAL
2980 BRN
10
21
TILT SPOOL LOCK GROUND
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
Dealer Copy -- Not for Resale
TILT (ACS/AHC ONLY)
4830 LGN
22
LEFT HANDLE RIGHT ROCKER UP
28
LEFT HANDLE PADDEL RIGHT
11
LEFT HANDLE PADDEL LEFT
12
B
4840 LGN
FLOAT (ACS/AHC ONLY)
A
RIGHT POSTION SWITCH
C
4810 LGN
F
4820 LGN
PADDLE
G
C410
J2A
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
670 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7331097
SCHEM ELEC MAN
Sheet 11 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 11 / 15
7331097
LIGHTS
C434-1
6100 PNK
SIG
A
37 WATT
C408
MFR HARN CONN 1 (BLACK)
2765 BLK
SHT4/F3
9
9
2735 BLK
2765 BLK
GND
2750 BLK
GND
SP14
LEFT FRONT
WORKLIGHT
B
B
50 WATT
SIG
6110 PNK
A
C434-2
C435-1
6000 PNK
8
8
6120 PNK
6000 PNK
SIG
SP15
FRONT WORK LIGHTS
RELAY - RC1
SHT2/E1
1350 RED/WHT
30
37 WATT
C438
MFR HARN CONN 3 (DK GRAY)
6620 PNK
87
SP23
6610 PNK
13 13
GND
2760 BLK
6610 PNK
6130 PNK
SIG
SP64
86
GND
2705 BLK
RC1
30
87
86
6340 PNK
SP10
6310 PNK
A
RC2
2115 BLK
A
2610 BLK
SHT4/D8
GND
2
RIGHT REAR
TAIL LIGHT
C103
TAILGATE HARN
85
RC2
SHT4/B8
Dealer Copy -- Not for Resale
6320 PNK
FRONT WORK LIGHTS
RELAY-RC2
RED/WHT
B
C435-2
2120 BLK
1330
SP49
6310 PNK
6320 PNK
SIG
1
C603
6330 PNK
SIG
1
LEFT REAR
TAIL LIGHT
GATEWAY CTRLR
2640 BLK
SHT4/D8
MRKR LIGHT PWR SIGNAL
5
MRKR LIGHT PWR FEEDBACK
31
REAR LIGHT RELAY SIGNAL
17
REAR LIGHT RELAY FEEDBACK
C604
28
E1
1
RIGHT REAR
WORK LIGHT
FRC1
REAR LIGHT
RELAY - E
6210 PNK
1320 RED/WHT
2620 BLK
SHT4/D8
3440 LBL
6210 PNK
2
C605
30
87
85
86
6200 PNK
E4
H
H
6200 PNK
6220 PNK
2
SP96
LEFT REAR
WORK LIGHT
E2
2630 BLK
SHT4/C8
FRC1
1
FRC1
2045 BLK
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
671 of 1148
2
3460 LBL
E5
SHT4/B8
GND
C602
J1A
SHT2/E1
RIGHT FRONT
WORK LIGHT
A
50 WATT
6630 PNK
SHT2/E1
B
85
RC1
SHT4/A8
A
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 12 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 12 / 15
7331097
HVAC
*
2440 BLK
GND
2
HVAC DUCT FAN
M
7440 WHT
SIG
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
C610
*
2560 BLK
C
7420 WHT
POTENTIOMETER (TEMP
CONTROL SWITCH)
A
7425 WHT
B
C483
*
D
2130 BLK
HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
87
10 10
B4
85
5
B2
86
FRC1
FRC1
GATEWAY CTRLR
HVAC RELAY SIGNAL
3
HVAC RELAY FEEDBACK
30
3050 LBL
2745 BLK
SHT4/F3
11 11
2745 BLK
AC SIGNAL MONITOR
11
7021 WHT
SP40
7020 WHT
12 12
M
SW10
7410 WHT
4
C611
2580 BLK
2100 BLK
2570 BLK
7015 WHT
*
THERMOSTAT
2
3
A
7023 WHT
7025 WHT
7024 WHT
C350
SHT4/C6
SW11
AC SWITCH
SIG
1
D4
B
*
1
C630
AC EVAPORATOR
SWITCH
LOW
3
3
7020 WHT
J1A
2
7510 WHT
SW10
HIGH
MED
7520 WHT
1
SP16
2
1
4
1
SW11
7050 WHT
B5
30
7530 WHT
7400 WHT
B1
1500 RNG/WHT
*
SW10
BLOWER SWITCH
C
SHT2/F1
1500 RNG/WHT
*
Dealer Copy -- Not for Resale
1140 RED/WHT
C438
MFR HARN CONN 3
(DK GRAY)
3
FRC1
HVAC RELAY-B
2290 BLK
MAGNET CLUTCH
(COMPRESSOR)
2280 BLK
GND
2
C486
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
672 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 13 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 13 / 15
7331097
C428
MFR HARN CONN 2 (LT GRAY)
C355
FUEL HARN
#
4470 LGN
1 SIG
POWER BOB
CLOSE
2 GND
SP33
2470 BLK
2770 BLK
E
E
B
B
F
F
4470 LGN
2770 BLK
OPTIONS 1
4470 LGN
11 11
#
4480 LGN
1 SIG
POWER BOB
OPEN
2
GND
SW5
POWER BOBTACH SWITCH
*
SHT4/E6
C607
4480 LGN
4480 LGN
10 10
1380 RED/WHT
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
*
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
2
3
SW5
2480 BLK
#
SW5
C606
6010 PNK
LEFT HANDLE
LIFT (ACS/AHC ONLY)
LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG)
1550 RNG/WHT
SHT3/F1
6010 PNK
13 13
1550 RNG/WHT
12 12
1405 RED/WHT
C438
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY)
1410 RED/WHT
SHT2/C1
1
SP43
1410 RED/WHT
1
SHT15/D6
1430 RED/WHT
X
*
T3
FLASHER
L
1200 RED/WHT
FLOAT (ACS/AHC ONLY)
B
6415 PNK
D
6515 PNK
A
TRIGGER
C103
TAILGATE HARN
C411
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
E
E
D
D
6400 PNK
6
3
3
SHT4/E3
4
2780 BLK
4
*
4450 LGN
A SIG
4455 LGN
5
4455 LGN
5
B
2
3
2450 BLK
GND
1
2455 BLK
4
SHT4/C6
C423
6
5
SW6
LEFT HANDLE
*
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG)
4
6
SHT15/F4
SHT15/D4
6700 PNK
*
2810 BLK
2420 BLK
6440 PNK
SHT4/E8
6540 PNK
AUX CTRLR
*
*
RIGHT SPEAKER
HIGH FLOW SOLENOID GROUND
26
2460 BRN
GND
B
HIGH FLOW
SOLENOID
7.5 OHM 12 V
J2A
HIGH FLOW SOLENOID SIGNAL
PADDLE
26
4460 LGN
SIG
7820 WHT
7830 WHT
C676
RADIO CONN
3
LEFT SPEAKER (+)
4
LEFT SPEAKER (-)
E
E
D
D
F
F
B
B
C
C
A
A
C670
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
A
L010
AIR RIDE SEAT
A
1460 RED/WHT
B
SHT2/C1
7210 WHT
13 13
C126
HORN CONNECTOR
7210 WHT
A
A
TWO SPEED GROUND
_
C412
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
2785 BLK
B
B
GND
PML
CHG NOTICE DWN
SHEET
TWO SPEED SIGNAL
2885 BLK
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
5
RIGHT SPEAKER (+)
GND
1
RADIO SWITCHED POWER
C277
2
RADIO GROUND
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
2210 BLK
5
PWR
GND
C676
2350 BRN
26
4350 LGN
26
GND
2
TWO SPEED
SOLENOID
5.1 OHM 12 V
SIG
1
TRACK 2 SPEED
(SEE ADDITIONAL
OPTIONS DWG)
C441
J1B
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
COPYRIGHT
110295
+
WARNING
RIGHT SPEAKER (-)
J1A
HORN
SHT4/E8
1885 RNG/WHT
GATEWAY CTRLR
SIG
4
6
SHT10/E1
7800 WHT
C278
SHT10/D1
C408
MFR HARN CONN 1
(BLACK)
1510 RNG/WHT
PWR
7810 WHT
1
SHT10/E1
LEFT POSITION SWITCH
SHT10/E1
*
2
C415
J2B
DESCRIPTION
2970 BLK
C279
RIGHT POSTION SWITCH
REV
2725 BLK
2905 BLK
SHT15/F6
1
FLOAT (ACS/AHC ONLY)
673 of 1148
SW2
(PINS 3 & 6
INTERNALLY INSULATED)
2
SEE SHEET 1
6
SP46
2850 BLK
1
SW3
SW3
HANDLE LOCK (ACS ONLY)
0
1
SW2
LEFT SPEAKER
TRIGGER
2
SW3
HAZARD SWITCH
2
SW6
2830 BLK
LIFT (ACS/AHC ONLY)
*
SW2
BEACON SWITCH
6430 PNK
3400 LBL
SW6
BUCKET POSITION SWITCH
D3
BUCKET
POSITION
SOLENOID
9.8 OHM
6530 PNK
D13
6400 PNK
SHT9/G8
2780 BLK
D14
6500 PNK
6510 PNK
6410 PNK
SP22
6
T3
3500 LBL
6570 PNK
PADDLE
6500 PNK
Dealer Copy -- Not for Resale
RIGHT POSTION SWITCH
LEFT POSITION SWITCH
SHT9/F8
SP21
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 14 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 14 / 15
7331097
*
SW7
RIDE CONTROL
C438
MFR HARN CONN 3 (DK GRAY)
AUX CTRLR
RIDE CONTROL SW AUTO
23
RIDE CONTROL RELAY SIGNAL
7
RIDE CONTROL COIL SIGNAL
21
3410 LBL
3410 LBL
14 14
1
SHT4/E8
3480 LBL
SP9
1
3415 LBL
3425 LBL
3435 LBL
3445 LBL
1
L5
RIDE CONTROL
COIL
2
2040 BLK
2020 BLK
SP32
C439
2155 BLK
3475 LBL
16
7
FRC1
REVERSING FAN AUTO SIGNAL
29
8
SHT4/C8
FRC1
C440
SW13
REVERSING FAN
3475 LBL
7
SHT14/D3
3470 LBL
2505 BLK
L2
SHT3/F1
2
C428
MFR HARN CONN 2 (LT GRAY)
REVERSING FAN MANUAL SIGNAL
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1575 RNG/WHT
L1
L4
RIDE CONTROL
COIL
*
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
SW7
SW7
OPTIONS 2
2890 BLK
2
3
2905 BLK
8
*
2970 BLK
2
1
3470 LBL
SHT4/G8
SHT14/D3
6
1555 RNG/WHT
5
SW13
4
SHT3/D1
SW13
C443
REVERSING FAN RETURN SIGNAL
2175 BRN
27
2
REVERSING
FAN COIL
J2A
25
C442
SHT4/C3
RIDE CONTROL PRESSURE SENSOR SIGNAL
RIDE CONTROL SENSOR +5V PWR
2185 BRN
3455 LBL
10
5105 YEL
24
A
C
RIDE CONTROL
PRESSURE SENSOR
B
J2B
*
SW8
SIDELIGHT
1405 RED/WHT
SHT14/G3
2
1
Dealer Copy -- Not for Resale
REVERSING FAN SIGNAL
3485 LBL
SHT14/D3
6
SW8
Wiring Schematic
Standard Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12003
B3GZ12003
B3H112018
B42S11024
B3Z712016 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
674 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
1
*
C672
SIDELIGHT CONN
6710 PNK
2810 BLK
2860 BLK
1
1
2
2
SHT4/E8
SW8
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331097
Printable Version Click Here
SCHEM ELEC MAN
Sheet 15 of 15
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 15 / 15
7331097
CONNECTOR ASSIGNMENTS
CONN
DESCRIPTION
NUM OF
PINS
SHEET
CONN
DESCRIPTION
NUM OF
PINS
SHEET
CONN
DESCRIPTION
NUM OF
PINS
SHEET
C100
C103
C105
C107
C108
C110
C111
C112
FUEL FILTER
TAILGATE
HYD CHARGE PRESSURE
MASS AIR FLOW SENSOR
HYD TEMPERATURE SENDER
ALTERNATOR
MFR-BCT ENG HARN CONN
HYD OIL FILTER SWITCH
2
8
3
6
2
2
3
2
8
6,13,14,16
10
8
10
8
8
10
C434-1
C434-2
C435-1
C435-2
C428
2
2
2
2
8
8
14
14
14
14
14
17,18
17,18
12,15,16
FRC1
FUSE RELAY CENTER
112
4,5,8,10,14,15
C429
C438
LEFT WORKLIGHT 1
LEFT WORKLIGHT 2
RIGHT WORKLIGHT 1
RIGHT WORKLIGHT 2
TILT ACTUATOR
LIFT ACTUATOR
CAB-MFR HARN CONN(DK GRY)
J1A
J1B
J2A
J2B
GATEWAY CONTROLLER
GATEWAY CONTROLLER
AUX CONTROLLER
AUX CONTROLLER
34
26
34
26
5,8,10,11,13,14,15,16
4,6,7,8,10,11,12,13,16
10,13,16
4,5,6,7,10,13,16
C114
C115
C116
C117
C117-1
HAND THROTTLE
FOOT THROTTLE
FOOT THROTTLE INTDM
CAN BUS 2
CAN BUS 2
6
6
3
2
2
8
8
8
7
7
C441
C446
C449
C450
C467
C468
C469
TWO SPEED
HYDRAULIC FAN
LEFT JOYSTICK(CAB HARN)
RIGHT JOYSTICK(CAB HARN)
LIFT PEDAL LOCK
TILT PEDAL LOCK
TILT HANDLE
2
2
4
4
3
3
3
16
10
7
7
17
17
17
J7A
J7B
ENG ECU CONTROLLER(BCT)
ENG ECU CONTROLLER(DSN)
58
96
5,6,7,8
9
SW1
SW2
SW3
SW4
BRAKE SWITCH
BEACON SWITCH
HAZARD SWITCH
HAND/FOOT, H/ISO SWITCH
6
6
6
6
11
16
16
12,14
C118
C126
C129
ENG-CROSSOVER
HORN
CAB ACCESSORY
4
2
3
5
16
12
C470
C471
C472
TILT PEDAL
LIFT PEDAL
LIFT HANDLE
3
3
3
17
17
17
SW5
SW6
POWER BOBTACH SWITCH
BUCKET POSITION SWITCH
6
6
16
16
18
ENGINE CAN (Diagnostic)
8
7
C474
BRAKE LIGHT
1
DOME LIGHT
3
12
C479
LEFT PANEL(BLACK)
12
11
SW9
TRAVEL CONTROL SWITCH
6
11
C212
C252
POWER SOCKET
WASHER
2
2
12
12
C480
C482
LEFT PANEL(GRAY)
SEATBAR SENSOR
12
3
12
15
SW10
SW11
BLOWER SWITCH
AC SWITCH
5
3
15
15
C277
C278
AIR RIDE SEAT
RIGHT SPEAKER
6
2
16
16
C483
C486
TEMP CONTROL SWITCH
AC COMPRESSOR
3
2
15
5,6
SW12
DPF SWITCH
10
11
C279
C308
C350
C355
LEFT SPEAKER
BRAKE SOLENOID
AC EVAPORATOR SWITCH
DLX or STD FUEL HARNESS
2
2
2
6
16
10
15
8,16
C489
C492
C493
C497
MFR ACCESSORY
ACS/SJC/AWS-MFR HARN
ACS/SJC/AWS-MFR HARN
SJC HORN/BLINKER
2
8
4
3
5,6,7,12
4,6
BATT GROUND
BUZZER GROUND
FLASHER
BATT GROUND
1
1
1
1
6
11
16
16
T1
T2
T3
T6
C404
BU ALARM-MFR HARN
2
5,13
C499
PTOL
4
11
T8
BATT GROUND
1
6
C405
AIR FILTER SWITCH
2
8
C500
RH KEY SWITCH
6
11
C406
C408
FUEL SENDER
CAB-MFR HARN CONN(BLK)
2
14
C501
C503
PUMP HARNESS
RH DLX PANEL
8
6
ENGINE SYSTEM GROUND
BUZZER POWER
1
1
6
11
T14
PRE HEATER
1
9
C409
C410
C411
C412
C415
RIGHT HANDLE
LEFT HANDLE
LEFT HANDLE 5 WAY
LEFT HANDLE 2 WAY
HIGH FLOW SOLENOID
10
10
5
2
2
8
4,6,7,11,
12,14,16
13
13
16
16
16
T10
T13
C536
C537
C602
C603
C606
RIGHT SWASH PLATE
LEFT SWASH PLATE
LEFT REAR TAIL LIGHT
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
4
4
2
2
2
T15
T16
T17
T18
RIGHT REAR WORK LIGHT(+)
RIGHT REAR WORK LIGHT(-)
LEFT REAR WORK LIGHT(+)
LEFT REAR WORK LIGHT(-)
1
1
14
14
FRONT ROD
FRONT BASE
HYD LOCK
TILT SPOOL LOCK
LIFT SPOOL LOCK
BUCKET POSITION
BRAKE SOLENOID
2
2
2
3
3
2
3
10
10
10
9
13
16
10
C607
C610
C611
C630
C635
C667
C670
POWER BOBTACH CLOSE
HVAC DUCT FAN
BLOWER MOTOR
THERMOSTAT
HEATER VALVE
DOOR
EXTERIOR BEACON
2
2
4
3
6
6
6
BACKUP ALARM
BACKUP ALARM(GND)
14
14
13
C418
C419
C420
C421
C422
C423
C425
T19
T20
T32
1
1
1
1
1
13
6
C676
RADIO
6
C426
CAN(Remote Start Tool, ACD)
7
7
C428
C404
CAB-MFR HARN CONN(LT GRY)
Back-up Alarm
14
2
5,6,8,12,16
18
Dealer Copy -- Not for Resale
C169
C209
18
7,11
18
18
14
14
16
16
15
15
15
15
12
16
ECU CASE GROUND
6
16
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 1 of 18
Printed In U.S.A.
675 of 1148
(PRINTED FEBRUARY 2015)
7228618 (A)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
FUNCTION
HYDRAULIC LOCK RETURN
LIFT SPOOL LOCK RETURN
FUEL PULL RELAY
SWITCHED POWER OUT RELAY
LIGHT 1 RELAY
GLOW PLUG RELAY
STARTER RELAY
TRACTION PULL RELAY
TILT SPOOL LOCK RETURN
AC SENSE
SPARE DIGITAL, ECU SOURCES
TRACTION PULL RELAY FDBK
GLOW PLUG RELAY FDBK
ENGINE SPEED
AIR FILTER SWITCH
REAR LIGHT 2 RELAY
FAN 2 RETURN
PTOL LED
PTOL SWITCH
SWITCHED POWER OUT RELAY FDBK
STATER RELAY FDBK
START ENGINE
WATER IN FUEL
TWO SPEED RETURN
TWO SPEED MAKE-UP RETURN
REAR LIGHT 2 RELAY FDBK
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
HYD CHARGE PRESS
UNSW BATT
UNSW BATT
FUEL HOLD
LIFT SPOOL LOCK
TRACTION LOCK HOLD
TILT SPOOL LOCK
CAN LO 1
CAN HI 1
SEAT BAR
FUEL LEVEL
BICS HYD LOCK HOLD
CAN HI 2
GROUND P1
GROUND P2
GROUND P3, SENSOR
FAN 2 OUTPUT
CAN LO 2
REMOTE RUN KEY
RUN/ENTER
SENSOR SUPPLY 8V
SENSOR SUPPLY 5V
TWO SPEED MAKEUP
TWO SPEED COIL
FUEL PULL RELAY FDBK
FRONT WORK LIGHT 1 RELAY FDBK
HYD OIL TEMP (8 VOLT)
HYD OIL FILTER SW1
MFR CTRL
DLX CAB
STD CAB
STD FUEL
DLX FUEL
BCT ENG START
ENGINE
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
BRAKE ADAPTER
WHL 2 SPD ADP
TRACK 2 SPD
ACS
SJC
HARNESS PART NUMBER
FOR 400 MODEL
FOR 500 MODELS
7220815
7228632
7235319
7234736
7227905
7227905
7200449
7149219
7200460
7220812
7030824
7217484
7217483
7163706
7124853
7159366
7184255
7220812
7030824
7217484
7217483
7163706
7165061
7159366
7222766
7200463 Wheel
7236542 Track
7190593
7210505 Wheel
7210505 Track
Dealer Copy -- Not for Resale
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
FUNCTION
PIN
FUNCTION
FRONT AUX (F) RETURN
B-1
REAR AUX (F) RETURN
B-2
UNSW BATT
LEFT BLINKER RELAY
B-3
UNSW BATT
B-4
RIGHT BLINKER RELAY
DIVERTED SOLENOID
B-5
HORN RELAY
REAR AUX (F)
B-6
RELIEF SOLENOID
B-7
REAR AUX (M)
B-8
CAN LO 1
B-9
CAN HI 1
REAR AUX (M) RETURN
B-10
B-11
B-12
B-13
FRONT AUX (F)
B-14
B-15
GROUND
B-16
GROUND
B-17
FRONT AUX (M) RETURN
B-18
B-19
FRONT AUX (M)
B-20
B-21
B-22
SWITCHED POWER
B-23
B-24
B-25
HYDRAULIC BOOST
HIGH FLOW RETURN
B-26
HIGH FLOW
HYDRAULIC BOOST RETURN
FOR 600 MODELS
7228718
7234736
7227905
7149219
7184255
7220812
7030824
7217484
7217483
7163706
7165061
7159366
7214626
7164144
7210503 Wheel
7210504 Track
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 2 of 18
676 of 1148
Printed In U.S.A.
(PRINTED FEBRUARY 2015)
7228618 (A)
ENGINE CONTROLLER
1
CONNECTOR J7
FUNCTION
SW POWER
2
GND
3
SW POWER
4
GND
5
SW POWER
6
GND
9
WATER FUEL SENSOR
13
PEDAL POS 2
14
PEDAL POS 2
15
AIR MASS FLOW SENSOR
19
IGN SW INPUT
21
AIR MASS FLOW SENSOR
24
PEDAL POS 1
25
PEDAL POS 1
26
PEDAL POS 1
28
AIR MASS FLOW SENSOR
29
PEDAL POS 2
33
AIR MASS FLOW SENSOR
34
WATER FUEL SENSOR
45
SW POWER SIGNAL
47
CAN 1 HI
48
CAN 1 LOW
56
GLOW PLUG SIGNAL
Dealer Copy -- Not for Resale
PIN
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 3 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
677 of 1148
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
CONTROLLER GROUND/RETURN
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
LIGHTS
OTHER FUNCTIONS
ENGINE
COMMUNICATION
COMMUNICATION
M
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
6000 THROUGH 6999
7000 THROUGH 7999
8000 THROUGH 8999
9000 THROUGH 9999
9000 THROUGH 9999
WIRE COLOR
COLOR CODE
RED
RED
RED/WHITE
RED/WHT
ORANGE/WHITE
RNG/WHT
BLACK
BLK
BRN
BROWN
LIGHT BLUE
LBL
LIGHT GREEN
LGN
YELLOW
YEL
PINK
PNK
WHITE
WHT
TAN
TAN
PURPLE
PUR
PURPLE/WHITE
PUR/WHT
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
LEGEND
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
PARTIAL CONNECTOR
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
1240 RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1450 RED/WHT
6
1110 RED/WHT
1130 RED/WHT
2
3
1400 RED/WHT
1450 RED/WHT
FRC1 FUSE RELAY CENTER
+12V
BATTERY
1025 RED
MEGAFUSE
100.0 Amps
1270 RED
1280 RED
FUSE 13 25 A
FUSE 15 25A
FUSE 17 25 A
1420 RED/WHT
1120 RED/WHT
1160 RED/WHT
1170 RED/WHT
1235 RED/WHT
SHEET 8
STARTER
FUSE 4 25 A
1010 RED
1140 RED/WHT
FUSE 3 30 A
1310 RED
1340 RED
1360 RED/WHT
FUSE 1 15 A
1320 RED/WHT
FUSE 2 20 A
1350 RED/WHT
1330 RED/WHT
1060 RED
1335 RED
1325 RED
SP1
1300 RED
FUSE 9 50 A
FUSE 20 5 A
FUSE 16 25 A
1065 RED/WHT
1345 RED/WHT
1035 RED/WHT
1445 RED/WHT
1190 RED
1040 RED
1290 RED
1055 RED
SP60
1050 RED
1030 RED
FUSE 18 25 A
FUSE 22 25 A
FUSE 24 15 A
1165 RED/WHT
1490 RED/WHT
1370 RED/WHT
J1B
GWY CTRLR
1150 RED/WHT
3
1180 RED/WHT
2
1440 RED/WHT
SHEET 11
C503 RH DLX PANEL
SHEET 12
C667 DOOR HARNESS
SHEET 11
C500 RH KEY SWITCH
SHEET 11
C479 LH PANEL
J2B
AUX CTRLR
1
Dealer Copy -- Not for Resale
1070 RED
FUSE 11 25 A
UNSWITCHED
BATT POWER
2
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
SHEET 15
FRC1 HVAC RELAY
SHEET 10
FRC 1 TRACTION LOCK RELAY
SHEET 14
FRC1 REAR LIGHT RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 14
FRC1 FRONT LIGHT RELAY
SHEET 14
FRC1 FRONT LIGHT RELAY
SHEET 5
FRC1 ENGINE ECU RELAY
SHEET 5
FRC 1 ENGINE ECU RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 7
C426 REMOTE RUN, ACD
1460 RED/WHT
1410 RED/WHT
SHEET 16 C412 LH HANDLE HORN
SHEET 16 C408 CAB-MFR CONN
(OPTIONS)
SHEET 12
C408 CAB-MFR CONN
(ACCESSORIES)
SHEET 5
FRC1 SWITCHED PWR RELAY
SHEET 8
FRC1 STARTER RELAY
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 4 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
678 of 1148
Printed In U.S.A.
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
CONTROLLER GROUND/RETURN
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
LIGHTS
OTHER FUNCTIONS
ENGINE
COMMUNICATION
COMMUNICATION
SHEET 4
M
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
6000 THROUGH 6999
7000 THROUGH 7999
8000 THROUGH 8999
9000 THROUGH 9999
9000 THROUGH 9999
1035 RED/WHT
+12V
PWR
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
WIRE COLOR
COLOR CODE
RED
RED
RED/WHITE
RED/WHT
ORANGE/WHITE
RNG/WHT
BLACK
BLK
BROWN
BRN
LIGHT BLUE
LBL
LIGHT GREEN
LGN
YELLOW
YEL
PINK
PNK
WHITE
WHT
TAN
TAN
PURPLE
PUR
PURPLE/WHITE
PUR/WHT
LEGEND
SWITCHED
POWER
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
FRC1
ENGINE ECU
RELAY
1505 RNG/WHT
1506 RNG/WHT
30
1504 RNG/WHT
87
85
86
SP54
1509 RNG/WHT
J7A ENGINE ECU
SHEET ?
8
MASS AIR FLOW SENSOR
1
1507 RNG/WHT
3
1508 RNG/WHT
5
45
8005 TAN
C118
ENG-CROSSOVER
FRC1 FUSE RELAY CENTER
Dealer Copy -- Not for Resale
SHEET 4
1345 RED/WHT
FUSE 21 15 A
1720 RNG/WHT
FUSE 5 25 A
1760 RNG/WHT
1790 RNG/WHT
FUSE 6 25 A
FUSE 12 15 A
SP50
1750 RNG/WHT
1780 RNG/WHT
1850 RNG/WHT
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
A
C489
MFR ACCESSORY
1550 RNG/WHT
1700 RNG/WHT
1705 RNG/WHT
SHEET 16 C408 CAB-MFR CONN (BKT POSITION)
1530 RNG/WHT
1805 RNG/WHT
B
SHEET 12 C408 CAB-MFR CONN (FR WIPER)
1520 RNG/WHT
FUSE 14 5 A
SP11
1570 RNG/WHT
1560 RNG/WHT
SHEET 13 C410 LEFT HANDLE
SHEET 13 C409 RIGHT HANDLE
22
C428
J2B
(LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
2
1660 RNG/WHT
1765 RNG/WHT
1795 RNG/WHT
FUSE 7 25 A
1730 RNG/WHT
SP65 1735 RNG/WHT
1725 RNG/WHT
FUSE 8 25 A
FRC1
SWITCHED
POWER RELAY
SHEET 4
SHEET 6
1050 RED
+12V
PWR 30
87
2055 BLK
GND 85
86
1815 RNG/WHT
3450 LBL
21
3380 LBL
4
J1A
GWY CTRLR
6
1580 RNG/WHT
1800 RNG/WHT
9
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
1920 RNG/WHT
1660 RNG/WHT
1620 RNG/WHT
1940 RNG/WHT
1930 RNG/WHT
1775 RNG/WHT
1960 RNG/WHT
1785 RNG/WHT
1950 RNG/WHT
1590 RNG/WHT
SHEET 11 SW12 DPF SWITCH
SHEET 11 SW12 DPF SWITCH
SHEET 11 C479 LH PANEL
SHEET 11 T13 LH PANEL BUZZER
SHEET 11 C499 RH PANEL PTOL
SHEET 11 SW1 BRAKE SWITCH
SHEET 11 SW9 TRAVEL CONTROL SWITCH
SHEET 12 SW4 H/ISO SWITCH
SHEET 11 C500 RH PANEL KEY SWITCH
SHEET 11 C503 RH DELUXE PANEL
SHEET 7 C426 REMOTE RUN, ACD
SHEET 7 C169 ENGINE CAN
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 8 C110 ALT EXCITATION
C428
(LT GRAY)
CAB-MFR HARN CONN 2
1920 RNG/WHT
1740 RNG/WHT
FUSE 23 15 A
B
1511 RNG/WHT
1840 RNG/WHT
1830 RNG/WHT
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 5 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
Printed
679 of
1148
In U.S.A.
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
PINK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
TAN
ENGINE
8000 THROUGH 8999
COMMUNICATION
9000 THROUGH 9999
PURPLE
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
J7A
ENG ECU CTRLR
4
6
T32
ECU CASE GND
SHEET 8
C107 MAF SENSOR
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
SHEET 11
C479 LH PANEL
SHEET 11
C499 PTOL
SHEET 11
C500 RH PANEL KEY SWITCH
SHEET 11
C503 RH DELUXE PANEL
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
2810 BLK
SP53
2004 BLK
2832 BLK
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
2080 BLK
2070 BLK
2920 BLK
2940 BLK
3
2235 BLK
4
2240 BLK
C408
(BLACK)
CAB-MFR HARN CONN 1
2950 BLK
10
2950 BLK
2960 BLK
16
2250 BLK
J1B
GWY CTRLR 15
C428
(LT GRAY)
CAB-MFR HARN CONN 2
2900 BLK
2510 BLK
2500 BLK
16
2540 BLK
J2B
15
AUX CTRLR
2550 BLK
1
2900 BLK
SHEET 16
C355 FUEL HARN (PWR BOB/AC)
SHEET 10
C425 BRAKE
C103
TAILGATE HARN
2600 BLK
C489
MFR ACCESSORY
B
2630 BLK
SHEET 14
FRC1 FRONT LIGHT RELAY
B
2770 BLK
2200 BLK
2120 BLK
SHEET 10
C112 HYD OIL FILTER SWITCH
2320 BRN
2370 BRN
SHEET 12
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN
SHEET 10
C108 HYD TEMP SENDER
2190 BRN
SHEET 10
C105 HYD CHG PRESSURE SENDER
2180 BRN
SHEET 8
C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 8
C405 AIR FILTER SWITCH
2690 BRN
SHEET 8
C408 CAB-MFR CONN (HAND THRTL)
2695 BRN
SHEET 8
C115 FOOT THROTTLE
J1B
GWY CTRLR
2230 BRN
17
2765 BLK
SHEET 14
C408 CAB-MFR CONN (FR LIGHTS)
2745 BLK
SHEET 15
C408 CAB-MFR CONN (HVAC)
2790 BLK
SHEET 12
C408 CAB-MFR CONN (ACCESSORIES)
2780 BLK
SHEET 16
C408 CAB-MFR CONN (OPTIONS)
2730 BLK
SHEET 12
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2110 BLK
2090 BLK
T8
BATT GND
2720 BLK
2455 BLK
SHEET 16
C423 BKT POSITION SOLENOID
2710 BLK
SHEET 7
C426 REMOTE RUN, ACD
2715 BLK
SHEET 7
C169 ENGINE CAN
2290 BLK
SHEET 15
D4 COMPRESSOR DIODE
SP55
GROUND
T6
BATT GND
2600 BLK
FRC1 STARTER RELAY
Printed In U.S.A.
CONNECTOR
2003 BLK
2045 BLK
SHEET 14
FRC1 REAR LIGHT RELAY
2035 BLK
SHEET 10
FRC1 TRACTION LOCK RELAY
2115 BLK
SHEET 14
FRC1 FRONT LIGHT RELAY
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY
2030 BLK
SHEET 15
FRC1 HVAC RELAY
2005 BLK
SHEET 8
680 of 1148
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
2001 BLK
2002 BLK
2065 BLK
SHEET 11
SW12 DPF SWITCH
2930 BLK
SHEET 11
SW1 BRAKE SWITCH
2830 BLK
SHEET 16
SW6 BKT POSITION SWITCH
2700 BLK
SHEET 11
SW9 TRAVEL CONTROL SWITCH
2785 BLK
SHEET 16
C126 HORN
2620 BLK
SHEET 14
T16 RH REAR LIGHT
2650 BLK
SHEET 13
T20 BU ALARM
2640 BLK
SHEET 14
C602 LH REAR LIGHT
2610 BLK
SHEET 14
C603 RH REAR LIGHT
SHEET 14
T18 LH REAR LIGHT
COLOR CODE
RED
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
YEL
PNK
WHT
TAN
PUR
PUR/WHT
PARTIAL CONNECTOR
Dealer Copy -- Not for Resale
2
SCHEMATIC INDEX
2105 BLK
2520 BLK
SHEET 13
C410 LEFT HANDLE
2530 BLK
SHEET 13
C409 RIGHT HANDLE
2390 BLK
T1
BATT GND
SHEET 8
ALTERNATOR GROUND
2015 BLK
T10
ENGINE
GROUND
2300 BLK
SP27
SP5
2000 BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 6 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
LEGEND
SCHEMATIC INDEX
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
BATT FEED, GENERAL
1000 THROUGH 1499
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
LIGHT GREEN
4000 THROUGH 4999
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
ENGINE
8000 THROUGH 8999
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
COLOR CODE
RED
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
YEL
PNK
WHT
TAN
PUR
PUR/WHT
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
CAN BUS
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
J1B
GWY CTRLR
J7A
ECU CNTRLR
47
CAN LO
48
CAN HI
9200 PUR
9100 PUR/WHT
9215 PUR
9115 PUR/WHT
SP90
SP91
9210 PUR
9110 PUR/WHT
120 OHM
0.5 W
RESISTOR
120 OHM
0.5W
RESISTOR
C117
CAN BUS 2
CAN HI
CAN LO
53
54
9700 PUR/WHT
9800 PUR
SP83
SP84
20
14
9205 PUR
9105 PUR/WHT
1
2
9705 PUR/WHT
9805 PUR
C169
ENGINE CAN
SHEET 5
SHEET 6
(FOR DEVELOPMENT
DIAGNOSTICS ONLY)
1725 RNG/WHT
2715 BLK
3
4
9155 PUR/WHT
9255 PUR
5
6
8
9
9260 PUR
9160 PUR/WHT
9230 PUR
9130 PUR/WHT
120 OHM
O.5W
RESISTOR
Dealer Copy -- Not for Resale
9710 PUR/WHT
9810 PUR
J1B
GWY CTRLR
7
8
C408
(BLACK)
CAB-MFR HARN CONN 1
9250 PUR
9220 PUR
SP31
SP79 9270 PUR SP19
9150 PUR/WHT
9120 PUR/WHT
9170 PUR/WHT SP20
SP30
SP80
4
3
9220 PUR
9120 PUR/WHT
9430 PUR
9410 PUR
9310 PUR/WHT 9330 PUR/WHT
CAN LO
9500 PUR/WHT
A
9600 PUR
B
3090 LBL
D
C
E
F
G
9280 PUR
9180 PUR/WHT
SHEET 5
SHEET 4
SHEET 6
1735 RNG/WHT
1165 RED/WHT
2710 BLK
7
8
SHEET 5
SHEET 6
9320 PUR/WHT
9420 PUR
C503
RIGHT DELUXE PANEL
1
4
SHEET 5
SHEET 6
1830 RNG/WHT
2070 BLK
1
2
3
4
C450
RIGHT JOYSTICK
SHEET 10
1840 RNG/WHT
2080 BLK
1
2
3
4
C449
LEFT JOYSTICK
SHEET 10
8
9
REMOTE RUN KEY
SWITCHED POWER
Printable Version Click Here
UNSWITCHED POWER
GROUND
Sheet 7 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
681 of 1148
4
2
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
J1B
GWY CTRLR
21
C479
LEFT PANEL (BLACK)
J2B
AUX CTRLR
C426
Remote Run Tool, ACD
20
4
3
120 OHM
0.5 W
RESISTOR
9300 PUR/WHT
9400 PUR
14
9460 PUR
9360 PUR/WHT
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
9240 PUR
9140 PUR/WHT
CAN HI
9450 PUR
9350 PUR/WHT
9440 PUR
9340 PUR/WHT
9290 PUR
9190 PUR/WHT
J2B
AUX CTRLR
1
2
LEGEND
SCHEMATIC INDEX
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
RED
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
1030 RED
2005 BLK
SHEET 6
7
8210 TAN
22
3560 LBL
C111
MFR-BCT HARN CONN
+12V STARTER RELAY
PWR 30
STARTER
8200 TAN
87
GND
85
86
8210 TAN
3560 LBL
1800 RNG/WHT
SHEET 5
FUSE 12
A
B
C
8220 TAN
3560 LBL
S
R
M
B
SHEET 4
1015 RED
C110
B
ALTERNATOR
J1A
GWY CTRLR
G
S
L
C405
GND
33
SHEET 6
C115
FOOT THROTTLE
5695 YEL
C
5695 YEL
3695 LBL
2695 BRN
A
3695 LBL
B
2695 BRN
C
A
B
E
D
F
FOOT THROTTLE
ADAPTER HARNESS
7217683
J1B
GWY CTRLR
C355
FUEL HARN
3180 LBL
2180 BRN
12
10
3690 LBL
4
8007 TAN
J7A
ENG ECU CTRLR
+5V PWR
SIG
GND
C406
C
D
A
B
3180 LBL
2180 BRN
SHEET 6
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 12
2015 BLK
SHEET 6
ENGINE GROUND TERMINAL
AIR FILTER
SWITCH (NC)
SIG
C116
FOOT THROTTLE INTDM
SHEET 12
1020 RED
1800 RNG/WHT
EXCITATION
B
A
Dealer Copy -- Not for Resale
2150 BRN
3150 LBL
SHEET 6
16
19
LOADER SIDE
SHEET #
FRC1
SHEET 4
ENGINE
SIG
GND
FUEL SENDER
(30 - 270 OHM)
C114
HAND THROTTLE
5690 YEL
7
5690 YEL
C
3690 LBL
6
3690 LBL
A
2690 BRN
8
2690 BRN
B
SHEET 6
+5V PWR
SIG
GND
D
E
F
8007 TAN
C100
9
34
1
2
3865 LBL
2865 BRN
SIG
GND
WATER IN FUEL SENSOR
(FUEL FILTER)
56
28
8013 TAN
35
8014 TAN
SHEET 4
1065 RED/WHT
+12V
PWR
8510 TAN
PREHEATER
RELAY
30
85
87
8500 TAN
86
1445 RED/WHT
SHEET 4
SHEET 5
SHEET 6
682 of 1148
Printed In U.S.A.
C107
MASS AIR FLOW SENSOR
3 +12V SW PWR
1505 RNG/WHT
2832 BLK
4
8013 TAN
5
8014 TAN
2
1
6
GND
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 8 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
WHITE
OTHER FUNCTIONS
7000 THROUGH 7999
ENGINE
8000 THROUGH 8999
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
T14
PRE HEATER
PRE HEATER
SCHEMATIC INDEX
COLOR CODE
RED
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
YEL
PNK
WHT
TAN
PUR
PUR/WHT
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
ENGINE
HARNESS
SHEET #
179
J7B
105
ENGINE ECU CONTROLLER
122
(ENGINE HARNESS)
186
C131
C152
5V
161
2
GND
167
3
SIG
112
123
SENSOR RETURN 2
107
1
EGR VREF3
164
5
POSITION SIGNAL
116
194
TEMP SENSOR 4
3
POSITION RETURN
172
169
SENSOR RETURN 4
6
H BRIDGE POS
192
2
H BRIDGE NEG
193
C133
144
171
C149
184
1
COOLANT TEMP SENSOR
109
2
COOLANT RETURN
145
1
FUEL TEMP SENSOR
110
FUEL TEMP
SENSOR
115
2
FUEL RETURN
146
185
C147
ENGINE BLOCK
ACCELEROMETER 1
1
2
183
163
170
C148
INTAKE
MANIFOLD
TEMP SENSOR
166
108
114
COOLANT TEMP
SENSOR
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
124
C151
EGR VALVE
DC MOTOR
TEMP SENSOR 2
Dealer Copy -- Not for Resale
MAP
1
106
GLOW PLUG RELAY DRIVER
165
VREF3 OIL PRESSURE
OIL PRESSURE SENSOR
SENSOR SIGNAL
131
111
SENSOR RETURN
SHIELD
130
128
148
104
C136 SHEET ?
OIL PRESSURE &
TEMPERATURE
SENSOR
RETURN GND
OIL TEMPERATURE SENSOR
C146
1
ENGINE BLOCK
ACCELEROMETER 2
2
SENSOR SIGNAL
SENSOR RETURN
SHIELD
132
133
129
156
157
154
C145
CRANK SENSOR POS
160
CRANK SENSOR NEG
136
1
SENSOR RETURN
147
2
POS SENSOR
159
3
VREF1 CAM
140
CRANKSHAFT
POSITION
SENSOR
155
182
C144
CAM SHAFT
SENSOR
RAIL PRESSURE
SENSOR
RAIL PRESSURE SENSOR
135
2
SENSOR RETURN
119
3
VREF 1 SENSOR
138
C141
CYL 3
FUEL INJECTOR HSDB
151
FUEL INJECTOR LSD1B
175
FUEL INJECTOR HSDA
103
FUEL INJECTOR LSD2A
125
C142
CYL 4
112
INTAKE PRESS SENSOR
A
167
INTAKE PRESS RETURN
D
134
C143
1
C138
141
168
C139
127
FUEL INJECTOR HSDA
126
FUEL INJECTOR LSD1A
150
FUEL INJECTOR HSDB
174
FUEL INJECTOR LSD2B
CYL 1
C140
CYL 2
PWM
2
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
C154
177
1
683 of 1148
INLET TEMP
PRESSURE
SENSOR
INLET METERING
VALVE
Sheet 9 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
1360 RED/WHT
SHEET 4
2035 BLK
SHEET 6
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
FRC1
TRACTION LOCK
RELAY
+12V
PWR 30
87
GND
85
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
PARTIAL CONNECTOR
HYDRAULICS
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
C425
4100 LGN
SHEET 6
86
4200 LGN
2200 BLK
B
A
C
C308
4200 LGN
2200 BLK
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS SHEET)
8
4110 LGN
13
3430 LBL
SHEET 6
32
C108
2220 BRN
3220 LBL
B
A
GND
SIG
C112
J1A
GWY CTRLR
34
SHEET 6
3320 LBL
2320 BRN
A
B
SIG
GND
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
(8 VOLT)
HYDRAULIC OIL
FILTER SWITCH (NC)
C446
18
2910 BRN
4010 LGN
1
2410 BRN
4410 LGN
2
1
GND
SIG
HYDRAULIC
FAN SOLENOID
7.2 OHM 12 V
C420
B
A
GND
SIG
Dealer Copy -- Not for Resale
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
HYDRAULIC LOCK
SOLENOID
9.8 OHM 12 V
C105
SHEET 6
2190 BRN
3190 LBL
5190 YEL
B
GND
C
SIG
A +8V PWR
4200 LGN
19 13
HYDRAULIC
CHARGE
PRESSURE
0.5-7.5V
1 23 6
+8V
J1B
GWY CTRLR
C418
J2A
AUX CTRLR
18
2330 BRN
4330 LGN
1
2340 BRN
4340 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
3.3 OHM PWM
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
C419
19 13
J2B
AUX CTRLR
Printed
684 of 1148
In U.S.A.
2
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 10 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
1940 RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
CAB DISPLAY
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
C499
Press To Operate Loader
(PTOL)
C479
LEFT PANEL (BLACK)
SHEET 5
SHEET 6
1960 RNG/WHT
SHEET 4
SW9
TRAVEL CONTROL
SWITCH (OPTIONAL)
2700 BLK
CONNECTOR
LEFT PANEL
BUZZER
T2
BUZZER (-)
SHEET 6
PARTIAL CONNECTOR
T13
BUZZER (+)
7040 WHT
SHEET 5
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
SHEET 5
SHEET 16
5 6
4
2 3
1
SHEET 5
SHEET 6
SHEET 16
3610 LBL
1775 RNG/WHT
2930 BLK
3
1
4
7040 WHT
10
2920 BLK
2
1440 RED/WHT
1
1620 RNG/WHT
5
3400 LBL
11
3500 LBL
8
3650 LBL
7
3600 LBL
9
6
SW1
2 BRAKE SWITCH
UNSWITCHED POWER
SWITCHED POWER
LEFT BLINKER INPUT
RIGHT BLINKER INPUT
TRAVEL CONTROL INPUT
PARK BRAKE INPUT
5
6
C480
LEFT PANEL (GRAY)
SHEET 5
1700 RNG/WHT
7 9
8050 TAN
12
11
10
3
2
8
7
6
4
SHEET 5
1705 RNG/WHT 10 8
8055 TAN
5
SHEET 12
3610 LBL
SW12
DIESEL PARTICULATE
FILTER SWITCH
SHEET 6
GROUND
12
3620 LBL
2065 BLK
2
3
1
5
4
6
8060 TAN
1
8070 TAN
9
C408
SHEET 6
(BLACK)
CAB-MFR HARN CONN 1
BUZZER
DOOR SIGNAL
Dealer Copy -- Not for Resale
SHEET 5
LEGEND
SCHEMATIC INDEX
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
WHITE
WHT
OTHER FUNCTIONS
7000 THROUGH 7999
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
1930 RNG/WHT
2940 BLK
1
3
20
3030 LBL
1
3030 LBL
2
19
2380 BRN
12
2380 BRN
4
J1A
GWY CTRLR
SWITCHED POWER
GROUND
PTOL OUTPUT
PTOL LED
C500
RIGHT PANEL - KEY SWITCH
24
2
8130 TAN
8130 TAN
2
START
6
J1B
GWY CTRLR
22
3040 LBL
14
3040 LBL
SHEET 5
SHEET 4
SHEET 6
1950 RNG/WHT
1420 RED/WHT
2960 BLK
4
5
1
3
RUN/ENTER SWITCH
SWITCHED POWER
UNSWITCHED POWE
GROUND
PARK BRAKE OUTPUT
C503
RIGHT PANEL DELUXE DISPLAY
DPF LAMP
DPF INHIBIT LAMP
SHEET 5
SHEET 4
DPF FORCE REGEN
SHEET 6
1590 RNG/WHT
5
1240 RED/WHT
1
2250 BLK
3
DPF INHIBIT REGEN
6
SWITCHED POWER
UNSWITCHED POW
GROUND
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 11 of 18
Printed In U.S.A.
685 of 1148
(PRINTED FEBRUARY 2015)
7228618 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
RED
RED
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
RNG/WHT
1500 THROUGH 1999
ORANGE/WHITE
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
SHEET 5
C492
ACS/SJC/AWS-MFR HARN
SHEET 13
(8 PIN)
SHEET 13
5
4230 LGN
C438
SHEET 12
(DK GRAY)
CAB-MFR HARN CONN 3
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CAB
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
*
SHEET #
*
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT
2 1
3
6
2060 BLK
5
4
4240 LGN
4220 LGN
3
4275 LGN
2
4550 LGN
SHEET 5
4235 LGN
1850 RNG/WHT
7
4235 LGN
8
4275 LGN
9
4550 LGN
2
1850 RNG/WHT
*
C212
POWER
SOCKET
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 4
1370 RED/WHT
7
1370 RED/WHT
C129
CAB ACCESSORY
SHEET 5
1580 RNG/WHT
5
1210 RED/WHT
1865 RNG/WHT
2800 BLK
1580 RNG/WHT
1510 RNG/WHT
1885 RNG/WHT
SHEET 6
2730 BLK
11
2730 BLK
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 6
2790 BLK
14
A
B
C
Dealer Copy -- Not for Resale
2795 BLK
1375 RED/WHT
*
2010 BLK
1390 RED/WHT
GND
SHEET 6
11
+5V
24
5100 YEL
SHEET 8
SHEET 8
SEATBAR
GND SENSOR
2370 BRN
4
2370 BRN
A
3370 LBL
5
3370 LBL
B
SIG
3
5370 YEL
C
+5V PWR
5370 YEL
GND
+12V PWR
C209
B
GND
A +12V PWR
C LBL
3640
DOOR SIG
DOME
LIGHT
SHEET 16
SHEET 16
2210 BLK
SHEET 16
2885 BLK
2060 BLK
SHEET 16
SHEET 12
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
2790 BLK
C482
1
2
+12V BATT PWR
+12V SW PWR
3620 LBL
1400 RED/WHT
SHEET 11
SHEET 4
J1B
GWY CTRLR
DLX CAB HARN 7207730 AND
7208877(SF) ONLY
(NOT IN STD CAB HARN)
*
5690 YEL
5695 YEL
2845 BLK
1850 RNG/WHT
3630 LBL
1
4
5
6
2840 BLK
2
7310 WHT
3
WIPER SWITCH, MOTOR SWITCHED POWER
DOOR SIGNAL
DOOR UNSW PWR
WIPER MOTOR GROUND
WASHER SIGNAL
C252
L
SIG
X
GND
WASHER
MOTOR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 12 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
686 of 1148
Printed In U S A
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
PARTIAL CONNECTOR
MANUAL
CONTROLS
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
A
C103
TAILGATE HARN
C
7100 WHT
SHEET 6
T19 TERMINAL (+)
7100 WHT
BACK UP
ALARM
2650 BLK
T20 TERMINAL (-)
C421
2980 BRN
4980 LGN
10
J1A
GWY CTRLR
3
1
2
GND
SIG
TILT SPOOL LOCK
7.8 OHM 12V
C422
2990 BRN
4990 LGN
2
3
1
2
GND
SIG
LIFT SPOOL LOCK
7.8 OHM 12V
Dealer Copy -- Not for Resale
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
SHEET 6
AUX CTRLR SHEET 12
30
31
SHEET 5
13
J2B
AUX CTRLR
20
28
22
12
11
SHEET 5
K
G
A
H
J
E
F
C
D
B
4640 LGN
4840 LGN
4830 LGN
4820 LGN
4810 LGN
1520 RNG/WHT
4240 LGN
2520 BLK
K
D
C
B
G
F
A
J
H
E
TWO SPD
PWM
SKI CTRL
SIDE SHIFT
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 13 of 18
Printed In U.S.A.
DETENT FLOW
5
J1B
GWY CTRLR
687 of 1148
SKI CTRL
C410
LEFT HANDLE
(MANUAL/ACS ONLY)
21 17 18 23
SHEET 12
SHEET 6
7
2530 BLK
4230 LGN
1530 RNG/WHT
4940 LGN
4930 LGN
4920 LGN
4910 LGN
4310 LGN
4320 LGN
4300 LGN
(PRINTED FEBRUARY 2015)
7228618 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
BATT FEED, GENERAL
1000 THROUGH 1499
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
PINK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
ENGINE
8000 THROUGH 8999
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
COLOR CODE
RED
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
YEL
PNK
WHT
TAN
PUR
PUR/WHT
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
LIGHTS
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
C434-1
2735 BLK
6100 PNK
C408
(BLACK)
CAB-MFR HARN CONN 1
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
37.00 Watts
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
50.00 Watts
C434-2
SHEET 6
2765 BLK
9
2765 BLK
2750 BLK
6110 PNK
6000 PNK
8
6000 PNK
6120 PNK
2760 BLK
B
A
C435-1
FRC1
FRONT WORK
LIGHT RELAY
SHEET 6
1350 RED/WHT
30
2120 BLK
85
87
6610 PNK
86
1330 RED/WHT
SHEET 4
30
87
2115 BLK
SHEET 6
J1A
GWY CTRLR
+12V
PWR
5
31
17
28
GND 85
86
6320 PNK
3460 LBL
6210 PNK
3440 LBL
13
6630 PNK
FRC1
FRONT WORK
LIGHTS RELAY
Dealer Copy -- Not for Resale
SHEET 4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
6340 PNK
C435-2
6130 PNK
2705 BLK
6610 PNK
A
C603
SHEET 6
6310 PNK
SHEET 4
SHEET 6
1320 RED/WHT
2045 BLK
GND 85
86
2610 BLK
6320 PNK
2
1
GND
SIG
RIGHT REAR
TAIL LIGHT
C602
SHEET 6
SHEET 6
FRC1
REAR LIGHT
+12V RELAY
PWR 30
87
A
B
SP64
C103
TAILGATE HARN
6310 PNK
A
B
6330 PNK
2640 BLK
2620 BLK
6210 PNK
1
2
SIG
GND
T16 TERMINAL (-)
GND
SIG
LEFT REAR
TAIL LIGHT
RIGHT REAR
WORK LIGHT
T15 TERMINAL (+)
6200 PNK
H
T17 TERMINAL (+)
SIG
6200 PNK
SHEET 6
2630 BLK
GND
LEFT REAR
WORK LIGHT
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 14 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
688 of 1148
Printed In U.S.A.
LEGEND
SCHEMATIC INDEX
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
PARTIAL CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
*
2560 BLK
7420 WHT
7425 WHT
*
3
30
+12V
PWR 30
1500 RNG/WHT
87
2030 BLK
GND 85
C610
2
1
C483
C
A
B
D
SIG
C
GND
A +12V PWR
B
E
F
2130 BLK
7430 WHT
HEATER
VALVE
SW10
*BLOWER
SWITCH
7410 WHT
3050 LBL
SHEET 6
2745 BLK
11
2745 BLK
OFF
5 2
1
4
6
3
SW11
AC SWITCH
*
3
7020 WHT
7021 WHT
2570 BLK
7020 WHT
7023 WHT
7024 WHT
C486
SHEET 6
2290 BLK
2280 BLK
D4
1
2
SIG
GND
*
C611
1
2
3
4
14.00 Amps
7.50 Amps
5.00 Amps
MAGNET CLUTCH
(COMPRESSOR)
C630
3
2
1
THERMOSTAT
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
(PRINTED FEBRUARY 2015)
7228618 (A)
689 of 1148
BLOWER
MOTOR
7400 WHT
Sheet 15 of 18
Printed In U.S.A.
High
Med
Low
12
C350
7025 WHT
C
7530 WHT
7520 WHT
7510 WHT
2580 BLK
1
*
B
A
POTENTIOMETER
(TEMP CONTROL
SWITCH)
C635
2100 BLK
7015 WHT
AC EVAPORATOR
SWITCH
BLK
DBL
WHT
10 1500 RNG/WHT
86
DLX CAB HARN 7207730 AND
7208877(SF) ONLY
(NOT IN STD CAB HARN)
HVAC DUCT
FAN
7050 WHT
J1A
GWY CTRLR
11
GND
SIG
C438
(DK GRAY)
CAB-MFR HARN CONN 3
FRC1
HVAC RELAY
SHEET 6
Dealer Copy -- Not for Resale
*
1140 RED/WHT
*
SHEET #
2440 BLK
7440 WHT
SHEET 4
HVAC
CONNECTOR
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
RED
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
#
POWER BOB
CLOSE
SIG
GND
#
POWER BOB
OPEN
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
4470 LGN
2470 BLK
2770 BLK
E
B
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
2
1
*
F
4480 LGN
4470 LGN
SW5
*POWER
2
1
BOBTACH
SWITCH
5
3
4
6
10
6010 PNK
13
1550 RNG/WHT
12
6010 PNK
1380 RED/WHT
SHEET 5
1550 RNG/WHT
LEFT HANDLE
(FLASHER) 5 WAY
1410 RED/WHT
SHEET 4
1
1410 RED/WHT
6515 PNK
6500 PNK
6
6500 PNK
6415 PNK
6400 PNK
3
6400 PNK
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS SHEET)
E
D
6410 PNK
6510 PNK
SHEET 6
C423
BUCKET
POSITION
SOLENOID
9.8 OHM
SIG
GND
A
B
C412
LEFT HANDLE
(HORN) 2 WAY
B
(SEE ADDITIONAL
A
OPTIONS SHEET)
4450 LGN
2450 BLK
D3
2455 BLK
2780 BLK
4
2780 BLK
4455 LGN
5
4455 LGN
SHEET 6
SHEET 6
2830 BLK
1460 RED/WHT
13
7210 WHT
J2A
AUX CTRLR
7200 WHT
6420 PNK
6520 PNK
D1
D2
3400 LBL
SHEET 11
6430 PNK
SW3
*HAZARD
SWITCH
(PINS 3 & 6
INTERNALLY
INSULATED)
2
5
B
A
C
A
B
5
1
3
4
SWITCH
6
5
4
1
2
3
2725 BLK
6700 PNK
2850 BLK
6
*
2420 BLK
6440 PNK
6540 PNK
*
GND
HORN
LEFT
SPEAKER
*
+
E
D
F
B
C
A
*
-
*
7820 WHT
7830 WHT
3
4
7810 WHT
7800 WHT
6
5
1
2
*
+
SHEET 12
SHEET 12
C278
2
1
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
C676
RADIO CONN
C279
1
2
C670
-
RIGHT
SPEAKER
SJC
HORN/BLINKER
(SEE ADDITIONAL
OPTIONS SHEET)
2
SW6
BUCKET
POSITION
SWITCH
SIG
T3
FLASHER
CONN
SW2
*BEACON
2780 BLK
3
1
4
*
6530 PNK
SHEET 4
C497
5
4
3
SHEET 11 3500 LBL
L
C126
2785 BLK
X
1430 RED/WHT
6
C408
(BLACK)
CAB-MFR HARN CONN 1 SHEET 6
7210 WHT
1200 RED/WHT
6570 PNK
(SEE ADDITIONAL
OPTIONS SHEET)
B
C
A
E
D
Dealer Copy -- Not for Resale
C438
(DK GRAY)
CAB-MFR HARN CONN 3
C411
DLX CAB HARN 7207730, 7208877(SF) ONLY
(NOT IN STD CAB HARN)
4480 LGN
SHEET 6
2480 BLK
4480 LGN
DLX FUEL HARN 7184255, 7200460(SF) ONLY
(NOT IN STD FUEL HARN 7149219, 7200449(SF) )
SHEET #
C606
GND
SIG
#
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
11
4470 LGN
2770 BLK
OPTIONS
CONNECTOR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C355
FUEL HARN
C607
1
2
SCHEMATIC INDEX
1885 RNG/WHT
2885 BLK
SHEET 12
SHEET 12
1510 RNG/WHT
2210 BLK
C277
1
2
3
4
5
6
AIR RID
SEAT
PWR
GND
C415
26
J2B
AUX CTRLR
26
J1A
GWY CTRLR
26
J1B
GWY CTRLR
26
2460 BRN
4460 LGN
B
A
GND
SIG
HIGH FLOW
SOLENOID
7.5 OHM 12 V
C441
2350 BRN
4350 GRN
2
1
GND
SIG
TWO SPEED
SOLENOID
5.1 OHM 12 V
TRACK 2 SPEED
ADAPTER
(SEE ADDITIONAL
OPTIONS SHEET)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 16 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
690 of 1148Printed
In U S A
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
PIN
A
B
C
D
E
F
G
H
J
K
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
ACS
CONTROLS
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
ACS AND AHC HARNESS
(500 Models - Track & Wheel) 7169053
(600 Models - Track & Wheel) 7164144
J1-ACS
CONTROLLER
2280 BLK
4220 LGN
4275 LGN
C
+5V
E
D
B
A
G
4550 LGN
9240 PUR
9140 PUR/WHT
1740 RNG/WHT
5
3
2
7
8
1
4
6
C493
4
3
2
1
2240 BLK
J3-ACS
CONTROLLER
1170 RED/WHT
2650 BRN
4650 LGN
5650 YEL
B
C
A
B
C
A
GRD
SIG
+5V PWR
LIFT HANDLE
HALL SENSOR
4220 LGN
2260 BLK
2270 BLK
4260 LGN
2750 BRN
4750 LGN
5750 YEL
G
D
F
C469
B
C
A
B
C
A
GND
SIG
+5V PWR
TILT HANDLE
HALL SENSOR
C467
2510 BLK
4280 LGN
3
1
2
C468
2500 BLK
4270 LGN
2
3
1
C429
4610 LGN
4600 LGN
5980 YEL
2980 BRN
3980 LBL
8
7
6
5
4
3
1
2
LIFT
SOLENOID
13 OHM
12V
FOOT PEDAL LOCK
TILT
SOLENOID
LIFT ACTUATOR
C409
C466
K
G
A
H
J
E
F
C
D
B
A
B
SKI CTRL
DETENT
FLOW
TWO SPD
PWM
C410
K
D
C
B
G
F
A
J
H
E
FLOAT
SKI CTR
SIDE
SHIFT
A
B
HANDLE
LOCK
+5V PWR
GND
SIG
2980 BRN
2990 BRN
2
3
1
GND
SIG
+5V PWR
C428
LIFT PEDAL
HALL SENSOR
C470
2760 BRN
4760 LGN
5760 YEL
3980 LBL
3990 LBL
2
3
1
GND
SIG
+5V PWR
TILT PEDAL
HALL SENSOR
K
4645 LGN
A
4640 LGN
5990 YEL
2990 BRN
3990 LBL
8
7
6
5
4
3
1
2
TILT ACTUATOR
+5V PWR
GND
SIG
5980 YEL
5990 YEL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 17 of 18
691 of 1148
HANDLE
LOCK
C471
2660 BRN
4660 LGN
5660 YEL
5750 YEL
5650 YEL
5970 YEL
H
E
E
J
H
G
C472
F
K
1190 RED/WHT
1180 RED/WHT
5970 YEL
2250 BRN
J2-ACS
CONTROLLER
A
B
C
J
D
B
C
SEE MANUAL CONTROL
PAGE FOR HARNESS CONN
4275 LGN
C492
2280 BLK
2240 BLK
1170 RED/WHT
MAINFRAME HARNESS
Dealer Copy -- Not for Resale
H
Printed In U.S.A.
(PRINTED FEBRUARY 2015)
7228618 (A)
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
HARNESS PART NUMBER
SJC
SEE SHEET 1
A22 PUMP
7188448
SUSP JSTK
7163706
3980 LBL
2890 BRN
5980 YEL
33
34
1710 RNG/WHT
1
3
2
GND
SIG
+12V PWR
RIGHT
SWASHPLATE
C537
5860 YEL
2860 BRN
7
3860/LBL LBL
1770 RNG/WHT
C542
2
4
3
1
2860 BRN
3860 LBL
1770 RNG/WHT
1
3
2
GND
SIG
+12V PWR
LEFT
SWASHPLATE
C546
C501
43
42
4260 LGN
2660 BRN
1
2
4260 LGN
2660 BRN
44
45
4250 LGN
2650 BRN
3
4
4250 LGN
2650 BRN
31
41
80 LGN
2680/BRN OR BLK BRN
5
6
21
11
4280 LGN
2670 BRN
7
8
1
2
RIGHT FORWARD DRIVE
C547
1
2
RIGHT REVERSE DRIVE
C545
4280 LGN
2680 BRN
1
2
LEFT REVERSE DRIVE
C544
4270 LGN
2670 BRN
1
2
2990 BRN
4290 LGN
4650 LGN
K
J
E
H
F
G
C
D
B
A
A
G
F
E
D
B
H
C
9240 PUR
9140 PUR/WHT
1760 RNG/WHT
2280 BLK
LEFT FORWARD DRIVE
C474
26
4210 LGN
A
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT
C492
12
22
4
6
16
9190 PUR/WHT
9290 PUR
4550 LGN
4220 LGN
4275 LGN
50
1750 RNG/WHT
27
28
47
48
2470 BLK
2490 BLK
1250 RED/WHT
1260 RED/WHT
9140 PUR/WHT
9240 PUR
1740 RNG/WHT
8
7
2
5
3
4
1
6
7100 WHT
Printed In U.S.A.
692 of 1148
J5 DRIVE CONTROLLER
FUNCTION
SAFETY IN
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
L SWASH PLATE ANGLE
R SWASH PLATE ANGLE
SPARE ANALOG 4
SPARE ANALOG 5
L FWD RETURN
CAN HIGH
LF ANGLE
RF ANGLE
LR ANGLE
H PAT LITE
RR ANGLE
L JOYSTICK X
L JOYSTICK Y
R JOYSTICK X
L FWD DRIVE
CAN LOW
R QUAD A DRIVE
R QUAD B DRIVE
TWO SPEED 1
BRAKE LIGHT OUTPUT
GROUND
GROUND
SENSOR GROUND
SENSOR SUPPLY 2 +5V
L REV DRIVE
CAN SHIELD
L QUAD A DRIVE
L QUAD B DRIVE
SAFETY OUT
BACKUP ALARM
R JOYSTICK Y
SPARE ANALOG 1
SPARE PWM COIL 7
SENSOR SUPPLY 1 +5V
L REV RETURN
R FWD RETURN
R FWD DRIVE
R REV DRIVE
R REV RETURN
TWO SPEED 2
UNSWITCHED BATTERY
UNSWITCHED BATTERY
SPARE PWN COIL 6
SWITCHED BATTERY
1
2
4
1830 RNG/WHT
2070 BLK
9660 PUR
1
2
4
3
9560 PUR/WHT
3
1
1480 RNG/WHT
1
+12V PWR
2
2080 BLK
2
GND
4
9640 PUR
4
CAN LO
3
9540 PUR/WHT
3
CAN HI
RIGHT
JOYSTICK
LEFT
JOYSTICK
C493
2235 BLK
1235 RED/WHT
1170 RED/WHT
2240 BLK
3
2
1
4
1760 RNG/WHT
2280 BLK
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT
36
K
A
D
F
H
J
C
B
E
G
J1-ACS
J2-ACS
ACS CONTROLLER
3810 LBL
A22 PUMP HARNESS (7169309 or 7188448)
C543
2810 BRN
3810 LBL
1710 RNG/WHT
Dealer Copy -- Not for Resale
2
4
3
1
2970 BRN
C536
5810 YEL
2810/BRN BRN
3990 LBL
TILT ACTUATOR
3 +5V PWR YEL
4
2 4770
SIGLBL
6
1
GND
64
BRN
5
4780 LGN
7
8
4790 LGN
J3-ACS
5970 YEL
5890 YEL
23
24
8
LIFT
ACTUATOR
5
61 LGN
6
8
4690 LGN
1
GND
62
BRN
4
2
SIG
63
LBL
7
3 +5V PWR YEL
C428
5990 YEL
40
PIN
A
B
C
D
E
F
G
H
J
K
C429
4600 LGN
4610 LGN
2980 BRN
29
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
A
B
(CONNECTS TO BACKUP
ALARM C404 ON MFR
HARNESS)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR811001 - ALR812540)
Printable Version Click Here
Sheet 18 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
CONNECTOR ASSIGNMENTS
CONN
DESCRIPTION
NUM OF
PINS
SHEET
CONN
DESCRIPTION
C100
C103
C105
WATER IN FUEL SENDER
TAILGATE HARNESS
HYD CHARGE PRESSURE SENSOR
2
8
3
8
6,12,13,15
9
C425
C426
C428
C434-1
C434-2
C435-1
C435-2
C438
BRAKE SOLENOID
CAN(Remote Start Tool, ACD)
CAB-MFR HARN CONN(LT GRY)
C108
C110
C111
C112
HYD TEMPERATURE SENDER
ALTERNATOR
HARNESS ENGINE START CONN
HYD OIL FILTER SWITCH
2
2
3
2
9
8
8
9
NUM OF
PINS
SHEET
CONN
DESCRIPTION
NUM OF
PINS
SHEET
9
7
5,6,8,11,15
13
13
13
13
11,13,14,15
FRC1
FUSE RELAY CENTER
112
4,5,8,9,13,14
J1A
J1B
J2A
J2B
GATEWAY CONTROLLER
GATEWAY CONTROLLER
AUX CONTROLLER
AUX CONTROLLER
34
26
34
26
5,8,9,10,12,13,14,15
4,6,7,8,9,10,11,12,15
9,12,15
4,5,6,7,9,12,15
CAB-MFR HARN CONN(DK GRY)
3
7
14
2
2
2
2
14
J7A
ENG ECU CONTROLLER(BCT)
58
5,6,7,8
C441
C446
C449
C450
C479
C480
TWO SPEED SOLENOID
HYDRAULIC FAN
LEFT JOYSTICK(CAB HARN)
RIGHT JOYSTICK(CAB HARN)
LEFT PANEL(BLACK)
LEFT PANEL(GRAY)
2
2
4
4
12
12
15
9
7
7
7,10
10
SW1
SW2
SW3
SW4
BRAKE SWITCH
BEACON SWITCH
HAZARD SWITCH
HAND/FOOT, H/ISO SWITCH
6
6
6
6
10
15
15
11
SW5
SW6
POWER BOBTACH SWITCH
BUCKET POSITION SWITCH
6
6
15
15
LEFT FRONT WORKLIGHT 1 (37W)
LEFT FRONT WORKLIGHT 2 (50W)
RIGHT FRONT WORKLIGHT 1 (37W)
RIGHT FRONT WORKLIGHT 2 (50W)
C114
C115
C116
HAND THROTTLE
FOOT THROTTLE
FOOT THROTTLE INTDM
6
6
3
8
8
8
C118
C126
C129
ENG-CROSSOVER
HORN
CAB ACCESSORY
4
2
3
8
15
11
C482
C483
C486
SEATBAR SENSOR
TEMP CONTROL SWITCH
AC COMPRESSOR
3
3
2
11
14
14
C169
ENGINE CAN (Diagnostic)
6
7
C489
MFR ACCESSORY
2
5,6
POWER SOCKET
2
11
C492
ACS/SJC/AWS-MFR HARN
8
5,7,11
SW9
TRAVEL CONTROL SWITCH
6
10
WASHER PUMP INTDM
WASHER PUMP
2
2
11
11
C493
C497
ACS/SJC/AWS-MFR HARN
SJC HORN/BLINKER
4
3
4,6
15
SW10
SW11
BLOWER SWITCH
AC SWITCH
6
3
14
14
C277
C278
AIR RIDE SEAT
RIGHT SPEAKER
6
2
15
15
C499
C500
PTOL
RH KEY SWITCH
4
6
10
10
SW12
DPF SWITCH
10
10
C279
C308
C350
C355
LEFT SPEAKER
BRAKE SOLENOID
AC EVAPORATOR SWITCH
FUEL HARNESS
2
2
2
6
15
9
14
8,15
C503
C602
C603
C606
RH DLX PANEL
LEFT REAR TAIL LIGHT
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
6
2
2
2
7,10
13
13
15
T1
T2
T3
T6
BATT GROUND
BUZZER GROUND
FLASHER
BATT GROUND
1
1
2
1
6
10
15
C404
BU ALARM-MFR HARN
2
5,12
C607
POWER BOBTACH CLOSE
2
15
T8
BATT GROUND
1
6
C405
AIR FILTER SWITCH
2
8
C610
HVAC DUCT FAN
2
14
C406
C408
FUEL SENDER
CAB-MFR HARN CONN(BLK)
2
14
C611
C630
BLOWER MOTOR
THERMOSTAT
4
3
14
14
ENGINE SYSTEM GROUND
BUZZER POWER
1
1
6
10
T14
PRE HEATER
1
8
C409
C410
C411
C412
C415
RIGHT HANDLE (MAN/ACS)
LEFT HANDLE (MAN/ACS)
LEFT HANDLE 5 WAY
LEFT HANDLE 2 WAY
HIGH FLOW SOLENOID
10
10
5
2
2
8
4,6,7,10,
11,13,15
12
12
15
15
15
T10
T13
C635
C667
C670
C676
HEATER VALVE
DOOR HARNESS
EXTERIOR BEACON HARNESS
RADIO
6
6
6
6
14
11
15
15
T15
T16
T17
T18
RIGHT REAR WORK LIGHT(+)
RIGHT REAR WORK LIGHT(-)
LEFT REAR WORK LIGHT(+)
LEFT REAR WORK LIGHT(-)
1
1
13
13
FRONT ROD
FRONT BASE
HYD LOCK
TILT SPOOL LOCK
LIFT SPOOL LOCK
BUCKET POSITION SOLENOID
2
2
2
3
3
2
9
9
9
12
12
15
BACKUP ALARM
BACKUP ALARM(GND)
13
13
12
C418
C419
C420
C421
C422
C423
T19
T20
T32
T37
T38
1
1
1
1
1
1
1
12
6
11
11
Dealer Copy -- Not for Resale
C212
C252
C253
ECU CASE GROUND
DOME LIGHT(+)
DOME LIGHT(-)
6
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 1 of 18
Printed In U.S.A.
693 of 1148
(PRINTED NOVEMBER 2016)
7253420 (0)
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
FUNCTION
HYDRAULIC LOCK RETURN
LIFT SPOOL LOCK RETURN
HVAC RELAY - B
SWITCHED PWR RELAY - A
FRONT LIGHT RELAY - J
STARTER RELAY - M
TRACTION PULL RELAY - D
TILT SPOOL LOCK RETURN
AC SENSE
SPARE DIGITAL, ECU SOURCES
TRACTION LOCK FDBK RELAY - D
AIR FILTER SWITCH
REAR LIGHT RELAY - E
HYD FAN RETURN
PTOL LED
PTOL SWITCH
SWITCHED PWR FDBK RELAY - A
STARTER FDBK RELAY - M
START ENGINE
TWO SPEED RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
HYD CHARGE PRESS
UNSW BATT
UNSW BATT
RUN SIG ENG ECU
LIFT SPOOL LOCK
TRACTION LOCK HOLD
TILT SPOOL LOCK
CAN LO 1
CAN HI 1
HAND THROTTLE
SEAT BAR
FUEL LEVEL
BICS HYD LOCK HOLD
CAN HI 2
GROUND P1
GROUND P2
GROUND P3, SENSOR
HYD FAN
CAN LO 2
REMOTE RUN KEY
RUN/ENTER
SENSOR SUPPLY 8V
SENSOR SUPPLY 5V
TWO SPEED COIL
REAR LIGHT FDBK RELAY - E
HVAC FDBK RELAY - B
LIGHT FDBK RELAY - K
HYD OIL TEMP (8 VOLT)
FOOT THROTTLE
HYD OIL FILTER SW1
Dealer Copy -- Not for Resale
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
FUNCTION
FRONT BASE RETURN
LEFT BLINKER RELAY
RIGHT BLINKER RELAY
HORN RELAY
LH PADDLE RIGHT
LH PADDLE LEFT
RH RIGHT ROCKER UP
FRONT ROD RETURN
LH SW-FLOAT (ACS)
LH RIGHT ROCKER DOWN
HIGH FLOW RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
UNSW BATT
UNSW BATT
CAN LO 1
CAN HI 1
FRONT BASE SOLENOID
CAN HI 2
GROUND
GROUND
RH PWM LOW
RH PWM SIGNAL
FRONT ROD
CAN LOW 2
RH TRIGGER
SWITCHED POWER
RH PWM HIGH
HIGH FLOW
LH RIGHT ROCKER UP
RH LEFT ROCKER UP
RH LEFT ROCKER DOWN
HARNESS PART NUMBER
MF MFR CTRL
7228632
7265268
EXMF MFR CTRL
DLX CAB
7253375
STD CAB
7227905
STD FUEL
7149219
DLX FUEL
7266824
BCT ENG START
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
BRAKE ADAPTER
WHL 2 SPD ADP
TRK 2 SPD
7220812
7217484
7217483
7163706
7165061
7159366
7214626
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 2 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
694 of 1148
Printed In U.S.A.
LEGEND
ENGINE CONTROLLER
PIN
CONNECTOR J7
FUNCTION
1
SW POWER
2
GND
3
SW POWER
4
GND
5
SW POWER
6
GND
9
WATER FUEL SENSOR
13
14
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
GROUP DESCRIPTION
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BLK
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
TAN
TAN
ENGINE
8000 THROUGH 8999
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
15
19
ECU RUN SIGNAL
21
24
25
29
35
D
C
MASS AIR FLOW (MAF)
SENSOR FREQUENCY
PEDAL POS 2
34
MASS AIR FLOW (MAF)
SENSOR TEMP
WATER FUEL SENSOR GND
45
ECU RELAY GND
47
ECU CAN 1 LO
48
ECU CAN 1 HI
56
GLOW PLUG SIGNAL
Dealer Copy -- Not for Resale
28
B
A
26
E
F
G
H
J
K
L
M
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 3 of 18
Printed In U.S.A.
695 of 1148
(PRINTED NOVEMBER 2016)
7253420 (0)
UNSWITCHED BATT POWER
1240 RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1450 RED/WHT
6
FRC1 FUSE RELAY CENTER
1070 RED
+12V
BATTERY
1025 RED
MEGAFUSE
100.0 Amps
1270 RED
FUSE 11 25 A
FUSE 13 25 A
FUSE 15 25A
SP7
1120 RED/WHT
SP2
1160 RED/WHT
1110 RED/WHT
1130 RED/WHT
SP36
FUSE 17 25 A
2
3
J1B
GWY CTRLR
1150 RED/WHT
3
1180 RED/WHT
2
1420 RED/WHT
1440 RED/WHT
SHEET 11
C667 DOOR HARNESS
SHEET 10
C500 RH KEY SWITCH
SHEET 10
C479 LH PANEL (BLACK)
J2B
AUX CTRLR
1
1170 RED/WHT
T4 1
1280 RED
1400 RED/WHT
1450 RED/WHT
SHEET 10
C503 RH DLX PANEL
2
1235 RED/WHT
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
SHEET 8
STARTER
FUSE 4 25 A
1010 RED
1140 RED/WHT
SHEET 14
FRC1 HVAC RELAY
1310 RED
1360 RED/WHT
FUSE 1 15 A
1340 RED
FUSE 2 20 A
1320 RED/WHT
1350 RED/WHT
1330 RED/WHT
SP26
1060 RED
1335 RED
1325 RED
SP1
1300 RED
FUSE 9 50 A
FUSE 20 5 A
FUSE 16 25 A
1065 RED/WHT
1345 RED/WHT
1035 RED/WHT
1445 RED/WHT
1190 RED
1040 RED
1290 RED
FUSE 18 25 A
FUSE 22 25 A
FUSE 24 25 A
1165 RED/WHT
1490 RED/WHT
1370 RED/WHT
Dealer Copy -- Not for Resale
FUSE 3 30 A
SHEET 9
FRC 1 TRACTION LOCK RELAY
SHEET 13
FRC1 REAR LIGHT RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 5
FRC1 ENGINE ECU RELAY
SHEET 5
FRC 1 ENGINE ECU RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 7
C426 REMOTE RUN, ACD
SP24
1460 RED/WHT
1410 RED/WHT
SHEET 15 C412 LH HANDLE HORN
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60
1050 RED
1030 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
SHEET 8
FRC1 STARTER RELAY
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 4 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
Printed
In U.S.A.
696 of 1148
SWITCHED POWER
FRC1
ENGINE
ECU
+12V
PWR RELAY -G
SHEET 4
1035 RED/WHT
J7A ENGINE ECU
86
SP54
1504 RNG/WHT
87
85
1
1506 RNG/WHT
30
1509 RNG/WHT
1507 RNG/WHT
3
1508 RNG/WHT
5
45
8005 TAN
SHEET 4
FRC1 FUSE RELAY CENTER
1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT
SHEET 8 ENG-CROSSOVER
1720 RNG/WHT
1760 RNG/WHT
1790 RNG/WHT
1805 RNG/WHT
FUSE 6 25 A
FUSE 12 15 A
FUSE 14 5 A
C489
1550 RNG/WHT
1570 RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION)
1795 RNG/WHT
FUSE 7 25 A
1730 RNG/WHT
1520 RNG/WHT
SHEET 12 C410 LEFT HANDLE
1530 RNG/WHT
SHEET 12 C409 RIGHT HANDLE
1560 RNG/WHT
SP11
1660 RNG/WHT
1765 RNG/WHT
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
A MFR ACCESSORY
1750 RNG/WHT 1780 RNG/WHT
SP50
1850 RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
Dealer Copy -- Not for Resale
FUSE 5 25 A
B
SP65
22
C428
J2B
(LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
2
1735 RNG/WHT
1725 RNG/WHT
FUSE 8 25 A
FRC1
SWITCHED
POWER RELAY -A
SHEET 4
SHEET 6
1050 RED
+12V
PWR 30
87
2055 BLK
GND 85
86
1815 RNG/WHT
3450 LBL
21
3380 LBL
4
J1A
GWY CTRLR
6
1800 RNG/WHT
9
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
SP37
1920 RNG/WHT
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 SW12 DPF SWITCH (UNUSED)
1620 RNG/WHT
1940 RNG/WHT
1930 RNG/WHT
1775 RNG/WHT
1960 RNG/WHT
1785 RNG/WHT
1950 RNG/WHT
1590 RNG/WHT
SHEET 10
SHEET 10
SHEET 10
SHEET 10
SHEET 10
SHEET 11
SHEET 10
SHEET 10
SP42
SHEET 7 C169 ENGINE CAN
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 8
C110 ALT EXCITATION
1840 RNG/WHT
1830 RNG/WHT
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 5 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
Printed In U.S.A.
697 of 1148
C479 LH PANEL (BLACK)
T13 LH PANEL BUZZER
C499 RH PANEL PTOL
SW1 BRAKE SWITCH
SW9 TRAVEL CONTROL SWITCH
SW4 H/ISO SWITCH
C500 RH PANEL KEY SWITCH
C503 RH DELUXE PANEL
SHEET 7 C426 REMOTE RUN, ACD
C428
(LT GRAY)
CAB-MFR HARN CONN 2
1920 RNG/WHT
1740 RNG/WHT
FUSE 23 15 A
1580 RNG/WHT
1660 RNG/WHT
1700 RNG/WHT
1705 RNG/WHT
2320 BRN
SHEET 9
C112 HYD OIL FILTER SWITCH
2370 BRN
SHEET 11
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN
SHEET 9
C108 HYD TEMP SENDER
2190 BRN
SHEET 9
C105 HYD CHG PRESSURE SENDER
2180 BRN
SHEET 8
C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 8
C405 AIR FILTER SWITCH
2690 BRN
SHEET 8
C408 CAB-MFR CONN (HAND THRTL)
2695 BRN
SHEET 8
C115 FOOT THROTTLE
GROUND
2001 BLK
4
2002 BLK
6
2003 BLK
T32
ECU CASE GND
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
SHEET 10
C479 LH PANEL (BLACK)
SHEET 10
C499 PTOL
SHEET 10
C500 RH PANEL KEY SWITCH
SP53
2810 BLK
2004 BLK
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
2080 BLK
2070 BLK
SP4
2950 BLK
J1B
GWY CTRLR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SP47 2900 BLK
2510 BLK
15
2500 BLK
16
2540 BLK
15
1
SHEET 9
C425 BRAKE
C103
TAILGATE HARN
SP51
2600 BLK
C489
MFR ACCESSORY
B
2765 BLK
SHEET 13
C408 CAB-MFR CONN (FR LIGHTS)
2745 BLK
SHEET 14
C408 CAB-MFR CONN (HVAC)
2790 BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES)
2780 BLK
SHEET 15
C408 CAB-MFR CONN (OPTIONS)
2730 BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SP3
2110 BLK
SP28
2090 BLK
T8
BATT GND
B
2770 BLK
2200 BLK
2720 BLK
2600 BLK
2045 BLK
2455 BLK
SHEET 15
C423 BKT POSITION SOLENOID
2710 BLK
SHEET 7
C426 REMOTE RUN, ACD
2715 BLK
SHEET 7
C169 ENGINE CAN
2290 BLK
SHEET 14
D4 COMPRESSOR DIODE
SP6
2390 BLK
T1
BATT GND
2015 BLK
SHEET 8
ALTERNATOR GROUND
T10
ENGINE
GROUND
SP27
2300 BLK
2035 BLK
2115 BLK
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY
2030 BLK
SHEET 14
FRC1 HVAC RELAY
2005 BLK
SHEET 8
FRC1 STARTER RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
2550 BLK
17
2900 BLK
SHEET 15
C355 FUEL HARN (PWR BOB/AC)
SHEET 13
FRC1 REAR LIGHT RELAY
SHEET 9
FRC1 TRACTION LOCK RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
698 of 1148
J2B
AUX CTRLR
16
SP12 2230 BRN
T6
BATT GND
2950 BLK
2250 BLK
Printed In U.S.A.
2240 BLK
10
2960 BLK
SHEET 10
C503 RH DELUXE PANEL
2065 BLK
SHEET 10
SW12 DPF SWITCH
2930 BLK
SHEET 10
SW1 BRAKE SWITCH
2830 BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700 BLK
SHEET 10
SW9 TRAVEL CONTROL SWITCH
2785 BLK
SHEET 15
C126 HORN
2620 BLK
SHEET 13
T16 RH REAR WORK LIGHT
2650 BLK
SHEET 12
T20 BU ALARM
2640 BLK
SHEET 13
C602 LH REAR TAIL LIGHT
2610 BLK
SHEET 13
C603 RH REAR TAIL LIGHT
2630 BLK
SHEET 13
T18 LH REAR WORK LIGHT
2235 BLK
4
C408
(BLACK)
CAB-MFR HARN CONN 1
2920 BLK
2940 BLK
3
Dealer Copy -- Not for Resale
J7A
ENG ECU CTRLR
2
J1B
GWY CTRLR
2120 BLK
SP55
2105 BLK
2520 BLK
SHEET 12
C410 LEFT HANDLE
2530 BLK
SHEET 12
C409 RIGHT HANDLE
SP5
2000 BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 6 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
CAN BUS
J7A
ECU CNTRLR
47
CAN LO
48
CAN HI
9200 PUR
9100 PUR/WHT
9215 PUR
9115 PUR/WHT
9210 PUR
9110 PUR/WHT
J1B
GWY CTRLR
9205 PUR
9105 PUR/WHT
20
14
R21
120 OHM
0.5W
RESISTOR
R18
120 OHM
0.5 W
RESISTOR
C169
ENGINE CAN
SHEET 5
SHEET 6
9155 PUR/WHT
9255 PUR
1725 RNG/WHT
2715 BLK
1
2
3
4
5
6
C408
(BLACK)
CAB-MFR HARN CONN 1
8
9
9260 PUR
9160 PUR/WHT
9230 PUR
9130 PUR/WHT
R14
120 OHM
O.5W
RESISTOR
9250 PUR
9150 PUR/WHT
Dealer Copy -- Not for Resale
J1B
GWY CTRLR
9270 PUR
9170 PUR/WHT
9220 PUR
9120 PUR/WHT
4
3
9220 PUR
9120 PUR/WHT
9410 PUR
9310 PUR/WHT
9430 PUR
9330 PUR/WHT
9450 PUR
9460 PUR
9350 PUR/WHT 9360 PUR/WHT
R19
120 OHM
0.5 W
RESISTOR
4
3
C479
LEFT PANEL (BLACK)
9440 PUR
9340 PUR/WHT
4
2
C503
RIGHT DELUXE PANEL
1830 RNG/WHT
2070 BLK
1
2
3
4
1840 RNG/WHT
2080 BLK
1
2
3
4
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
9290 PUR
9190 PUR/WHT
7
8
9240 PUR
9140 PUR/WHT
1
4
SHEET 5
SHEET 6
9320 PUR/WHT
9420 PUR
SHEET 5
SHEET 6
9300 PUR/WHT
9400 PUR
J2B
AUX CTRLR
14
CAN HI
20
CAN LO
C426
Remote Run Tool, ACD
9500 PUR/WHT
A
9600 PUR
B
21
3090 LBL
SHEET 5
SHEET 4
SHEET 6
1735 RNG/WHT
1165 RED/WHT
2710 BLK
D
C
E
F
G
REMOTE RUN KEY
SWITCHED POWER
UNSWITCHED POWER
GROUND
8
9
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 7 of 18
Printed In U.S.A.
699 of 1148
C449
LEFT JOYSTICK
J2B
AUX CTRLR
9280 PUR
9180 PUR/WHT
J1B
GWY CTRLR
C450
RIGHT JOYSTICK
(PRINTED NOVEMBER 2016)
7253420 (0)
ENGINE
NOTE: SEE ENGINE HARNESS ON Sheet 16 of 18
FRC1
STARTER RELAY - M
1030 RED
SHEET 4
2005 BLK
SHEET 6
7
8210 TAN
22
3560 LBL
C111
HARN ENG START CONN
+12V
PWR 30
STARTER
8200 TAN
87
GND
85
86
8210 TAN
SHEET 5
FUSE 12
8220 TAN
3560 LBL
S
R
M
B
SHEET 4
1015 RED
C110
B
ALTERNATOR
J1A
GWY CTRLR
G
S
L
2150 BRN
3150 LBL
GND
C116
FOOT THROTTLE INTDM
SHEET 11
33
SHEET 6
5695 YEL
C
5695 YEL
C
3695 LBL
A
3695 LBL
A
2695 BRN
B
2695 BRN
B
E
D
F
C355
FUEL HARN
3180 LBL C
2180 BRN D
12
SHEET 6
10
3690 LBL
4
8007 TAN
J7A
ENG ECU CTRLR
3180 LBL
2180 BRN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 11
SHEET 6
ENGINE GROUND TERMINAL
C115
FOOT THROTTLE
FOOT THROTTLE
ADAPTER HARNESS
7217683
J1B
GWY CTRLR
1800 RNG/WHT
2015 BLK
AIR FILTER
SWITCH (NC)
SIG
Dealer Copy -- Not for Resale
SHEET 6
B
A
1020 RED
EXCITATION
C405
16
19
3560 LBL
1800 RNG/WHT
A
B
C
+5V PWR
SIG
GND
C406
A
B
SIG
GND
FUEL SENDER
(30 - 270 OHM)
C114
HAND THROTTLE
5690 YEL
7
3690 LBL
6
3690 LBL
2690 BRN
8
2690 BRN
5690 YEL
SHEET 6
8007 TAN
C
A
B
D
E
F
+5V PWR
SIG
GND
C100
9
34
1
2
3865 LBL
2865 BRN
SIG
GND
WATER IN FUEL SENDER
(FUEL FILTER)
C118
ENG-CROSSOVER
MAF FREQ
MAF TEMP
28
SHEET 5
8013 TAN
35
8014 TAN
SHEET 4
56
1
1511 RNG/WHT
1065 RED/WHT
8510 TAN
+12V
PWR 30
85
87
8525 TAN
86
1445 RED/WHT
PREHEATER
RELAY - C
8013 TAN
2
8014 TAN
3
3420 LBL
4
8500 TAN
PRE-HEATER
To C154 - PIN1 and
C155 - PIN 3
MAF Sensor - PIN 1
MAF Sensor - PIN 4
TO J4B - PIN 179
Sheet 16 of 18
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
SHEET 4
Sheet 8 of 18
(PRINTED NOVEMBER 2016)
Printed In U.S.A.
700 of 1148
7253420 (0)
1360 RED/WHT
SHEET 4
2035 BLK
SHEET 6
HYDRAULICS
FRC1
TRACTION LOCK
+12V RELAY - D
PWR 30
87
GND
85
C425
4100 LGN
SHEET 6
86
4200 LGN
2200 BLK
B
A
C
C308
4200 LGN
2200 BLK
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061
8
4110 LGN
13
3430 LBL
32
2220 BRN
3220 LBL
SHEET 6
C108
B
A
GND
SIG
C112
J1A
GWY CTRLR
34
SHEET 6
3320 LBL
2320 BRN
A
B
SIG
GND
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
(8 VOLT)
HYDRAULIC OIL
FILTER SWITCH (NC)
2910 BRN
4010 LGN
2
1
GND
SIG
C420
1
2410 BRN
4410 LGN
B
A
GND
SIG
C105
SHEET 6
2190 BRN
3190 LBL
5190 YEL
B
C
A
GND
SIG
+8V PWR
4200 LGN
19 13
1 23
Dealer Copy -- Not for Resale
C446
18
HYDRAULIC
FAN SOLENOID
7.2 OHM 12 V
HYDRAULIC LOCK
SOLENOID
9.8 OHM 12 V
HYDRAULIC
CHARGE
PRESSURE SENSOR
0.5-7.5V
6
+8V
J1B
GWY CTRLR
C418
J2A
AUX CTRLR
18
2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
3.3 OHM PWM
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
C419
1
2340 BRN
4340 LGN
2
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
19 13
J2B
AUX CTRLR
Printed In U.S.A.
701 of 1148
sheet 9 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
1940 RNG/WHT
C479
LEFT PANEL (BLACK)
T2
BUZZER (-)
SHEET 6
SHEET 5
1960 RNG/WHT
SHEET 4
SW9
TRAVEL CONTROL
SWITCH (OPTIONAL)
SHEET 6
2700 BLK
C499
Press To Operate Loader
(PTOL)
LEFT PANEL
BUZZER
7040 WHT
SHEET 5
SHEET 15
5 6
4
2 3
1
SHEET 5
SHEET 6
SHEET 15
3610 LBL
1775 RNG/WHT
2930 BLK
3
1
4
7040 WHT
10
2920 BLK
2
1440 RED/WHT
1
1620 RNG/WHT
5
3400 LBL
11
3500 LBL
8
3650 LBL
7
3600 LBL
9
6
SW1
2 BRAKE SWITCH
SWITCHED POWER
8050 TAN
12
11
10
3
2
8
7
6
4
1705 RNG/WHT 10
8
8055 TAN
5
2
3
8060 TAN
1
1
4
8070 TAN
9
2065 BLK
1
3
20
3030 LBL
1
3030 LBL
2
19
2380 BRN
12
2380 BRN
4
J1A
GWY CTRLR
LEFT BLINKER INPUT
24
TRAVEL CONTROL INPUT
SWITCHED POWER
GROUND
PTOL OUTPUT
PTOL LED
C500
RIGHT PANEL - KEY SWITCH
RIGHT BLINKER INPUT
8130 TAN
2
8130 TAN
PARK BRAKE INPUT
C480
LEFT PANEL (GRAY)
3620 LBL
3610 LBL
SHEET 6
UNSWITCHED POWER
6
SW12
DIESEL PARTICULATE
DERATE OVERRIDE SWITCH
SHEET 5
GROUND
5
1700 RNG/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
BUZZER
1930 RNG/WHT
2940 BLK
2
START
6
12
SHEET 11
SHEET 5
SHEET 5
SHEET 6
7 9
DOOR SIGNAL
PARK BRAKE OUTPUT
DPF LAMP
DPF INHIBIT LAMP
Dealer Copy -- Not for Resale
SHEET 5
CAB DISPLAY
T13
BUZZER (+)
J1B
GWY CTRLR
22
3040 LBL
14
SHEET 5
SHEET 4
SHEET 6
3040 LBL
4
1950 RNG/WHT
1420 RED/WHT
2960 BLK
5
1
3
RUN/ENTER SWITCH
SWITCHED POWER
UNSWITCHED POWER
GROUND
C503
RIGHT PANEL DELUXE DISPLAY
SHEET 5
SHEET 4
DPF OVERRIDE
SHEET 6
1590 RNG/WHT
5
1240 RED/WHT
1
2250 BLK
3
DPF INHIBIT REGEN
6
SWITCHED POWER
UNSWITCHED POWER
GROUND
NOT USED
Printed In U.S.A.
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 10 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
702 of 1148
*
SHEET 5
C492
ACS/SJC/AWS-MFR HARN
SHEET 12
(8 PIN)
SHEET 12
4230 LGN
4240 LGN
C438
SHEET 11
(DK GRAY)
CAB-MFR HARN CONN 3
SP29
4235 LGN
5
4220 LGN
7
4235 LGN
3
4275 LGN
8
4275 LGN
4550 LGN
9
4550 LGN
2
1850 RNG/WHT
2
SHEET 5
1850 RNG/WHT
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
3
6
2060 BLK
5
4
CAB
*
DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN)
*
C212
POWER
SOCKET
2795 BLK
1375 RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 4
1370 RED/WHT
7
*
1390 RED/WHT
SP45
1370 RED/WHT
1580 RNG/WHT
5
1580 RNG/WHT
SP8
1510 RNG/WHT
SHEET 15
SHEET 15
SP44
2730 BLK
11
2730 BLK
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 6
2790 BLK
14
2790 BLK
C482
J1B
GWY CTRLR
SHEET 6
11
+5V
24
5100 YEL
SHEET 8
SHEET 8
2370 BRN
4
2370 BRN
A
SEATBAR
GND SENSOR
3370 LBL
5
3370 LBL
B
SIG
5370 YEL
SP13
3
5370 YEL
C
+5V PWR
T38
DOME LIGHT (-)
GND
1885 RNG/WHT
SHEET 6
T37
DOME LIGHT (+)
DOME
LIGHT
*
+12V BATT PWR
+12V SW PWR
Dealer Copy -- Not for Resale
SHEET 5
A
B
C
GND
+12V PWR
SP41
2010 BLK
C129
CAB ACCESSORY
1210 RED/WHT
1865 RNG/WHT
2800 BLK
1
2
2210 BLK
SHEET 15
2885 BLK
2060 BLK
SHEET 15
SHEET 11
SHEET 10
SHEET 4
7310 WHT
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
1850 RNG/WHT
3620 LBL
1400 RED/WHT
1
4
5
6
2840 BLK
2
3
WIPER SWITCH, MOTOR SWITCHED POWER
DOOR SIGNAL
DOOR UNSW PWR
WIPER MOTOR GROUND
WASHER SIGNAL
5690 YEL
5695 YEL
HARNESS WASHER PUMP
7253378
*
C253
C252
2845 BLK
A
7310 WHT
1
B
2845 BLK
2
PWR
WASHER
MOTOR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
GND
sheet 11 of 18
Printed In U.S.A.
703 of 1148
(PRINTED NOVEMBER 2016)
7253420 (0)
MANUAL CONTROLS
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
AUX CTRLR
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
A
C103
TAILGATE HARN
C
7100 WHT
SHEET 6
30
31
T19 TERMINAL (+)
7100 WHT
BACK UP
ALARM
2650 BLK
2530 BLK
4230 LGN
1530 RNG/WHT
4940 LGN
4930 LGN
4920 LGN
4910 LGN
4310 LGN
4320 LGN
4300 LGN
SHEET 6
SHEET 11
SHEET 5
13
C421
10
J1A
GWY CTRLR
2980 BRN
4980 LGN
3
1
2
GND
SIG
TILT SPOOL LOCK
17.8 OHM 12V
C422
2
2990 BRN
4990 LGN
7
5
J1B
GWY CTRLR
3
1
2
GND
SIG
LIFT SPOOL LOCK
17.8 OHM 12V
Dealer Copy -- Not for Resale
T20 TERMINAL (-)
J2B
AUX CTRLR
SHEET 5
SHEET 11
SHEET 6
A
B
HANDLE LOCK (ACS)
SKI CTRL
DETENT FLOW
TWO SPD
PWM
C410
LEFT HANDLE
(MANUAL/ACS ONLY)
21 17 18 23
20
28
22
12
11
C466
K
G
A
H
J
E
F
C
D
B
4640 LGN
4840 LGN
4830 LGN
4820 LGN
4810 LGN
1520 RNG/WHT
4240 LGN
2520 BLK
K
D
C
B
G
F
A
J
H
E
FLOAT (ACS)
SKI CTRL
SIDE SHIFT
C465
A
B
HANDLE LOCK (ACS)
SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 12 of 18
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7253420 (0)
LIGHTS
C434-1
2735 BLK
6100 PNK
C408
(BLACK)
CAB-MFR HARN CONN 1
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
37.00 Watts
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
50.00 Watts
C434-2
SHEET 6
2765 BLK
9
2765 BLK
2750 BLK
6110 PNK
6000 PNK
8
6000 PNK
6120 PNK
2760 BLK
B
A
C435-1
FRC1
FRONT WORK
LIGHTS RELAY - J
SHEET 6
1350 RED/WHT
30
2120 BLK
85
87
6610 PNK
13
86
SHEET 4
SHEET 6
5
31
J1A
17
GWY CTRLR
28
1330 RED/WHT
+12V
PWR
30
87
2115 BLK
GND 85
6630 PNK
FRC1
FRONT WORK
LIGHTS RELAY - K
6340 PNK
C435-2
6130 PNK
2705 BLK
6310 PNK
86
6320 PNK
3460 LBL
6210 PNK
3440 LBL
A
C603
6310 PNK
2610 BLK
6320 PNK
SHEET 6
SHEET 6
1320 RED/WHT
SHEET 6
2620 BLK
SHEET 6
6210 PNK
2045 BLK
GND 85
86
GND
SIG
RIGHT REAR
TAIL LIGHT
1
2
SIG
LEFT REAR
TAIL LIGHT
GND
T16 TERMINAL (-)
GND
SIG
RIGHT REAR
WORK LIGHT
T15 TERMINAL (+)
+12V
PWR 30
87
2
1
C602
6330 PNK
2640 BLK
FRC1
REAR LIGHT
RELAY - E
SHEET 4
A
B
6610 PNK
C103
TAILGATE HARN
Dealer Copy -- Not for Resale
SHEET 4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
A
B
6200 PNK
H
6200 PNK
SHEET 6
SP96
6200 PNK
2630 BLK
T17 TERMINAL (+)
SIG
GND
LEFT REAR
WORK LIGHT
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
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Printed In U.S.A.
705 of 1148
sheet 13 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
HVAC
*
2560 BLK
7420 WHT
7425 WHT
DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN)
SHEET 4
SHEET 6
3
30
FRC1
+12V HVAC RELAY - B
1140 RED/WHT PWR 30
87
GND 85
2030 BLK
11
AC EVAPORATOR
SWITCH
1500 RNG/WHT
2745 BLK
SP40
7021 WHT
C
A
B
BLK
DBL
WHT
7020 WHT
11 2745 BLK
12
7023 WHT
7024 WHT
HVAC DUCT
FAN
POTENTIOMETER
(TEMP CONTROL
SWITCH)
C635
D
SIG
C
GND
A +12V PWR
B
E
F
HEATER
VALVE
SW10
*BLOWER
SWITCH
10 1500 RNG/WHT
C350
B
A
GND
SIG
C483
2130 BLK
7430 WHT
SP48
86
SHEET 6
2
1
C438
(DK GRAY)
CAB-MFR HARN CONN 3
7050 WHT
3050 LBL
J1A
GWY CTRLR
*
*
Dealer Copy -- Not for Resale
*
C610
2440 BLK
7440 WHT
7410 WHT
OFF
5 2
1
4
6
3
SW11
AC SWITCH
*
SP16
3
2100 BLK
7015 WHT
*
C611
1
2
3
4
14.00 Amps
7.50 Amps
5.00 Amps
High
Med
Low
BLOWER
MOTOR
7400 WHT
1
*
2570 BLK
7020 WHT
C
7530 WHT
7520 WHT
7510 WHT
2580 BLK
C630
3
2
1
THERMOSTAT
C486
7025 WHT
SHEET 6
2290 BLK
2280 BLK
D4
1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 14 of 18
(PRINTED NOVEMBER 2016)
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#
POWER BOB
CLOSE
SIG
GND
#
POWER BOB
OPEN
GND
SIG
C607
1
2
4470 LGN
2470 BLK
2770 BLK
E
B
OPTIONS
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C355
FUEL HARN
11
4470 LGN
2770 BLK
4470 LGN
2480 BLK
F
4480 LGN
4480 LGN
1550 RNG/WHT
SHEET 5
10
4480 LGN
13
6010 PNK
12
1550 RNG/WHT
SW5
*POWER
2
1
BOBTACH
SWITCH
5
3
4
6
1380 RED/WHT
6010 PNK
C438
(DK GRAY)
CAB-MFR HARN CONN 3
C411
RIGHT
(SEE ADDITIONAL
OPTIONS DWG)
LEFT
1410 RED/WHT
SHEET 4
1
6515 PNK
6500 PNK
6
6500 PNK
6415 PNK
6400 PNK
3
6400 PNK
E
D
6410 PNK
6510 PNK
C423
BUCKET
POSITION
SOLENOID
6.13 OHM
LEFT HANDLE
(HORN) 2 WAY
(SEE ADDITIONAL
OPTIONS DWG)
SIG
GND
A
B
2780 BLK
SHEET 6
4450 LGN
2450 BLK
4455 LGN
D3
2455 BLK
B
A
4455 LGN
SHEET 6
C408
(BLACK)
CAB-MFR HARN CONN 1
13
7210 WHT
1460 RED/WHT
SHEET 6
2830 BLK
2785 BLK
7210 WHT
J2A
AUX CTRLR
7200 WHT
6420 PNK
6520 PNK
26
2460 BRN
4460 LGN
D1
D2
C
A
B
6430 PNK
SW3
*HAZARD
SHEET 10
SWITCH
(PINS 3 & 6
INTERNALLY
INSULATED)
2
5
6
*
C126
B
A
GND
SIG
T3
FLASHER
CONN
SW2
*BEACON
5
1
3
4
SWITCH
6
5
4
1
2
3
2725 BLK
6700 PNK
2850 BLK
6
*
C670
2420 BLK
6440 PNK
6540 PNK
SW6
BUCKET
POSITION
SWITCH
HORN
LEFT
SPEAKER
*
+
1
2
*
-
+
SHEET 11
SHEET 11
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
7820 WHT
7830 WHT
3
4
7810 WHT
7800 WHT
1885 RNG/WHT
2885 BLK
6
5
1
2
*
C278
2
1
E
D
F
B
C
A
C676
RADIO CONN
C279
-
RIGHT
SPEAKER
SJC
HORN/BLINKER
(SEE ADDITIONAL
OPTIONS DWG)
2
2780 BLK
3
1
4
*
6530 PNK
3400 LBL
SHEET 4
C497
5
4
3
L
3500 LBL
2780 BLK
5
SHEET 6
C412
SIG
PWR
4
X
1430 RED/WHT
SHEET 10
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN)
1200 RED/WHT
1410 RED/WHT
Dealer Copy -- Not for Resale
LEFT HANDLE
(FLASHER) 5 WAY
*
6570 PNK
B
C
A
E
D
PWR
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
SHEET 6
C606
2
1
#
SHEET 11
SHEET 11
1510 RNG/WHT
2210 BLK
C277
1
2
3
4
5
6
AIR RIDE
SEAT
PWR
GND
C415
J2B
AUX CTRLR
B
A
GND
SIG
HIGH FLOW
SOLENOID
7.5 OHM 12 V
26
C441
J1A
GWY CTRLR
26
J1B
GWY CTRLR
26
2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
5.1 OHM 12 V
TRACK 2 SPEED
ADAPTER
(SEE ADDITIONAL
OPTIONS DWG)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 15 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
Printed In U.S.A.
707 of 1148
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
RED
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
RED/WHITE
RED/WHT
1000 THROUGH 1499
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PRE HEATER
TO C118 - PIN 4
See Sheet 8 of 18
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
ENGINE
HARNESS
SHEET #
179
J7B
ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
106
TEMP SENSOR 2
123
SENSOR RETURN 2
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
C151
EGR VREF3
164
5
POSITION SIGNAL
116
3
POSITION RETURN
172
120
137
6
H BRIDGE POS
192
2
H BRIDGE NEG
193
2
COOLANT TEMP SENSOR
109
1
COOLANT RETURN
145
C148
FUEL TEMP
SENSOR
1
FUEL TEMP SENSOR
110
2
FUEL RETURN
146
2
SENSOR SIGNAL
131
1
SENSOR RETURN
SHIELD
130
128
C146
2
ENGINE BLOCK
ACCELEROMETER 2
1
SENSOR SIGNAL
SENSOR RETURN
SHIELD
5V
3
2
VREF3 OIL PRESSURE
3
111
OIL PRESSURE SENSOR
4
148
104
1
RETURN GND
.
RETURN
1
194
SENSOR
2
133
129
OIL PRESSURE &
TEMPERATURE
SENSOR
2
OIL TEMPERATURE SENSOR
169
132
MAF
SENSOR
1
165
C147
ENGINE BLOCK
ACCELEROMETER 1
4
SENSOR GROUND
TO C113 PIN 2
See Sheet 5 of 14
C149
COOLANT TEMP
SENSOR
C136
TO C113 PIN 3
See Sheet 5 of 14
Dealer Copy -- Not for Resale
EGR VALVE
DC MOTOR
1
INTAKE
MANIFOLD
TEMPERATURE
C145
CRANKSHAFT
POSITION
SENSOR
1
CRANK SENSOR POS
160
2
CRANK SENSOR NEG
136
1
SENSOR RETURN
147
2
POS SENSOR
159
3
VREF1 CAM
TO C118 - PIN 1
See Sheet 8 of 18
NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
C144
CAM SHAFT
SENSOR
C143
RAIL
PRESSURE
SENSOR
1
RAIL PRESSURE SENSOR
1
112
INTAKE PRESS SENSOR
3
INTAKE PRESS RETURN
2
INTAKE MANIFOLD
PRESSURE
SENSOR
135
2
SENSOR RETURN
119
3
VREF1 SENSOR
138
1
FUEL INJECTOR HSDA
151
2
FUEL INJECTOR LSD1B
175
C139
127
FUEL INJECTOR HSDA
1
126
FUEL INJECTOR LSD1A
2
150
FUEL INJECTOR HSDB
2
FUEL INJECTOR LSD2B
1
1
FUEL INJECTOR HSDA
103
2
FUEL INJECTOR LSD2A
125
CYL 1
C140
174
C142
CYL 4
INTAKE MANIFOLD PRESSURE
167
C141
CYL 3
C138
. 161
CYL 2
C154
177
PWM
TO C118 - PIN 1
SEE Sheet 8 of 18
2
1
INLET METERING
VALVE
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
sheet 16 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
Printed In U.S.A.
708 of 1148
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
PIN
A
B
C
D
E
F
G
H
J
K
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
ACS
CONTROLS
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
ACS AND AHC HARNESS
(500 Models - Track & Wheel) 7169053
(600 Models - Track & Wheel) 7164144
J1-ACS
CONTROLLER
H
2280 BLK
C
+5V
E
D
B
A
G
4550 LGN
9240 PUR
9140 PUR/WHT
1740 RNG/WHT
5
3
2
7
8
1
4
6
4
3
2
1
2240 BLK
J3-ACS
CONTROLLER
1170 RED/WHT
5970 YEL
2250 BRN
J2-ACS
CONTROLLER
C472
2650 BRN
4650 LGN
5650 YEL
F
B
C
A
B
C
A
GRD
SIG
+5V PWR
LIFT HANDLE
HALL SENSOR
C469
2750 BRN
4750 LGN
5750 YEL
G
K
GND
SIG
+5V PWR
TILT HANDLE
HALL SENSOR
1190 RED/WHT
1180 RED/WHT
E
J
H
G
4220 LGN
2260 BLK
2270 BLK
4260 LGN
C467
2510 BLK
4280 LGN
3
1
2
C468
2500 BLK
4270 LGN
2
3
1
C429
D
4610 LGN
F
4600 LGN
5980 YEL
2980 BRN
3980 LBL
8
7
6
5
4
3
1
2
LIFT
SOLENOID
13 OHM
12V
FOOT PEDAL LOCK
TILT
SOLENOID
LIFT ACTUATOR
C409
C466
K
G
A
H
J
E
F
C
D
B
A
B
SKI CTRL
DETENT
FLOW
TWO SPD
PWM
C410
K
D
C
B
G
F
A
J
H
E
FLOAT
SKI CTRL
SIDE
SHIFT
A
B
HANDLE
LOCK
+5V PWR
GND
SIG
2
3
1
GND
SIG
+5V PWR
C428
LIFT PEDAL
HALL SENSOR
C470
2760 BRN
4760 LGN
5760 YEL
3980 LBL
3990 LBL
2
3
1
GND
SIG
+5V PWR
TILT PEDAL
HALL SENSOR
K
4645 LGN
A
4640 LGN
5990 YEL
2990 BRN
3990 LBL
8
7
6
5
4
3
1
2
TILT ACTUATOR
+5V PWR
GND
SIG
5980 YEL
5990 YEL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
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Printed In U.S.A.
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HANDLE
LOCK
C471
5750 YEL
5650 YEL
5970 YEL
H
E
B
C
A
2660 BRN
4660 LGN
5660 YEL
2980 BRN
2990 BRN
A
B
C
J
D
B
C
A
B
C
Dealer Copy -- Not for Resale
4220 LGN
4275 LGN
C493
4275 LGN
C492
2280 BLK
2240 BLK
1170 RED/WHT
MAINFRAME HARNESS
SEE MANUAL CONTROL
PAGE FOR HARNESS CONN
(PRINTED NOVEMBER 2016)
7253420 (0)
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
SJC
CONTROLS
GROUND
GROUND
PIN
A
B
C
D
E
F
G
H
J
K
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
HARNESS PART NUMBER
SJC
SEE SHEET 1
A22 PUMP
7188448
SUSP JSTK
7163706
4610 LGN
2980 BRN
3980 LBL
2890 BRN
5980 YEL
33
34
1710 RNG/WHT
1
3
2
GND
SIG
+12V PWR
RIGHT
SWASHPLATE
C537
5860 YEL
2860 BRN
3860/LBL LBL
1770 RNG/WHT
2
4
3
1
2860 BRN
3860 LBL
1770 RNG/WHT
C542
1
3
2
GND
SIG
+12V PWR
LEFT
SWASHPLATE
C546
C501
43
42
4260 LGN
2660 BRN
1
2
4260 LGN
2660 BRN
44
45
4250 LGN
2650 BRN
3
4
4250 LGN
2650 BRN
31
41
4280 LGN
2680/BRN BRN
5
6
21
11
4270 LGN
2670 BRN
7
8
1
2
RIGHT FORWARD DRIVE
C547
1
2
RIGHT REVERSE DRIVE
C545
4280 LGN
2680 BRN
1
2
LEFT REVERSE DRIVE
C544
4270 LGN
2670 BRN
1
2
3990 LBL
2990 BRN
4640 LGN
4650 LGN
4210 LGN
A
G
F
E
D
B
H
C
9240 PUR
9140 PUR/WHT
1760 RNG/WHT
2280 BLK
LEFT FORWARD DRIVE
A
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT
C492
12
22
4
6
16
9190 PUR/WHT
9290 PUR
4550 LGN
4220 LGN
4275 LGN
50
1750 RNG/WHT
27
28
47
48
2470 BLK
2490 BLK
1250 RED/WHT
1260 RED/WHT
9140 PUR/WHT
9240 PUR
1740 RNG/WHT
8
7
2
5
3
4
1
6
7100 WHT
Printed In U.S.A.
710 of 1148
+5V PWR
K
A
D
F
H
J
C
B
E
G
TILT ACTUATOR
+5V PWR
SIG
GND
J5 DRIVE CONTROLLER
FUNCTION
SAFETY IN
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
L SWASH PLATE ANGLE
R SWASH PLATE ANGLE
SPARE ANALOG 4
SPARE ANALOG 5
L FWD RETURN
CAN HIGH
LF ANGLE
RF ANGLE
LR ANGLE
H PAT LITE
RR ANGLE
L JOYSTICK X
L JOYSTICK Y
R JOYSTICK X
L FWD DRIVE
CAN LOW
R QUAD A DRIVE
R QUAD B DRIVE
TWO SPEED 1
BRAKE LIGHT OUTPUT
GROUND
GROUND
SENSOR GROUND
SENSOR SUPPLY 2 +5V
L REV DRIVE
CAN SHIELD
L QUAD A DRIVE
L QUAD B DRIVE
SAFETY OUT
BACKUP ALARM
R JOYSTICK Y
SPARE ANALOG 1
SPARE PWM COIL 7
SENSOR SUPPLY 1 +5V
L REV RETURN
R FWD RETURN
R FWD DRIVE
R REV DRIVE
R REV RETURN
TWO SPEED 2
UNSWITCHED BATTERY
UNSWITCHED BATTERY
SPARE PWN COIL 6
SWITCHED BATTERY
1
2
4
1830 RNG/WHT
2070 BLK
9660 PUR
1
2
4
+12V PWR
GND
CAN LO
3
9560 PUR/WHT
3
CAAN HI
1
1840 RNG/WHT
1
+12V PWR
2
2080 BLK
2
GND
4
9640 PUR
4
CAN LO
3
9540 PUR/WHT
3
CAN HI
RIGHT
JOYSTICK
LEFT
JOYSTICK
C493
2235 BLK
1235 RED/WHT
1170 RED/WHT
2240 BLK
3
2
1
4
1760 RNG/WHT
2280 BLK
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT
36
3
4
2
6
1
5
7
8
K
J
E
H
F
G
C
D
B
A
C474
26
SIG
J2-ACS
3810 LBL
A22 PUMP HARNESS (7169309 or 7188448)
C543
2810 BRN
3810 LBL
1710 RNG/WHT
Dealer Copy -- Not for Resale
2
4
3
1
2970 BRN
C536
5810 YEL
2810/BRN BRN
7
GND
J1-ACS
ACS CONTROLLER
5970 YEL
5890 YEL
23
24
8
LIFT
ACTUATOR
C428
5990 YEL
40
5
6
8
1
4
2
7
3
J3-ACS
29
PIN
A
B
C
D
E
F
G
H
J
K
C429
4600 LGN
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
A
B
(CONNECTS TO BACKUP
ALARM C404 ON MFR
HARNESS)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR812541 - ALR814313)
Printable Version Click Here
Sheet 18 of 18
(PRINTED NOVEMBER 2016)
7253420 (0)
CONNECTOR ASSIGNMENTS
CONN
DESCRIPTION
NUM OF
PINS
SHEET
CONN
DESCRIPTION
NUM OF
PINS
SHEET
CONN
DESCRIPTION
NUM OF
PINS
SHEET
C100
C103
C105
WATER IN FUEL SENDER
TAILGATE HARNESS
HYD CHARGE PRESSURE SENSOR
2
8
3
8
6,12,13,15
9
BRAKE SOLENOID
CAN(Remote Start Tool, ACD)
CAB-MFR HARN CONN(LT GRY)
9
7
5,6,8,11,15
13
13
13
13
11,13,14,15
FRC1
FUSE RELAY CENTER
112
4,5,8,9,13,14
J1A
J1B
J2A
J2B
GATEWAY CONTROLLER
GATEWAY CONTROLLER
AUX CONTROLLER
AUX CONTROLLER
34
26
34
26
5,8,9,10,12,13,14,15
4,6,7,8,9,10,11,12,15
9,12,15
4,5,6,7,9,12,15
CAB-MFR HARN CONN(DK GRY)
3
7
14
2
2
2
2
14
J7A
ENG ECU CONTROLLER(BCT)
58
5,6,7,8
C108
C110
C111
C112
HYD TEMPERATURE SENDER
ALTERNATOR
HARNESS ENGINE START CONN
HYD OIL FILTER SWITCH
2
2
3
2
9
8
8
9
C425
C426
C428
C434-1
C434-2
C435-1
C435-2
C438
C114
C115
C116
C118
C126
HAND THROTTLE
FOOT THROTTLE
FOOT THROTTLE INTDM
ENG-CROSSOVER
HORN
6
6
3
4
2
8
8
8
8
15
C441
C446
C449
C450
C479
C480
TWO SPEED SOLENOID
HYDRAULIC FAN
LEFT JOYSTICK(CAB HARN)
RIGHT JOYSTICK(CAB HARN)
LEFT PANEL(BLACK)
LEFT PANEL(GRAY)
2
2
4
4
12
12
15
9
7
7
7,10
10
SW1
SW2
SW3
SW4
BRAKE SWITCH
BEACON SWITCH
HAZARD SWITCH
HAND/FOOT, H/ISO SWITCH
6
6
6
6
10
15
15
11
C129
C169
C212
CAB ACCESSORY
ENGINE CAN (Diagnostic)
POWER SOCKET
3
6
2
11
7
11
C482
C483
C486
SEATBAR SENSOR
TEMP CONTROL SWITCH
AC COMPRESSOR
3
3
2
11
14
14
SW5
SW6
POWER BOBTACH SWITCH
BUCKET POSITION SWITCH
6
6
15
15
C252
WASHER PUMP INTDM
2
11
C489
MFR ACCESSORY
2
5,6
C253
WASHER PUMP
2
11
C492
ACS/SJC/AWS-MFR HARN
8
5,7,11
SW9
TRAVEL CONTROL SWITCH
6
10
C277
C278
AIR RIDE SEAT
RIGHT SPEAKER
6
2
15
15
C493
C497
ACS/SJC/AWS-MFR HARN
SJC HORN/BLINKER
4
3
4,6
15
SW10
SW11
BLOWER SWITCH
AC SWITCH
6
3
14
14
C279
C308
LEFT SPEAKER
BRAKE SOLENOID
2
2
15
9
C499
C500
PTOL
RH KEY SWITCH
4
6
10
10
SW12
T1
DPF SWITCH
BATT GROUND
10
1
10
6
C350
C355
C404
C405
AC EVAPORATOR SWITCH
FUEL HARNESS
BU ALARM-MFR HARN
AIR FILTER SWITCH
2
6
2
2
14
8,15
5,12
8
C503
C602
C603
C606
RH DLX PANEL
LEFT REAR TAIL LIGHT
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
6
2
2
2
7,10
13
13
15
T2
T3
T4
T6
BUZZER GROUND
FLASHER
MEGAFUSE LOAD SIDE
BATT GROUND
1
2
1
1
10
15
4
C406
FUEL SENDER
2
8
C607
POWER BOBTACH CLOSE
2
15
T8
BATT GROUND
1
6
C408
CAB-MFR HARN CONN(BLK)
14
C610
HVAC DUCT FAN
2
14
T10
ENGINE SYSTEM GROUND
1
6
C409
C410
RIGHT HANDLE (MAN/ACS)
LEFT HANDLE (MAN/ACS)
10
10
4,6,7,10,
11,13,15
12
12
C611
C630
BLOWER MOTOR
THERMOSTAT
4
3
14
14
T13
BUZZER POWER
1
10
T14
PRE HEATER
1
8
C411
C412
C415
C418
C419
LEFT HANDLE 5 WAY
LEFT HANDLE 2 WAY
HIGH FLOW SOLENOID
FRONT ROD
FRONT BASE
5
2
2
2
2
15
15
15
9
9
C635
C667
C670
C676
HEATER VALVE
DOOR HARNESS
EXTERIOR BEACON HARNESS
RADIO
6
6
6
6
14
11
15
15
T15
T16
T17
T18
RIGHT REAR WORK LIGHT(+)
RIGHT REAR WORK LIGHT(-)
LEFT REAR WORK LIGHT(+)
LEFT REAR WORK LIGHT(-)
1
1
13
13
T19
13
13
12
C420
C421
C422
C423
HYD LOCK
TILT SPOOL LOCK
LIFT SPOOL LOCK
BUCKET POSITION SOLENOID
2
3
3
2
9
12
12
15
BACKUP ALARM
BACKUP ALARM(GND)
1
1
1
1
1
1
1
12
6
11
11
LEFT FRONT WORKLIGHT 1 (37W)
LEFT FRONT WORKLIGHT 2 (50W)
RIGHT FRONT WORKLIGHT 1 (37W)
Dealer Copy -- Not for Resale
RIGHT FRONT WORKLIGHT 2 (50W)
T20
T32
T37
T38
ECU CASE GROUND
DOME LIGHT(+)
DOME LIGHT(-)
6
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 1 of 18 Printable Version Click Here
Printed In U.S.A.
711 of 1148
(PRINTED NOVEMBER 2016)
7279775 (A)
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
FUNCTION
HYDRAULIC LOCK RETURN
LIFT SPOOL LOCK RETURN
HVAC RELAY - B
SWITCHED PWR RELAY - A
FRONT LIGHT RELAY - J
STARTER RELAY - M
TRACTION PULL RELAY - D
TILT SPOOL LOCK RETURN
AC SENSE
SPARE DIGITAL, ECU SOURCES
TRACTION LOCK FDBK RELAY - D
AIR FILTER SWITCH
REAR LIGHT RELAY - E
HYD FAN RETURN
PTOL LED
PTOL SWITCH
SWITCHED PWR FDBK RELAY - A
STARTER FDBK RELAY - M
START ENGINE
TWO SPEED RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
HYD CHARGE PRESS
UNSW BATT
UNSW BATT
RUN SIG ENG ECU
LIFT SPOOL LOCK
TRACTION LOCK HOLD
TILT SPOOL LOCK
CAN LO 1
CAN HI 1
HAND THROTTLE
SEAT BAR
FUEL LEVEL
BICS HYD LOCK HOLD
CAN HI 2
GROUND P1
GROUND P2
GROUND P3, SENSOR
HYD FAN
CAN LO 2
REMOTE RUN KEY
RUN/ENTER
SENSOR SUPPLY 8V
SENSOR SUPPLY 5V
TWO SPEED COIL
REAR LIGHT FDBK RELAY - E
HVAC FDBK RELAY - B
LIGHT FDBK RELAY - K
HYD OIL TEMP (8 VOLT)
FOOT THROTTLE
HYD OIL FILTER SW1
Dealer Copy -- Not for Resale
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
PIN
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
A-30
A-31
A-32
A-33
A-34
FUNCTION
FRONT BASE RETURN
LEFT BLINKER RELAY
RIGHT BLINKER RELAY
HORN RELAY
LH PADDLE RIGHT
LH PADDLE LEFT
RH RIGHT ROCKER UP
FRONT ROD RETURN
LH SW-FLOAT (ACS)
LH RIGHT ROCKER DOWN
HIGH FLOW RETURN
PIN
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
FUNCTION
UNSW BATT
UNSW BATT
CAN LO 1
CAN HI 1
FRONT BASE SOLENOID
CAN HI 2
GROUND
GROUND
RH PWM LOW
RH PWM SIGNAL
FRONT ROD
CAN LOW 2
RH TRIGGER
SWITCHED POWER
RH PWM HIGH
HIGH FLOW
LH RIGHT ROCKER UP
RH LEFT ROCKER UP
RH LEFT ROCKER DOWN
HARNESS PART NUMBER
MF MFR CTRL
7276760
EXMF MFR CTRL
7276758
DLX CAB
7253375
STD CAB
7227905
7149219
STD FUEL
712 of 1148
Printed In U.S.A.
DLX FUEL
7266824
BCT ENG START
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
BRAKE ADAPTER
WHL 2 SPD ADP
TRK 2 SPD
7220812
7217484
7217483
7266829
7165061
7159366
7214626
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 2 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
LEGEND
ENGINE CONTROLLER
PIN
CONNECTOR J7
FUNCTION
1
SW POWER
2
GND
3
SW POWER
4
GND
5
SW POWER
6
GND
9
WATER FUEL SENSOR
13
14
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PARTIAL CONNECTOR
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
15
19
ECU RUN SIGNAL
21
26
28
MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
35
34
MASS AIR FLOW (MAF)
SENSOR TEMP
WATER FUEL SENSOR GND
45
ECU RELAY GND
47
ECU CAN 1 LO
48
ECU CAN 1 HI
56
GLOW PLUG SIGNAL
E
F
J
K
Dealer Copy -- Not for Resale
25
D
C
B
A
24
G
H
L
M
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 3 of 18
Printed In U.S.A.
713 of 1148
(PRINTED NOVEMBER 2016)
7279775 (A)
UNSWITCHED BATT POWER
1240/RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
1450/RED/WHT
6
1400/RED/WHT
1070/RED
+12V
BATTERY
1025/RED
MEGAFUSE
100.0 Amps
1270/RED
FUSE 11 25 A
FUSE 13 25 A
FUSE 15 25A
SP7
1120/RED/WHT
SP2
1160/RED/WHT
SP36
FUSE 4 25 A
1010/RED
1310/RED
FUSE 3 30 A
FUSE 1 15 A
1340/RED
SP26
1060/RED
1335/RED
1325/RED
SP1
1300/RED
FUSE 2 20 A
1140/RED/WHT
1360/RED/WHT
1320/RED/WHT
1350/RED/WHT
1330/RED/WHT
FUSE 9 50 A
FUSE 20 5 A
FUSE 16 25 A
1065/RED/WHT
1345/RED/WHT
1035/RED/WHT
1445/RED/WHT
1190/RED
1040/RED
1290/RED
1055/RED
FUSE 18 25 A
FUSE 22 25 A
FUSE 24 25 A
2
1235/RED/WHT
1165/RED/WHT
1490/RED/WHT
1370/RED/WHT
Dealer Copy -- Not for Resale
SHEET 8
STARTER
FUSE 17 25 A
J1B
GWY CTRLR
1150/RED/WHT
3
1180/RED/WHT
2
1030/RED
Printed In U.S.A.
714 of 1148
SHEET 10
C500 RH KEY SWITCH
1440/RED/WHT
SHEET 10
C479 LH PANEL (BLACK)
J2B
AUX CTRLR
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
SHEET 14
FRC1 HVAC RELAY
SHEET 9
FRC 1 TRACTION LOCK RELAY
SHEET 13
FRC1 REAR LIGHT RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
SHEET 5
FRC1 ENGINE ECU RELAY
SHEET 5
FRC 1 ENGINE ECU RELAY
SHEET 8
FRC1 PRE HEATER RELAY
SHEET 7
C426 REMOTE RUN, ACD
1460/RED/WHT
SP24
1410/RED/WHT
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
SP60
1050/RED
1420/RED/WHT
1
1170/RED/WHT
T4 1
1280/RED
2
3
SHEET 11
C667 DOOR HARNESS
1450/RED/WHT
FRC1 FUSE RELAY CENTER
1110/RED/WHT
1130/RED/WHT
SHEET 10
C503 RH DLX PANEL
SHEET 5
FRC1 SWITCHED PWR RELAY
SHEET 8
FRC1 STARTER RELAY
SHEET 15 C412 LH HANDLE HORN
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 4 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
SWITCHED POWER
FRC1
+12V ENGINE ECU
PWR RELAY -G
SHEET 4
1035/RED/WHT
30
85
1504/RNG/WHT
87
86
SP54
1509/RNG/WHT
1506/RNG/WHT
1
1507/RNG/WHT
3
1508/RNG/WHT
5
45
8005/TAN
SHEET 4
FRC1 FUSE RELAY CENTER
1345/RED/WHT
FUSE 21 15 A
1511/RNG/WHT
SHEET 8 ENG-CROSSOVER
FUSE 5 25 A
1760/RNG/WHT
1790/RNG/WHT
1805/RNG/WHT
FUSE 6 25 A
FUSE 12 15 A
FUSE 14 5 A
1795/RNG/WHT
FUSE 7 25 A
B
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
C489
A MFR ACCESSORY
1750/RNG/WHT 1780/RNG/WHT
SP50
1850/RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1550/RNG/WHT
1570/RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION)
1730/RNG/WHT
1520/RNG/WHT
SHEET 12 C410 LEFT HANDLE
1530/RNG/WHT
SHEET 12 C409 RIGHT HANDLE
1560/RNG/WHT
SP11
1660/RNG/WHT
1765/RNG/WHT
Dealer Copy -- Not for Resale
1720/RNG/WHT
SP65
22
C428
J2B
(LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
2
1735/RNG/WHT
1725/RNG/WHT
FUSE 8 25 A
FRC1
SWITCHED
POWER RELAY -A
SHEET 4
SHEET 6
1050/RED
+12V
PWR 30
2055/BLK
GND 85
87
86
1815/RNG/WHT
3450/LBL
21
3380/LBL
4
J1A
GWY CTRLR
1740/RNG/WHT
715 of 1148
6
FUSE 23 15 A
1580/RNG/WHT
1800/RNG/WHT
9
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
SP37
1920/RNG/WHT
1660/RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SHEET 8
C110 ALT EXCITATION
1840/RNG/WHT
SHEET 7
C449 LH JOYSTICK
1830/RNG/WHT
1700/RNG/WHT
1705/RNG/WHT
SHEET 10 SW12 DPF SWITCH (UNUSED)
SHEET 10 SW12 DPF SWITCH (UNUSED)
1620/RNG/WHT
1940/RNG/WHT
1930/RNG/WHT
1775/RNG/WHT
1960/RNG/WHT
1785/RNG/WHT
1950/RNG/WHT
1590/RNG/WHT
SHEET 10
SHEET 10
SHEET 10
SHEET 10
SHEET 10
SHEET 11
SHEET 10
SHEET 10
C479 LH PANEL (BLACK)
T13 LH PANEL BUZZER
C499 RH PANEL PTOL
SW1 BRAKE SWITCH
SW9 TRAVEL CONTROL SWITCH
SW4 H/ISO SWITCH
C500 RH PANEL KEY SWITCH
C503 RH DELUXE PANEL
SP42
SHEET 7 C169 ENGINE CAN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
1920/RNG/WHT
Printed In U.S.A.
J7A ENGINE ECU
SHEET 7
C450 RH JOYSTICK
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 5 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
GROUND
2
2001/BLK
4
2002/BLK
6
2003/BLK
T32
ECU CASE GND
SHEET 7
C449 LH JOYSTICK
SHEET 7
C450 RH JOYSTICK
SHEET 10
C479 LH PANEL (BLACK)
SHEET 10
C499 PTOL
SHEET 10
C500 RH PANEL KEY SWITCH
SP53
2810/BLK
2004/BLK
C493
ACS/SJC/AWS-MFR HARN
(4 PIN)
2080/BLK
2070/BLK
SP4
2950/BLK
16
2250/BLK
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SP47
1
2900/BLK
SHEET 9
C425 BRAKE
C103
TAILGATE HARN
SP51
2600/BLK
C489
MFR ACCESSORY
B
2550/BLK
B
2770/BLK
2200/BLK
2720/BLK
2600/BLK
2045/BLK
2455/BLK
SHEET 15
C423 BKT POSITION SOLENOID
2710/BLK
SHEET 7
C426 REMOTE RUN, ACD
2715/BLK
SHEET 7
C169 ENGINE CAN
2290/BLK
SHEET 14
D4 COMPRESSOR DIODE
SP28
2090/BLK
SP6
2390/BLK
2115/BLK
2055/BLK
2030/BLK
SHEET 8
FRC1 STARTER RELAY
2005/BLK
2120/BLK
SP55
2105/BLK
2520/BLK
SHEET 12
C410 LEFT HANDLE
2530/BLK
SHEET 12
C409 RIGHT HANDLE
17
T1
BATT GND
2015/BLK
SHEET 8
ALTERNATOR GROUND
T8
BATT GND
T10
ENGINE
GROUND
SP27
2300/BLK
Printable Version Click Here
2035/BLK
SHEET 14
FRC1 HVAC RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
2540/BLK
2900/BLK
SHEET 15
C355 FUEL HARN (PWR BOB/AC)
SHEET 5
FRC1 SWITCHED POWER RELAY
716 of 1148
16
J2B
15
AUX CTRLR
SP12 2230/BRN
2765/BLK
SHEET 13
C408 CAB-MFR CONN (FR LIGHTS)
2745/BLK
SHEET 14
C408 CAB-MFR CONN (HVAC)
2790/BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES)
2780/BLK
SHEET 15
C408 CAB-MFR CONN (OPTIONS)
2730/BLK
SHEET 11
C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SP3
2110/BLK
2510/BLK
2500/BLK
J1B
GWY CTRLR
T6
BATT GND
2950/BLK
J1B
GWY CTRLR 15
SHEET 13
FRC1 REAR LIGHT RELAY
SHEET 9
FRC1 TRACTION LOCK RELAY
SHEET 13
FRC1 FRONT LIGHT RELAY
Printed In U.S.A.
2240/BLK
10
2960/BLK
SHEET 10
C503 RH DELUXE PANEL
2065/BLK
SHEET 10
SW12 DPF SWITCH
2930/BLK
SHEET 10
SW1 BRAKE SWITCH
2830/BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700/BLK
SHEET 10
SW9 TRAVEL CONTROL SWITCH
2785/BLK
SHEET 15
C126 HORN
2620/BLK
SHEET 13
T16 RH REAR WORK LIGHT
2650/BLK
SHEET 12
T20 BU ALARM
2640/BLK
SHEET 13
C602 LH REAR TAIL LIGHT
2610/BLK
SHEET 13
C603 RH REAR TAIL LIGHT
2630/BLK
SHEET 13
T18 LH REAR WORK LIGHT
2235/BLK
4
C408
(BLACK)
CAB-MFR HARN CONN 1
2920/BLK
2940/BLK
3
Dealer Copy -- Not for Resale
J7A
ENG ECU CTRLR
2320/BRN
SHEET 9
C112 HYD OIL FILTER SWITCH
2370/BRN
SHEET 11
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220/BRN
SHEET 9
C108 HYD TEMP SENDER
2190/BRN
SHEET 9
C105 HYD CHG PRESSURE SENDER
2180/BRN
SHEET 8
C355 FUEL HARN (FUEL SENDER)
2150/BRN
SHEET 8
C405 AIR FILTER SWITCH
2690/BRN
SHEET 8
C408 CAB-MFR CONN (HAND THRTL)
2695/BRN
SHEET 8
C115 FOOT THROTTLE
SP5
2000/BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 6 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
J7A
ECU CNTRLR
47
CAN LO
48
CAN HI
CAN BUS
9200/PUR
9100/PUR/WHT
J1B
GWY CTRLR
9215/PUR
9115/PUR/WHT
9210/PUR
9110/PUR/WHT
9205/PUR
9105/PUR/WHT
20
14
R21
120 OHM
0.5W
RESISTOR
R18
120 OHM
0.5 W
RESISTOR
C169
ENGINE CAN
SHEET 5
SHEET 6
9155/PUR/WHT
9255/PUR
1725/RNG/WHT
2715/BLK
1
2
3
4
J1B
GWY CTRLR
8
9
9260/PUR
9160/PUR/WHT
9230/PUR
9130/PUR/WHT
R14
120 OHM
O.5W
RESISTOR
J2B
AUX CTRLR
CAN HI
CAN LO
C426
Remote Run Tool, ACD
14
9500/PUR/WHT
A
20
9600/PUR
B
3090/LBL
D
C
E
F
G
SHEET 5
SHEET 4
SHEET 6
Printed In U.S.A.
717 of 1148
1735/RNG/WHT
1165/RED/WHT
2710/BLK
9270/PUR
9170/PUR/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
9220/PUR
9120/PUR/WHT
REMOTE RUN KEY
SWITCHED POWER
UNSWITCHED POWER
GROUND
4
3
9220/PUR
9120/PUR/WHT
9410/PUR
9310/PUR/WHT
9430/PUR
9330/PUR/WHT
9450/PUR
9460/PUR
9350/PUR/WHT 9360/PUR/WHT
R19
120 OHM
0.5 W
RESISTOR
4
3
C479
LEFT PANEL (BLACK)
9440/PUR
9340/PUR/WHT
4
2
C503
RIGHT DELUXE PANEL
1830/RNG/WHT
2070/BLK
1
2
3
4
1840/RNG/WHT
2080/BLK
1
2
3
4
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
9290/PUR
9190/PUR/WHT
7
8
9240/PUR
9140/PUR/WHT
1
4
J2B
AUX CTRLR
9280/PUR
9180/PUR/WHT
J1B
GWY CTRLR
21
9250/PUR
9150/PUR/WHT
Dealer Copy -- Not for Resale
5
6
8
9
SHEET 5
SHEET 6
9320/PUR/WHT
9420/PUR
SHEET 5
SHEET 6
9300/PUR/WHT
9400/PUR
C450
RIGHT JOYSTICK
C449
LEFT JOYSTICK
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 7 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
ENGINE
FRC1
STARTER RELAY - M
1030/RED
SHEET 4
2005/BLK
SHEET 6
7
8210/TAN
22
3560/LBL
+12V
PWR 30
8200/TAN
87
GND
85
86
8210/TAN
SHEET 5
FUSE 12
3560/LBL
1800/RNG/WHT
A
B
C
STARTER
8220/TAN
3560/LBL
S
R
M
B
SHEET 4
1015/RED
C110
B
ALTERNATOR
J1A
GWY CTRLR
G
S
L
2150/BRN
3150/LBL
GND
5695/YEL
33
SHEET 6
C115
FOOT THROTTLE
C
5695/YEL
C
3695/LBL
A
3695/LBL
A
2695/BRN
B
2695/BRN
B
E
D
F
FOOT THROTTLE
ADAPTER HARNESS
7217683
J1B
GWY CTRLR
C355
FUEL HARN
3180/LBL C
2180/BRN D
12
SHEET 6
10
3690/LBL
4
8007/TAN
J7A
ENG ECU CTRLR
+5V PWR
SIG
GND
C406
3180/LBL
2180/BRN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 11
SHEET 6
ENGINE GROUND TERMINAL
AIR FILTER
SWITCH (NC)
SIG
C116
FOOT THROTTLE INTDM
SHEET 11
2015/BLK
Dealer Copy -- Not for Resale
SHEET 6
B
A
1020/RED
1800/RNG/WHT
EXCITATION
C405
16
19
C111
HARN ENG START CONN
A
B
SIG
GND
FUEL SENDER
(30 - 270 OHM)
C114
HAND THROTTLE
5690/YEL
7
5690/YEL
3690/LBL
6
3690/LBL
2690/BRN
8
2690/BRN
SHEET 6
8007/TAN
C
A
B
+5V PWR
SIG
GND
D
E
F
C100
9
34
1
2
3865/LBL
2865/BRN
SIG
GND
WATER IN FUEL SENDER
(FUEL FILTER)
C118
ENG-CROSSOVER
MAF FREQ
MAF TEMP
28
SHEET 5
8013/TAN
35
8014/TAN
SHEET 4
56
1065/RED/WHT
8510/TAN
+12V
PWR 30
85
87
8525/TAN
86
1445/RED/WHT
PREHEATER
RELAY - C
Printed In U.S.A.
718 of 1148
1
1511/RNG/WHT
8013/TAN
2
8014/TAN
3
3420/LBL
4
8500/TAN
SHEET 4
PRE-HEATER
To C154 - PIN 1, &
To C114, Pin 3, Sheet 16 of 18
MAF Sensor - PIN 1, Sheet 16 of 18
MAF Sensor - PIN 4, Sheet 16 of 18
Printable Version Click Here
TO GLOW PLUG, J7B - PIN 79,
Sheet 16 of 18
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 8 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
1360/RED/WHT
SHEET 4
2035/BLK
SHEET 6
FRC1
TRACTION LOCK
+12V RELAY - D
PWR 30
87
GND
85
HYDRAULICS
4100/LGN
SHEET 6
86
4200/LGN
2200/BLK
C425
B
A
C
C308
4200/LGN
2200/BLK
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061
8
4110/LGN
13
3430/LBL
32
2220/BRN
3220/LBL
SHEET 6
C108
B
A
GND
SIG
C112
J1A
GWY CTRLR
34
SHEET 6
3320/LBL
2320/BRN
A
B
SIG
GND
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
(8 VOLT)
HYDRAULIC OIL
FILTER SWITCH (NC)
2910/BRN
4010/LGN
1
2410/BRN
4410/LGN
2
1
GND
SIG
C420
B
A
GND
SHEET 6
B
C
A
HYDRAULIC LOCK
SOLENOID
9.8 OHM 12 V
GND
SIG
+8V PWR
HYDRAULIC
CHARGE
PRESSURE SENSOR
0.5-7.5V
4200/LGN
19 13
HYDRAULIC
FAN SOLENOID
7.2 OHM 12 V
SIG
C105
2190/BRN
3190/LBL
5190/YEL
Dealer Copy -- Not for Resale
C446
18
1 23 6
+8V
J1B
GWY CTRLR
Printable Version Click Here
C418
J2A
AUX CTRLR
18
2330/BRN
4330/LGN
1
2340/BRN
4340/LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
3.3 OHM PWM
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
C419
19 13
J2B
AUX CTRLR
Printed In U.S.A.
719 of 1148
2
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 9 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
1940/RNG/WHT
LEFT PANEL
BUZZER
7040/WHT
C479
LEFT PANEL (BLACK)
T2
BUZZER (-)
SHEET 6
SHEET 5
SHEET 6
1960/RNG/WHT
SHEET 4
SW9
TRAVEL CONTROL
SWITCH (OPTIONAL)
2700/BLK
SHEET 5
SHEET 15
5 6
4
2 3
1
SHEET 5
SHEET 6
SHEET 15
3610/LBL
1775/RNG/WHT
2930/BLK
3
1
4
7040/WHT
10
2920/BLK
2
1440/RED/WHT
1
1620/RNG/WHT
5
3400/LBL
11
3500/LBL
8
3650/LBL
7
3600/LBL
9
6
SW1
BRAKE
SWITCH
2
8050/TAN
12
11
10
3
2
8
7
6
4
1705/RNG/WHT 10
8
8055/TAN
5
2
3
8060/TAN
1
1
4
8070/TAN
9
3610/LBL
SW12
DIESEL PARTICULATE
DERATE OVERRIDE SWITCH
SHEET 5
SHEET 6
1700/RNG/WHT
2065/BLK
7 9
NOT USED
Printed In U.S.A.
720 of 1148
UNSWITCHED POWER
SWITCHED POWER
C499
Press To Operate Loader
(PTOL)
1930/RNG/WHT
2940/BLK
1
3
20
3030/LBL
1
3030/LBL
2
19
2380/BRN
12
2380/BRN
4
J1A
GWY CTRLR
LEFT BLINKER INPUT
24
TRAVEL CONTROL INPUT
8130/TAN
2
8130/TAN
PARK BRAKE INPUT
DOOR SIGNAL
PARK BRAKE OUTPUT
DPF LAMP
DPF INHIBIT LAMP
DPF OVERRIDE
SWITCHED POWER
GROUND
PTOL OUTPUT
PTOL LED
C500
RIGHT PANEL - KEY SWITCH
RIGHT BLINKER INPUT
C480
LEFT PANEL (GRAY)
SHEET 11
SHEET 5
GROUND
5
3620/LBL
SHEET 5
C408
SHEET 6
(BLACK)
CAB-MFR HARN CONN 1
BUZZER
12
6
CAB DISPLAY
2
START
6
Dealer Copy -- Not for Resale
SHEET 5
T13
BUZZER (+)
J1B
GWY CTRLR
22
3040/LBL
14
SHEET 5
SHEET 4
SHEET 6
3040/LBL
4
1950/RNG/WHT
1420/RED/WHT
2960/BLK
5
1
3
RUN/ENTER SWITCH
SWITCHED POWER
UNSWITCHED POWER
GROUND
C503
RIGHT PANEL DELUXE DISPLAY
SHEET 5
SHEET 4
SHEET 6
1590/RNG/WHT
5
1240/RED/WHT
1
2250/BLK
3
DPF INHIBIT REGEN
6
SWITCHED POWER
UNSWITCHED POWER
GROUND
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 10 of 18 Printable Version Click Here
(PRINTED NOVEMBER 2016)
7279775 (A)
*
SHEET 5
C492
ACS/SJC/AWS-MFR HARN
SHEET 12
(8 PIN)
4230/LGN
4240/LGN
SHEET 12
5
4220/LGN
3
4275/LGN
2
4550/LGN
SHEET 5
C438
SHEET 11
(DK GRAY)
CAB-MFR HARN CONN 3
SP29
4235/LGN
1850/RNG/WHT
7
4235/LGN
8
4275/LGN
9
4550/LGN
2
1850/RNG/WHT
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785/RNG/WHT
2 1
3
6
2060/BLK
5
4
CAB
*
DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN)
*
C212
POWER
SOCKET
2795/BLK
1375/RED/WHT
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 4
1370/RED/WHT
7
*
SP45
1370/RED/WHT
1390/RED/WHT
1580/RNG/WHT
5
1580/RNG/WHT
SP8
1865/RNG/WHT
2800/BLK
SHEET 15
SHEET 15
1885/RNG/WHT
SP44
SHEET 6
11
2730/BLK
C428
(LT GRAY)
CAB-MFR HARN CONN 2
SHEET 6
2790/BLK
14
2790/BLK
2210/BLK
SHEET 15
2885/BLK
2060/BLK
SHEET 15
SHEET 11
SHEET 10
SHEET 4
C482
J1B
GWY CTRLR
SHEET 6
11
+5V
24
5100/YEL
SHEET 8
SHEET 8
SEATBAR
SENSOR
2370/BRN
4
2370/BRN
A
GND
3370/LBL
5
3370/LBL
B
SIG
5370/YEL
SP13
3
5370/YEL
C
+5V PWR
7310/WHT
*
C253
C252
2845/BLK
Printed In U.S.A.
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
1850/RNG/WHT
3620/LBL
1400/RED/WHT
1
4
5
6
2840/BLK
2
3
WIPER SWITCH, MOTOR SWITCHED POWER
DOOR SIGNAL
DOOR UNSW PWR
WIPER MOTOR GROUND
WASHER SIGNAL
Printable Version Click Here
5690/YEL
5695/YEL
HARNESS WASHER PUMP
7253378
721 of 1148
T38
DOME LIGHT (-)
GND
1510/RNG/WHT
2730/BLK
T37
DOME LIGHT (+)
DOME
LIGHT
*
+12V BATT PWR
+12V SW PWR
Dealer Copy -- Not for Resale
SHEET 5
A
B
C
GND
+12V PWR
SP41
2010/BLK
C129
CAB ACCESSORY
1210/RED/WHT
1
2
A
7310/WHT
1
B
2845/BLK
2
PWR
GND
WASHER
MOTOR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 11 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
MANUAL CONTROLS
J2A
AUX CTRLR
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
A
C103
TAILGATE HARN
C
7100/WHT
SHEET 6
30
31
T19 TERMINAL (+)
7100/WHT
BACK UP
ALARM
2650/BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
2530/BLK
SHEET 6
SHEET 11
SHEET 5
4230/LGN
1530/RNG/WHT
4940/LGN
4930/LGN
4920/LGN
4910/LGN
4310/LGN
4320/LGN
4300/LGN
13
T20 TERMINAL (-)
2980/BRN
4980/LGN
3
1
2
GND
SIG
TILT SPOOL LOCK
17.8 OHM 12V
C422
2
2990/BRN
4990/LGN
7
5
3
1
2
GND
SIG
LIFT SPOOL LOCK
17.8 OHM 12V
Dealer Copy -- Not for Resale
10
J1A
GWY CTRLR
J2B
AUX CTRLR
4640/LGN
4840/LGN
4830/LGN
4820/LGN
4810/LGN
20
28
22
12
11
SHEET 5
SHEET 11
SHEET 6
A
B
HANDLE LOCK (ACS)
SKI CTRL
DETENT FLOW
TWO SPD
PWM
C410
LEFT HANDLE
(MANUAL/ACS ONLY)
21 17 18 23
C421
K
G
A
H
J
E
F
C
D
B
C466
1520/RNG/WHT
4240/LGN
2520/BLK
K
D
C
B
G
F
A
J
H
E
FLOAT (ACS)
SKI CTRL
SIDE SHIFT
C465
A
B
HANDLE LOCK (ACS)
SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS
J1B
GWY CTRLR
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 12 of 18
Printed In U.S.A.
722 of 1148
(PRINTED NOVEMBER 2016)
7279775 (A)
C434-1
LIGHTS
2735/BLK
6100/PNK
C408
(BLACK)
CAB-MFR HARN CONN 1
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
37.00 Watts
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
SIG
GND
RIGHT FRONT
WORK LIGHT
50.00 Watts
C434-2
2765/BLK
SHEET 6
9
2765/BLK
2750/BLK
6110/PNK
8
6000/PNK
6120/PNK
2760/BLK
B
A
C435-1
RC1
FRONT WORK
LIGHTS RELAY 1
SHEET 6
1350/RED/WHT
30
2120/BLK
85
87
6620/PNK
13
86
SHEET 4
SHEET 6
5
31
J1A
17
GWY CTRLR
28
1330/RED/WHT
2115/BLK
30
GND 85
87
86
6320/PNK
3460/LBL
6210/PNK
3440/LBL
6340/PNK
6000/PNK
6630/PNK
RC2
FRONT WORK
LIGHTS RELAY 2
+12V
PWR
6610/PNK
C435-2
6130/PNK
2705/BLK
6310/PNK
A
C603
6310/PNK
2610/BLK
6320/PNK
SHEET 6
SHEET 4
SHEET 6
1320/RED/WHT
2045/BLK
87
GND 85
86
2
1
GND
SIG
RIGHT REAR
TAIL LIGHT
C602
6330/PNK
2640/BLK
SHEET 6
2620/BLK
SHEET 6
6210/PNK
FRC1
REAR LIGHT
RELAY - E
+12V
PWR 30
A
B
6610/PNK
C103
TAILGATE HARN
Dealer Copy -- Not for Resale
SHEET 4
C438
(DK GRAY)
CAB-MFR HARN CONN 3
A
B
1
2
SIG
GND
T16 TERMINAL (-)
GND
SIG
LEFT REAR
TAIL LIGHT
RIGHT REAR
WORK LIGHT
T15 TERMINAL (+)
6200/PNK
H
6200/PNK
SHEET 6
SP96
6200/PNK
2630/BLK
T17 TERMINAL (+)
SIG
GND
LEFT REAR
WORK LIGHT
T18 TERMINAL (-)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Printable Version Click Here
Sheet 13 of 18
Printed In U.S.A.
723 of 1148
(PRINTED NOVEMBER 2016)
7279775 (A)
HVAC
*
2440/BLK
7440/WHT
*
2560/BLK
C610
2
1
DLX CAB HARN 7253375 ONLY
(NOT IN STD CAB HARN)
C
A
B
SHEET 6
3
30
GND 85
2745/BLK
SHEET 6
11
SP40
7021/WHT
7020/WHT
11 2745/BLK
12
C350
B
A
C486
SHEET 6
724 of 1148
7410/WHT
OFF
5 2
1
4
6
3
*
SW11
AC SWITCH
SP16
3
2100/BLK
7015/WHT
C
1
*
C630
3
2
1
7530/WHT
7520/WHT
7510/WHT
2580/BLK
*
C611
1
2
3
4
14.00 Amps
7.50 Amps
5.00 Amps
High
Med
Low
BLOWER
MOTOR
7400/WHT
THERMOSTAT
Printable Version Click Here
7025/WHT
Printed In U.S.A.
SWITCH
2570/BLK
7020/WHT
7023/WHT
7024/WHT
HEATER
VALVE
SW10
*BLOWER
10 1500/RNG/WHT
86
7050/WHT
3050/LBL
J1A
GWY CTRLR
AC EVAPORATOR
SWITCH
1500/RNG/WHT
POTENTIOMETER
(TEMP CONTROL
SWITCH)
D
SIG
C
GND
A +12V PWR
B
E
F
C438
(DK GRAY)
CAB-MFR HARN CONN 3
FRC1
+12V HVAC RELAY - B
1140/RED/WHT PWR 30
87
2030/BLK
BLK
DBL
WHT
C635
2130/BLK
7430/WHT
SP48
Dealer Copy -- Not for Resale
SHEET 4
*
HVAC DUCT
FAN
C483
7420/WHT
7425/WHT
*
GND
SIG
2290/BLK
2280/BLK
D4
1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 14 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
#
POWER BOB
CLOSE
SIG
GND
#
POWER BOB
OPEN
GND
SIG
C607
1
2
4470/LGN
2470/BLK
2770/BLK
E
B
OPTIONS
C428
(LT GRAY)
CAB-MFR HARN CONN 2
C355
FUEL HARN
11
4470/LGN
2770/BLK
4470/LGN
#
SHEET 6
SW5
*POWER
BOBTACH
SWITCH
C606
2
1
2480/BLK
4480/LGN
F
4480/LGN
1550/RNG/WHT
SHEET 5
4480/LGN
13
6010/PNK
12
1550/RNG/WHT
C411
RIGHT
(SEE ADDITIONAL
OPTIONS DWG)
LEFT
1
E
D
6515/PNK
6500/PNK
6
6500/PNK
6415/PNK
6400/PNK
3
6400/PNK
6410/PNK
6510/PNK
BUCKET
POSITION
SOLENOID
6.13 OHM
LEFT HANDLE
(HORN) 2 WAY
(SEE ADDITIONAL
OPTIONS DWG)
2780/BLK
SHEET 6
C423
SIG
A
4450/LGN
GND
B
2450/BLK
4455/LGN
D3
2455/BLK
B
A
5
4
3
7200/WHT
6420/PNK
6520/PNK
26
2460/BRN
4460/LGN
C
A
B
26
J1A
GWY CTRLR
26
J1B
GWY CTRLR
26
SHEET 6
SHEET 6
B
A
GND
SIG
Printed In U.S.A.
725 of 1148
2785/BLK
7210/WHT
2
1
GND
SIG
6430/PNK
3400/LBL
SW3
*HAZARD
SWITCH
(PINS 3 & 6
INTERNALLY
INSULATED)
TWO SPEED
SOLENOID
5.1 OHM 12 V
2
5
1
3
4
2
5
6
*
GND
SIG
2725/BLK
2850/BLK
6
SWITCH
6
5
4
1
2
3
* C670E
2420/BLK
6440/PNK
6540/PNK
SW6
BUCKET
POSITION
SWITCH
C126
B
A
SW2
*BEACON
6700/PNK
2780/BLK
HORN
LEFT
SPEAKER
RIGHT
SPEAKER
*+
1
2
*-
SHEET 11
SHEET 11
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
*
3
4
7820/WHT
7830/WHT
*
C278
2
1
D
F
B
C
A
C676
RADIO CONN
C279
-
+
HIGH FLOW
SOLENOID
7.5 OHM 12 V
C441
2350/BRN
4350/LGN
2830/BLK
SJC
HORN/BLINKER
(SEE ADDITIONAL
OPTIONS DWG)
C415
J2B
AUX CTRLR
4455/LGN
CONN
6530/PNK
SHEET 10
SHEET 4
C497
J2A
AUX CTRLR
5
13
7210/WHT
1460/RED/WHT
D1
D2
3
1
4
T3
* FLASHER
X
L
3500/LBL
2780/BLK
C408
(BLACK)
CAB-MFR HARN CONN 1
C412
SIG
PWR
4
SHEET 6
1200/RED/WHT
1430/RED/WHT
SHEET 10
C103
TAILGATE HARN
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
* DLX CAB HARN 7253375 ONLY
1410/RED/WHT
Dealer Copy -- Not for Resale
LEFT HANDLE
(FLASHER) 5 WAY
1410/RED/WHT
SHEET 4
3
4
6
6570/PNK
B
C
A
E
D
5
(NOT IN STD CAB HARN)
C438
(DK GRAY)
CAB-MFR HARN CONN 3
PWR
1
1380/RED/WHT
6010/PNK
10
2
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
7810/WHT
7800/WHT
1885/RNG/WHT
2885/BLK
6
5
1
2
SHEET 11
SHEET 11
1510/RNG/WHT
2210/BLK
C277
1
2
3
4
5
6
AIR RIDE
SEAT
PWR
GND
Printable Version Click Here
TRACK 2 SPEED
ADAPTER
(SEE ADDITIONAL
OPTIONS DWG)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 15 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
RED
RED
BATT FEED, GENERAL
1000 THROUGH 1499
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
PNK
WHITE
WHT
OTHER FUNCTIONS
7000 THROUGH 7999
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PRE HEATER
TO C118 - PIN 4
See Sheet 8 of 18
SCHEMATIC INDEX
OVERVIEW
POWER
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
HVAC
OPTIONS
PARTIAL CONNECTOR
PAGE 1-3
PAGE 4-5
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 16
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
ENGINE
HARNESS
SHEET #
179
J7B
ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
106
TEMP SENSOR 2
123
SENSOR RETURN 2
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
C151
EGR VREF3
164
5
POSITION SIGNAL
116
3
POSITION RETURN
172
120
137
6
H BRIDGE POS
192
2
H BRIDGE NEG
193
TO C118 PIN 3
See Sheet 8 of 18
2
COOLANT TEMP SENSOR
109
1
COOLANT RETURN
145
C148
FUEL TEMP
SENSOR
1
FUEL TEMP SENSOR
110
2
FUEL RETURN
146
2
SENSOR SIGNAL
131
1
SENSOR RETURN
SHIELD
130
128
C146
ENGINE BLOCK
ACCELEROMETER 2
CRANKSHAFT
POSITION
SENSOR
2
1
SENSOR SIGNAL
SENSOR RETURN
SHIELD
C145
132
RAIL
PRESSURE
SENSOR
CRANK SENSOR POS
160
2
CRANK SENSOR NEG
136
1
SENSOR RETURN
147
2
POS SENSOR
159
3
C143
VREF1 CAM
TO C118 - PIN 1
See Sheet 8 of 18
1
RAIL PRESSURE SENSOR
3
4
104
169
194
119
3
VREF1 SENSOR
138
2
FUEL INJECTOR LSD1B
C142
CYL 4
Printed In U.S.A.
2
OIL TEMPERATURE SENSOR
RETURN
SENSOR
.
1
2
INTAKE
MANIFOLD
TEMPERATURE
NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
INTAKE MANIFOLD PRESSURE
112
INTAKE PRESS SENSOR
INTAKE PRESS RETURN
151
175
1
FUEL INJECTOR HSDA
103
2
FUEL INJECTOR LSD2A
125
127
C138
1
3
2
INTAKE
PRESSURE
SENSOR
126
150
174
C139
FUEL INJECTOR HSDA
FUEL INJECTOR LSD1A
Printable Version Click Here
1
2
CYL 1
C140
FUEL INJECTOR HSDB
FUEL INJECTOR LSD2B
2
1
CYL 2
C154
177
PWM
TO C118 - PIN 1
SEE Sheet 8 of 18
726 of 1148
1
RETURN GND
OIL PRESSURE &
TEMPERATURE
SENSOR
135
SENSOR RETURN
FUEL INJECTOR HSDB
C136
OIL PRESSURE SENSOR
167
2
1
1
111
148
MAF
SENSOR
133
129
1
C141
CYL 3
2
VREF3 OIL PRESSURE
C144
CAM SHAFT
SENSOR
3
165
C147
ENGINE BLOCK
ACCELEROMETER 1
5V
TO C118 PIN 2
See Sheet 8 of 18
C149
COOLANT TEMP
SENSOR
4
SENSOR GROUND
Dealer Copy -- Not for Resale
EGR VALVE
DC MOTOR
1
2
1
INLET METERING
VALVE
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 16 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
PIN
A
B
C
D
E
F
G
H
J
K
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
ACS
CONTROLS
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
ACS AND AHC HARNESS
(500 Models - Track & Wheel) 7190593
(600 Models - Track & Wheel) 7164144
J1-ACS
CONTROLLER
2280/BLK
4220/LGN
4275/LGN
C
+5V
E
D
B
A
G
4550/LGN
9240/PUR
9140/PUR/WHT
1740/RNG/WHT
5
3
2
7
8
1
4
6
C493
4
3
2
1
2240/BLK
J3-ACS
CONTROLLER
1170/RED/WHT
B
C
A
B
C
A
GRD
SIG
+5V PWR
LIFT HANDLE
HALL SENSOR
C469
2750/BRN
4750/LGN
5750/YEL
G
4220/LGN
2260/BLK
2270/BLK
4260/LGN
B
C
A
GND
SIG
+5V PWR
TILT HANDLE
HALL SENSOR
GND
SIG
+5V PWR
LIFT PEDAL
HALL SENSOR
D
4610/LGN
F
4600/LGN
C467
2510/BLK
4280/LGN
3
1
2
C468
2500/BLK
4270/LGN
2
3
1
C429
5980/YEL
2980/BRN
3980/LBL
8
7
6
5
4
3
1
2
C471
2980/BRN
2990/BRN
2
3
1
C428
C470
2760/BRN
4760/LGN
5760/YEL
3980/LBL
3990/LBL
Printed In U.S.A.
727 of 1148
B
C
A
2660/BRN
4660/LGN
5660/YEL
5750/YEL
5650/YEL
5970/YEL
H
E
E
J
H
G
C472
2650/BRN
4650/LGN
5650/YEL
F
K
1190/RED/WHT
1180/RED/WHT
5970/YEL
2250/BRN
J2-ACS
CONTROLLER
A
B
C
J
D
B
C
4275/LGN
C492
SEE MANUAL CONTROL
PAGE FOR HARNESS CONN
2280/BLK
2240/BLK
1170/RED/WHT
MAINFRAME HARNESS
Dealer Copy -- Not for Resale
H
5980/YEL
5990/YEL
2
3
1
GND
SIG
+5V PWR
TILT PEDAL
HALL SENSOR
K
4645/LGN
A
4640/LGN
5990/YEL
2990/BRN
3990/LBL
8
7
6
5
4
3
1
2
LIFT
SOLENOID
13 OHM
12V
FOOT PEDAL LOCK
TILT
SOLENOID
LIFT ACTUATOR
C409
C466
K
G
A
H
J
E
F
C
D
B
A
B
HANDLE
LOCK
SKI CTRL
DETENT
FLOW
TWO SPD
PWM
C410
K
D
C
B
G
F
A
J
H
E
FLOAT
SKI CTRL
SIDE
SHIFT
A
B
HANDLE
LOCK
+5V PWR
GND
SIG
TILT ACTUATOR
+5V PWR
GND
SIG
Printable Version Click Here
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 17 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
SJC
CONTROLS
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
PIN
A
B
C
D
E
F
G
H
J
K
HARNESS PART NUMBER
SJC
SEE SHEET 1
A22 PUMP
7198705
SUSP JSTK
7284703
4610/LGN
2980/BRN
3980/LBL
2890/BRN
5980/YEL
33
34
3810/LBL
1710/RNG/WHT
2810/BRN
3810/LBL
1710/RNG/WHT
1
3
2
GND
SIG
+12V PWR
RIGHT
SWASHPLATE
C537
5860/YEL
2860/BRN
3860/LBL/LBL
1770/RNG/WHT
2
4
3
1
2860/BRN
3860/LBL
1770/RNG/WHT
C542
1
3
2
GND
SIG
+12V PWR
C546
C501
43
42
4260/LGN
2660/BRN
1
2
4260/LGN
2660/BRN
44
45
4250/LGN
2650/BRN
3
4
4250/LGN
2650/BRN
1
2
LEFT
SWASHPLATE
RIGHT FORWARD DRIVE
C547
31
41
4280/LGN
2680/BRN/BRN
5
6
21
11
4270/LGN
2670/BRN
7
8
4280/LGN
2680/BRN
1
2
RIGHT REVERSE DRIVE
C545
1
2
LEFT REVERSE DRIVE
3990/LBL
2990/BRN
4640/LGN
4650/LGN
4270/LGN
2670/BRN
1
2
A
G
F
E
D
B
H
C
9240/PUR
9140/PUR/WHT
1760/RNG/WHT
2280/BLK
LEFT FORWARD DRIVE
C474
4210/LGN
A
2270/BLK
2260/BLK
1180/RED/WHT
1190/RED/WHT
C492
12
22
4
6
16
9190/PUR/WHT
9290/PUR
4550/LGN
4220/LGN
4275/LGN
50
1750/RNG/WHT
27
28
47
48
2470/BLK
2490/BLK
1250/RED/WHT
1260/RED/WHT
9140/PUR/WHT
9240/PUR
1740/RNG/WHT
8
7
2
5
3
4
1
6
728 of 1148
+5V PWR
7100/WHT
Printed In U.S.A.
K
A
D
F
H
J
C
B
E
G
TILT ACTUATOR
+5V PWR
SIG
GND
4780
4790
J5 DRIVE CONTROLLER
FUNCTION
SAFETY IN
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
L SWASH PLATE ANGLE
R SWASH PLATE ANGLE
SPARE ANALOG 4
SPARE ANALOG 5
L FWD RETURN
CAN HIGH
LF ANGLE
RF ANGLE
LR ANGLE
H PAT LITE
RR ANGLE
L JOYSTICK X
L JOYSTICK Y
R JOYSTICK X
L FWD DRIVE
CAN LOW
R QUAD A DRIVE
R QUAD B DRIVE
TWO SPEED 1
BRAKE LIGHT OUTPUT
GROUND
GROUND
SENSOR GROUND
SENSOR SUPPLY 2 +5V
L REV DRIVE
CAN SHIELD
L QUAD A DRIVE
L QUAD B DRIVE
SAFETY OUT
BACKUP ALARM
R JOYSTICK Y
SPARE ANALOG 1
SPARE PWM COIL 7
SENSOR SUPPLY 1 +5V
L REV RETURN
R FWD RETURN
R FWD DRIVE
R REV DRIVE
R REV RETURN
TWO SPEED 2
UNSWITCHED BATTERY
UNSWITCHED BATTERY
SPARE PWN COIL 6
SWITCHED BATTERY
1
2
4
1830/RNG/WHT
2070/BLK
9660/PUR
1
2
4
+12V PWR
GND
CAN LO
3
9560/PUR/WHT
3
CAAN HI
1
1480/RNG/WHT
1
+12V PWR
2
2080/BLK
2
GND
4
9640/PUR
4
CAN LO
3
9540/PUR/WHT
3
CAN HI
RIGHT
JOYSTICK
LEFT
JOYSTICK
C493
2235/BLK
1235/RED/WHT
1170/RED/WHT
2240/BLK
3
2
1
4
Printable Version Click Here
1760/RNG/WHT
2280/BLK
2270/BLK
2260/BLK
1180/RED/WHT
1190/RED/WHT
36
3
4
2
6
1
5
7
8
K
J
E
H
F
G
C
D
B
A
C544
26
SIG
J2-ACS
2
4
3
1
Dealer Copy -- Not for Resale
5810/YEL
2810/BRN/BRN
A22 PUMP HARNESS (7198705)
C543
2970/BRN
C536
7
4690
GND
J1-ACS
ACS CONTROLLER
23
24
8
4680
C428
5990/YEL
5890/YEL
5970/YEL
40
5
6
8
1
4
2
7
3
J3-ACS
29
LIFT
ACTUATOR
C429
4600/LGN
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
A
B
(CONNECTS TO BACKUP
ALARM C404 ON MFR
HARNESS)
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S530 (S/N ALR814314 - ALR815170)
(S/N B42T11001 - B42T11009)
Sheet 18 of 18
(PRINTED NOVEMBER 2016)
7279775 (A)
Index Diagram
1
SH01 - INDEX
2
SH02 - UNSWITCHED BATT POWER
3
SH03 - SWITCHED POWER
4
SH04 - GROUND
5
SH05 - CAN BUS
6
SH06 - ENGINE
7
SH07 - ENGINE CONTROL UNIT
8
SH08 - HYDRAULICS
9
SH09 - CAB DISPLAY
10
SH10 - CAB
11
SH11 - MANUAL CONTROLS
12
SH12 - LIGHTS
13
SH13 - HVAC
14
SH14 - OPTIONS 1
15
SH15 - OPTIONS 2
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
7300790
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
7300339
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
7301237
LIGHTS
6000 THROUGH 6999
PINK
PNK
MF MFR CTRL
EXMF MFR CTRL
DLX CAB
STD CAB
STD FUEL
DLX FUEL
BCT ENG
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
WHL 2 SPD ADP
TRK 2 SPD
7266824
7220812
7267103
7217483
7163706
7159366
7243409
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
B3
Wiring Schematic
/ SJC Machine
ACS
MOVED "GND" TEXT FROM A5 TO A2
104399
AEW
3
B2
2195 ASSIGNED
SIZEInteractive
OF 18
Click
Here For
PDF
104399
AEW
11
104399
AEW
5
B1
729 of 1148
7303755
7149219
REV
9205 SWAPPED SIZE AND MATERIAL VALUES
DESCRIPTION
CHG NOTICE DWN
SHEET
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
Dealer Copy -- Not for Resale
HARNESS PART NUMBER
COLOR CODE
WIRE COLOR
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
LEGEND
CONNECTOR
1
1
PARTIAL CONNECTOR
1
1
1
1
WIRE BREAK
SHT1/F2
SHT1/F2
ECN
WIRE #
WIRE #
SHT1/F2
SHT1/F2
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 1 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 1 / 15
7300789
UNSWITCHED
BATT POWER
1240 RED/WHT
1400 RED/WHT
C408
1450 RED/WHT
6
6
1450 RED/WHT
1440 RED/WHT
1110 RED/WHT
FUSE 11 25 A
1070 RED
11A
11B
13A
13B
1130 RED/WHT
1120 RED/WHT
FUSE 13 25 A
1025 RED
SHT10/D3
SP7
1420 RED/WHT
FUSE RELAY CENTER
1160 RED/WHT
SP2
SP36
SHT9/E4
2
SHT9/E4
SHT9/G8
GATEWAY CTRLR
3
J1B
1150 RED/WHT
1180 RED/WHT
3
AUX CTRLR
2
J2B
+12V BATTERY
MEGAFUSE
1
HW11
100.0 Amps
T5
C493
FUSE 15 25A
1
1270 RED
15A
T4
1170 RED/WHT
15B
1
1
2
2
FUSE 17 25 A
1280 RED
17A
1235 RED/WHT
17B
1310 RED
4A
1140 RED/WHT
4B
Dealer Copy -- Not for Resale
1010 RED
SHT6/G1
BUS BAR
FUSE 4 25 A
SHT13/E8
FUSE 3 30 A
3A
1360 RED/WHT
3B
SHT8/H8
BUS BAR
FUSE 1 15 A
1340 RED
1A
1320 RED/WHT
1B
FUSE 2 20 A
2A
SP26
1330 RED/WHT
2B
1325 RED
9A
SHT12/D8
1350 RED/WHT
FUSE 9 50 A
1060 RED
SHT12/B8
SHT12/F8
1065 RED/WHT
9B
SHT6/C3
FUSE 20 5 A
1335 RED
20A
1345 RED/WHT
20B
SHT3/G8
FUSE 16 25 A
SP1
1300 RED
16A
1035 RED/WHT
16B
SHT3/H8
RED
1445 RED/WHT
SHT6/C3
1055
FUSE 18 25 A
1190 RED
18A
1165 RED/WHT
18B
SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
1040 RED
22A
22B
1490 RED/WHT
1410 RED/WHT
SHT14/F7
SP24
FUSE 24 25 A
SP60
1290 RED
24A
FRC1
24B
1370 RED/WHT
SHT10/F8
FRC1
1050 RED
SHT3/D8
1030 RED
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
730 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
SHT6/G8
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 2 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 2 / 15
7300789
FRC1 ENGINE
ECU RELAY - G
ENG ECU CTRLR
1506 RNG/WHT
SHT2/D1
1035 RED/WHT
+12V PWR
30
G1
86
G2
87
G4
85
SP54
1540 RNG/WHT
1507 RNG/WHT
3
1508 RNG/WHT
G5
FRC1
1
5
FRC1
8005 TAN
SHT2/D1
SWITCHED
POWER
45
1345 RED/WHT
ENG ECU SW SIG
J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT
21A
1511 RNG/WHT
21B
1720 RNG/WHT
B
C404
BU ALARM-MFR HARN
B
(SEE ADDITIONAL
OPTION DWG)
A
A
BUS BAR
FUSE 5 25 A
1760 RNG/WHT
5A
1780 RNG/WHT
1750 RNG/WHT
5B
SP50
C489
MFR ACCESSORY
FUSE 6 25 A
6A
1850 RNG/WHT
6B
SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
1790 RNG/WHT
12A
1550 RNG/WHT
12B
SHT14/G7
1700 RNG/WHT
14A
FRC1
SWITCHED
POWER
RELAY - A
1050 RED
30
A1
B3
86
A5
87
85
A2
SP25
1765 RNG/WHT
A4
1795 RNG/WHT
GND
FRC1
FRC1
7A
BUS BAR
SHT2/B1
+12V PWR
Dealer Copy -- Not for Resale
1520 RNG/WHT
1805 RNG/WHT
SHT6/B7
SHT11/D2
1530 RNG/WHT
1705 RNG/WHT
1620 RNG/WHT
SHT11/G2
1940 RNG/WHT
1930 RNG/WHT
FUSE 14 5 A
1560 RNG/WHT
1570 RNG/WHT
14B
SP11
1775 RNG/WHT
22 AUX CTRLR
1960 RNG/WHT
J2B
C428
MFR HARN CONN 2
(LT GRAY)
1660 RNG/WHT
2
2
1785 RNG/WHT
1950 RNG/WHT
1660 RNG/WHT
SP42
1590 RNG/WHT
1555 RNG/WHT
FUSE 7 25 A
SP65
1730 RNG/WHT
7B
1735 RNG/WHT
1725 RNG/WHT
8B
1580 RNG/WHT
23B
1800 RNG/WHT
SHT9/B8
SHT9/G8
SHT9/H8
SHT9/H4
SHT9/D8
SHT9/F8
SHT10/H8
SHT9/F4
SHT9/E4
SHT15/F4
SHT5/B8
SHT5/C2
FUSE 8 25 A
8A
SHT9/C8
SHT10/F8
FUSE 23 15 A
1815 RNG/WHT
23A
FRC1
SHT6/G8
FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
21
SWITCHED POWER RELAY FEEDBACK
4
SWITCHED POWER RELAY SIGNAL
J1A
C428
1920 RNG/WHT
9
SP37
1920 RNG/WHT
9
1840 RNG/WHT
SHT5/E3
1830 RNG/WHT
1740 RNG/WHT
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
731 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
6
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
6
SHT5/F3
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300789 (B)
SCHEM ELEC CTRL
Sheet 3 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 3 / 15
7300789
ENG ECU CTRLR
2
4
6
J7A
T32
ECU CASE GND
1
SHT15/F4
GROUND
2001 BLK
SP53
2002 BLK
2810 BLK
2004 BLK
SHT5/F3
SHT9/G8
SHT9/G4
SHT9/E4
SHT9/D4
2220 BRN
SHT8/F7
2155 BLK
3
2080 BLK
4
2070 BLK
2950 BLK
4
2695 BRN
SHT6/E7
1
T6
BATT GND
2950 BLK
10 10
2960 BLK
2250 BLK
2510 BLK
16
GATEWAY CTRLR
SP3
2110 BLK
2500 BLK
15
J1B
2765 BLK
SHT12/H8
2745 BLK
SHT13/D7
SHT15/H4
SHT9/C8
SHT9/E8
SHT14/D5
SHT9/F8
SHT14/B7
16
2860 BLK
AUX CTRLR
2890 BLK
2550 BLK
15
2065 BLK
C428
MFR HARN CONN 2 (LT GRAY)
2930 BLK
2900 BLK
2830 BLK
1
SP47
2700 BLK
SP28
J2B
2900 BLK
1
2785 BLK
2770 BLK
SHT14/H6
2200 BLK
SHT8/H4
SHT12/C4
SHT11/F8
SHT12/C4
SHT12/E4
SHT12/B4
C489
MFR ACCESSORY B
2620 BLK
2650 BLK
B
C103
TAILGATE HARN
2640 BLK
2600 BLK
SP51
B
2600 BLK
B
SHT12/D8
SHT3/C1
SHT13/F8
SHT6/G7
SHT12/E8
732 of 1148
REV
DESCRIPTION
T1
AUX CTRLR
BATT GND
2195 BRN
SHT11/G2
2185 BRN
SP58
2995 BRN
17
SENSOR GROUND
2505 BLK
SHT13/B8
2455 BLK
2710 BLK
SP27
2300 BLK
2715 BLK
2290 BLK
2045 BLK
2035 BLK
SP55
2115 BLK
2105 BLK
2055 BLK
SHT11/D2
2030 BLK
SHT11/F2
SP5
2000 BLK
2520 BLK
2530 BLK
2005 BLK
2120 BLK
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
SEE SHEET 1
1
2630 BLK
Wiring Schematic
ACS / SJC Machine
B
2390 BLK
T10
ENGINE GROUND
J2B
SHT5/C2
SHT8/G8
SP6
1
2015 BLK
SHT6/F3
SHT15/E7
SHT5/B8
SHT12/B8
2730 BLK
SHT10/E8
2610 BLK
SHT14/D6
SHT15/G4
2720 BLK
T8
BATT GND
2780 BLK
SHT14/E7
2090 BLK
1
2790 BLK
SHT10/D8
2540 BLK
Dealer Copy -- Not for Resale
SHT15/D4
SENSOR GROUND
2240 BLK
C408
MFR HARN CONN 1 (BLACK)
SP4
2940 BLK
17
J1B
2150 BRN
SHT6/F7
C493
2920 BLK
2230 BRN
2180 BRN
SHT6/D7
3
SP12
2190 BRN
SHT8/D7
2235 BLK
GATEWAY CTRLR
2370 BRN
SHT10/D8
C493
ACS/SJC/AWS CONN 2
SHT5/E3
2320 BRN
SHT8/F7
2003 BLK
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 4 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 4 / 15
7300789
CAN BUS
*
RE016
120 OHM 0.5 W RESISTOR
R3-1
GATEWAY CTRLR
CAN LO
8
CAN HI
9
TP-09 9260 PUR
TP-09
TP-10
9230 PUR
9160 PUR/WHT
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
TP-10
9130 PUR/WHT
SP31 TP-12
SP30
R3-2
J1B
9250 PUR
TP-12
9150 PUR/WHT
SP79
TP-14 9270 PUR
SP80
TP-11
TP-14
TP-16 9220 PUR
9170 PUR/WHT
SP20
TP-13
C408
MFR HARN CONN 1 (BLACK)
SP19
TP-16
9120 PUR/WHT
4
4
3
3
TP-01
SP18
9220 PUR
TP-01
TP-03
SP17
9120 PUR/WHT
TP-15
9410 PUR
TP-03
SP39
TP-05
SP38
9310 PUR/WHT
9430 PUR
TP-05
SP35 TP-07
SP34
9330 PUR/WHT
C479
LEFT PANEL (BLACK)
TP-08
9450 PUR
9360 PUR/WHT
9350 PUR/WHT
TP-04
TP-02
RE019
120 OHM 0.5 W RESISTOR
TP-07 R1 TP-08 9460 PUR
4
CAN LO
3
CAN HI
R2
TP-06
C479
C503
RH DLX PANEL
TP-15
9290 PUR
9190 PUR/WHT
TP-13
9240 PUR
9140 PUR/WHT
7
7
8
8
1
1
4
9340 PUR/WHT
*
C450
RIGHT JOYSTICK CONN
4
SHT3/B1
1830 RNG/WHT
2070 BLK
Dealer Copy -- Not for Resale
9320 PUR/WHT TP-04
9420 PUR
AUX CTRLR
9180 PUR/WHT
TP-11
8
9
J2B
CAN HI
14
CAN LO
20
TP-22
TP-22
9500 PUR/WHT
9600 PUR
24
1
1
2
2
3
3
4
4
2070 BLK
9560 PUR/WHT
9660 PUR
C449
LEFT JOYSTICK CONN
CAN HI
SHT3/B1
SHT4/G8
1840 RNG/WHT
2080 BLK
9300 PUR/WHT TP-02
9400 PUR
2
CAN HI
1
1
2
2
3
3
4
4
1
1
2
2
3
3
4
4
RIGHT JOYSTICK
+12V PWR
GND
CAN HI
CAN LO
C459
LEFT JOYSTICK
1840 RNG/WHT
2080 BLK
9540 PUR/WHT
9640 PUR
1
1
2
2
3
3
4
4
LEFT JOYSTICK
+12V PWR
GND
CAN HI
CAN LO
SUSP SEAT JOYSTICK HARNESS
A
A
CAN HI
B
B
CAN LO
R18
120 OHM 0.5W RESISTOR
R1-1
ENG ECU CTRLR
J2B
REMOTE RUN KEY
CAN LO
C460
RIGHT JOYSTICK
1830 RNG/WHT
*
CAN LO
C426
Remote Run Tool, ACD
AUX CTRLR
4
C503
SHT4/G8
9280 PUR
TP-06
9440 PUR
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
ENG CAN LO
47
ENG CAN HI
48
TP-17
9200 PUR
TP-17
9100 PUR/WHT
SP90
9215 PUR
9115 PUR/WHT
R1-2
J7A
3095 LBL
TP-18
R21
120 OHM 0.5W RESISTOR
TP-18
TP-20
SP91
R2-1
9210 PUR TP-20
9105 PUR/WHT
9110 PUR/WHT
TP-19
GATEWAY CTRLR
B1
TP-21 9205 PUR TP-21
R2-2
20
ENG CAN LO
14
ENG CAN HI
J1B
C169
ENGINE CAN
J2A
GATEWAY CTRLR
REMOTE RUN KEY
21
3090 LBL
3085 LBL
D
D
SHT3/D1
REMOTE RUN KEY
1725 RNG/WHT
1
SP93
J1B
SHT4/C6
2715 BLK
2
9155 PUR/WHT TP-19
1735 RNG/WHT
SHT3/D1
2710 BLK
SHT4/C6
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
Wiring Schematic
ACS / SJC Machine
733 of 1148
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
SWITCHED POWER
F
F
UNSWITCHED POWER
G
G
GROUND
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
B
E
9255 PUR
1165 RED/WHT
SHT2/C1
E
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
3
ENG CAN HI
4
ENG CAN LO
C169
TOLERANCES:
ECN
Printed On August 2018
(B)
Printable Version ClickSCHEM
Here ELEC7300789
CTRL
Sheet 5 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 5 / 15
7300789
ENGINE
1030 RED
SHT2/B1
M1
8210 TAN
30
87
85
M5
86
FRC1
C111
MFR-BCT HARN CONN
8200 TAN
M4
M2
A
A
B
B
C
C
1
1
R
T21
S
T9
1
B
8220 TAN
3560 LBL
FRC1
1800 RNG/WHT
SHT3/C1
STARTER
T7
FRC1 STARTER
RELAY - M
2005 BLK
SHT4/B8
SHT2/E7
1800 RNG/WHT
1015 RED
GATEWAY CTRLR
7
STARTER RELAY FEEDBACK
22
3560 LBL
2150 BRN
SHT4/G3
AIR FILTER SENDER SIGNAL
33
SHT4/G3
AIR FILTER
SWITCH (NC)
A
FOOT THROTTLE INTDM
C
C
3695 LBL
A
A
2695 BRN
B
B
J1A
C355
FUEL HARN
FUEL SENDER SIGNAL
3180 LBL
12
2180 BRN
SHT4/G3
THROTTLE PRIMARY SIGNAL
IGN SW ON
C
D
D
3180 LBL
A
2180 BRN
FUEL SENDER
(30 - 270 OHM)
B
C406
3690 LBL
10
4
C
D
E
F
C116
SIG
C405
5695 YEL
SHT10/C8
THROTTLE SECONDARY SIGNAL
B
3150 LBL
16
FOOT THROTTLE
GND
8007 TAN
Dealer Copy -- Not for Resale
STARTER RELAY SIGNAL
5695 YEL
3695 LBL
2695 BRN
+5V PWR
C
SIG
A
GND
B
FOOT THROTTLE
ADAPTER
HARNESS
7217683
C110
1020 RED
L
SHT4/E3
1
2015 BLK
T11
1
T12
C115
HAND THROTTLE
F
E
D
SHT10/C7
C428
MFR HARN CONN 2 (LT GRAY)
6
6
SHT10/D5
5690 YEL
+5V PWR
3690 LBL
SIG
A
2690 BRN
GND
B
FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
19
WATER IN FUEL RETURN
34
WIF SENSOR
PRE HEATER RELAY DRIVER
2865 BRN
GND
3865 LBL
SIG
C100
WATER IN FUEL SENSOR
(FUEL FILTER)
2
C118
35
1445 RED/WHT
C5
FRC1
C4
8525 TAN
SP77
8500 TAN
1
T14
C2
FRC1
8510 TAN
1511 RNG/WHT
SHT3/G1
AIR INLET TEMP
SHT2/C1
C1
1
56
28
1065 RED/WHT
SHT2/D1
C100
9
MAFS FREQU SIGNAL
C
C114
J1B
IGN SW ON
ALTERNATOR
S
8013 TAN
8014 TAN
J7A
KL87
SHT7/B6
1
1
SHT7/C6
2
2
SHT7/G3
3
3
SHT7/F3
4
4
SHT7/H7
ENG-CROSSOVER
3420 LBL
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
734 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 6 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 6 / 15
7300789
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK
79
GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EGR VALVE DC MOTOR
1
5
3
4
64
16
72
OPEN
EXHAUST GAS TEMP SENSOR 2 RETURN
23
EXHAUST GAS TEMP SENSOR 2
6
1
2
C131
VREF 3 EGR
EGR POSITION SENSOR SIGNAL
EGR SENSOR RETURN GND
6
92
EGR H BRIDGE POSITIVE
2
93
EGR H BRIDGE NEGATIVE
T
SHT6/B5
SHT6/B5
MASS AIR FLOW SENSOR 5V
37
MASS AIR FLOW SENSOR GND
20
C151
MAF SENSOR
MAF FREQ
1
2
3
SHT6/B5
MAF TEMP
4
C136
1
45
COOLANT TEMP SENSOR RETURN
2
9
COOLANT TEMP SENSOR
OIL PRESSURE & TEMPERATURE SENSOR
OIL TEMP SENSOR
4
2
VREF 3 OIL PRESSURE
65
3
OIL PRESSURE SENSOR
11
4
OIL PRESSURE & TEMP RETURN GND
48
C149
T
FUEL TEMP SENSOR
1
10
FUEL TEMP SENSOR
2
46
FUEL TEMP SENSOR RETURN GND
INTAKE MANIFOLD TEMPERATURE
1
30
ENGINE BLOCK ACCELEROMETER #1 RETURN
2
31
ENGINE BLOCK ACCELEROMETER #1
3
28
ENGINE BLOCK ACCELEROMETER #1 SHIELD
C147
KNOCK SENSOR 2
SHIELD-02
SHIELD-02
33
ENGINE BLOCK ACCELEROMETER #2 RETURN
2
32
ENGINE BLOCK ACCELEROMETER #2
3
29
ENGINE BLOCK ACCELEROMETER #2 SHIELD
1
C146
CRANKSHAFT POSITION SENSOR
SHIELD-03
SHIELD-03
36
CRANKSHAFT SENSOR NEG
2
60
CRANKSHAFT POSITION SENSOR
3
87
CRANKSHAFT SENSOR SHIELD
1
Dealer Copy -- Not for Resale
SHIELD-01
SHIELD-01
1
C137
C148
KNOCK SENSOR 1
T
P
AIR INTAKE TEMP SENSOR RETURN
69
AIR INTAKE TEMP SENSOR
94
1
2
T
T
COOLANT TEMP SENSOR
C150
INTAKE MANIFOLD PRESSURE SENSOR
VREF 2, INTAKE PRESSURE SENSOR
61
1
INTAKE MANIFOLD PRESSURE SENSOR
12
3
INTAKE MANIFOLD PRESSURE RETURN GND
67
2
C145
P
C138
INJECTOR #1
FUEL INJECTOR #1 HSDA
27
FUEL INJECTOR #1 LSD1A
26
1
2
C139
INJECTOR #2
FUEL INJECTOR #2 HSDB
50
FUEL INJECTOR #2 LSD2B
74
1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1
SHT6/B5
2
59
CAM SHAFT POSITION SENSOR
3
47
CAM SHAFT POSITION SENSOR RETURN
C144
2
C140
INJECTOR #3
FUEL INJECTOR #3 HSDB
51
FUEL INJECTOR #3 LSD1B
75
1
RAIL PRESSURE SENSOR
P
3
38
VREF 1 RAIL PRESSURE SENSOR
1
35
RAIL PRESSURE SENSOR
2
19
RAIL PRESSURE SENSOR RETURN
C143
INLET METERING VALVE
VREF 1 INLET METERING VALVE
1
77
735 of 1148
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
FUEL INJECTOR #4 LSD2A
25
1
2
INLET METERING VALVE (PWM)
J7B
J7B
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
B
3
C142
2
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
INJECTOR #4
FUEL INJECTOR #4 HSDA
SHT6/C5
C154
Wiring Schematic
ACS / SJC Machine
2
C141
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 7 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 7 / 15
7300789
FRC1
TRACTION LOCK RELAY - D
+12V PWR
1360 RED/WHT
SHT2/E1
D1
D5
30
87
85
86
D4
D2
B
B
A
A
C
C
2200 BLK
SHT4/D6
C308
BRAKE
SOLENOID 9.8
OHM 12 V
A
2200 BLK
B
C308
2035 BLK
SHT4/B8
4200 LGN
GND
FRC1
FRC1
HYDRAULICS
C425
4100 LGN
TRACK 2 SPEED ADAPTER
(SEE ADDITIONAL OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
TRACTION LOCK RELAY SIGNAL
8
TRACTION LOCK RELAY FEEDBACK
13
4110 LGN
3430 LBL
SHT4/H3
2220 BRN
GND
3220 LBL
SIG
B
T
HYD TEMP SIGNAL
32
HYDRAULIC TEMPERATURE SENDER
500 - 3000 OHM (8 VOLT)
A
C108
HYD FILTER DIFF PRESS
34
SHT4/H3
3320 LBL
SIG
2320 BRN
GND
A
HYDRAULIC OIL FILTER SWITCH
(NC)
B
4010 LGN
HYDRAULIC FAN GROUND
SIG
2910 BRN
18
GND
1
HYDRAULIC FAN SOLENOID
7.2 OHM 12 V
2
C446
HYD LOCK VALVE SOL GROUND
1
2410 BRN
GND
4410 LGN
SIG
J1A
2
HYDRAULIC LOCK SOLENOID
9.8 OHM 12 V
1
C420
SHT4/G3
2190 BRN
GND
3190 LBL
SIG
5190 YEL
+8 PWR
13
1
23
6
HYD CHARGE
PRESS SENDER
HYD CHARGE PRESS
SENDER POWER
TRACTION SOLENOID
OUTPUT
HYDRAULIC CHARGE
PRESSURE 0.5-7.5V
A
J1B
19
HYD LOCK
SOLENOID
P
C105
4200 LGN
HYDRAULIC
FAN
B
C
Dealer Copy -- Not for Resale
C112
4330 LGN
1
2330 BRN
2
AUX CTRLR
FRONT ROD SOLENOID GROUND
18
GND
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
SIG
C418
4340 LGN
GATEWAY CTRLR
2340 BRN
1
13
2
GND
FRONT BASE SOLENOID (FEMALE)
3.3 OHM PWM
SIG
C419
FRONT BASE
SOLENOID
FRONT ROD
SOLENOID
19
J2A
J2B
FRONT BASE SOLENOID GROUND
1
AUX CTRLR
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
736 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 8 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 8 / 15
7300789
CAB DISPLAY
LEFT PANEL BUZZER
1
1940 RNG/WHT
SHT3/E1
T13
1
7040 WHT
C499
PTOL CONN
T2
C479
LEFT PANEL (BLACK)
1930 RNG/WHT
SHT3/E1
2940 BLK
SHT4/F8
2920 BLK
SHT4/G8
1440 RED/WHT
SHT2/G1
1620 RNG/WHT
SHT3/E1
3400 LBL
SHT14/F4
3500 LBL
SHT14/F4
SHT3/E1
10
BUZZER
2
GROUND
20
1
UNSWITCHED POWER
19
5
SWITCHED POWER
11
LEFT BLINKER INPUT
8
RIGHT BLINKER INPUT
3
GROUND
2380 BRN
1
3030 LBL
1
2
PTOL OUTPUT
2380 BRN
12 12
4
PTOL LED
C499
C500
RH KEY SWITCH CONNECTOR
24
8130 TAN
2
8130 TAN
2
2
START
4
RUN/ENTER SWITCH
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
J1A
2
3
5
4
3650 LBL
7
TRAVEL CONTROL INPUT
9
PARK BRAKE INPUT
2930 BLK
1
5
6
C479
SHT5/G1
4
SW1
3040 LBL
14 14
J1B
1950 RNG/WHT
1420 RED/WHT
SHT2/G1
3600 LBL
SW9
2
3040 LBL
SHT3/D1
SW1
Dealer Copy -- Not for Resale
2700 BLK
22
SW1
BRAKE SWITCH
SHT3/E1
3030 LBL
GATEWAY CTRLR
1960 RNG/WHT
SW9
SHT4/E8
SWITCHED POWER
C408
MFR HARN CONN 1 (BLACK)
SW9
TRAVEL CONTROL SWITCH(OPTIONAL)
SHT4/E8
1
C480
LEFT PANEL CONN (GRAY)
1775 RNG/WHT
3620 LBL
SHT10/D3
12
3610 LBL
DOOR SIGNAL
2
PARK BRAKE OUTPUT
9
DESOX INHIBIT
4
DPF LAMP
2960 BLK
SHT4/F8
C500
C503
RH DLX PANEL
1590 RNG/WHT
SHT3/D1
1240 RED/WHT
SHT2/H1
2250 BLK
SHT4/F8
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
C503
SHT5/F1
SW12
DESOX INHIBIT SWITCH(OPT KIT)
SHT4/E8
SHT3/E1
SHT3/E1
2065 BLK
1700 RNG/WHT
1705 RNG/WHT
2
4
7
9
10
8
3
8070 TAN
8050 TAN
8055 TAN
8060 TAN
SW12
SW12
5
DESOX INHIBIT LAMP
1
DPF FORCE REGEN
C480
NOT USED
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
737 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 9 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 9 / 15
7300789
*
1785 RNG/WHT
SHT3/E1
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
2
*
1
6
2060 BLK
SHT10/D1
5
4230 LGN
SHT11/F2
SW4
4240 LGN
SHT11/D2
5
3
3
2
2
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
4
3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
5
CAB
C438
MFR HARN CONN 3 (DK GRAY)
SP29
4220 LGN
4235 LGN
4275 LGN
4550 LGN
1850 RNG/WHT
SHT3/F1
7
7
8
8
9
9
2
2
4235 LGN
4275 LGN
*
C212
POWER SOCKET
4550 LGN
2795 BLK
1850 RNG/WHT
1375 RED/WHT
GND
1
+12V PWR
2
C212
C408
MFR HARN CONN 1 (BLACK)
1370 RED/WHT
SHT2/B1
7
SP45
1370 RED/WHT
7
1390 RED/WHT
DOME LIGHT
*
1
C129
CAB ACCESSORY
1210 RED/WHT
5
2730 BLK
SHT4/E3
5
2730 BLK
11 11
C428
MFR HARN CONN 2 (LT GRAY)
2790 BLK
SHT4/E3
2790 BLK
14 14
2690 BRN
2370 BRN
SHT4/H3
4
4
SEATBAR
SENSOR
SP56
GATEWAY CTRLR
SEATBAR SENSOR SIGNAL
5V PWR
11
24
3370 LBL
5
SP13
5100 YEL
5370 YEL
3
3
GND
A
SIG
B
+5V PWR
C
3370 LBL
5
5370 YEL
SP52
2800 BLK
A
A
+12V BATT PWR
B
B
+12V SW PWR
C
C
GND
2010 BLK
SP41
1
*
T38
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SP44
SHT14/B3
2210 BLK
SHT14/B2
2885 BLK
SHT14/B3
2060 BLK
SHT10/H8
*
SHT6/D4
2375 BRN
2370 BRN
1865 RNG/WHT
2845 BLK
SHT3/D1
SP8
1580 RNG/WHT
Dealer Copy -- Not for Resale
1580 RNG/WHT
T37
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
3620 LBL
SHT9/D8
1400 RED/WHT
SHT2/G1
2840 BLK
7310 WHT
5375 YEL
C482
1
1
WIPER SWITCH, MOTOR SWITCHED POWER
4
4
DOOR SIGNAL
5
5
DOOR UNSW PWR
2
2
WIPER MOTOR GROUND
3
3
WASHER SIGNAL
J1B
SHT6/F7
SHT6/E4
5695 YEL
5690 YEL
*
HARNESS WASHER PUMP
7253378
C252
B
A
2845 BLK
B
7310 WHT
A
GND
PWR
2
WASHER
MOTOR
1
C253
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
Wiring Schematic
ACS / SJC Machine
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
ALM416381
AR9R17222
B3NK11396
B3NL11312
B42S11006
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155
B3GZ11234
B3H111109
ALNW13719
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
738 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 10 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 10 / 15
7300789
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3
RIGHT HANDLE LEFT ROCKER DOWN
31
RIGHT HANDLE LEFT ROCKER UP
30
A
C103
TAILGATE HARN
7100 WHT
A
C
C
SHT4/D8
RIGHT HANDLE RIGHT ROCKER UP
7100 WHT
T19
2650 BLK
1
1
J
4940 LGN
B2
C404
BU ALARM-MFR HARN (SEE
ADDITIONAL OPTION DWG)
A
4930 LGN
H
2195 BRN
SHT4/D3
4320 LGN
D
4300 LGN
B
4910 LGN
13
F
4920 LGN
BACK UP ALARM
T20
E
2530 BLK
SHT4/B6
K
4230 LGN
SHT10/H8
LEFT POSITION SWITCH
C
PADDLE
RIGHT POSITION SWITCH
TRIGGER
HANDLE LOCK (ACS ONLY)
G
C409
4980 LGN
SIG
1
C421
LIFT SPOOL LOCK
SOLENOID GROUND
2990 BRN
2
GND
3
J1A
4990 LGN
SIG
1
5
LIFT SPOOL
LOCK SOLENOID
J1B
7
TILT SPOOL
LOCK SOLENOID
C422
LIFT SPOOL LOCK
7.8 OHM 12V
J2B
23
TILT SPOOL LOCK
7.8 OHM 12V
18
3
RIGHT HANDLE
PWM HIGH
GND
RIGHT HANDLE
PWM SIGNAL
2980 BRN
10
21
TILT SPOOL LOCK
SOLENOID GROUND
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
Dealer Copy -- Not for Resale
TILT (ACS/AHC ONLY)
LEFT HANDLE
AUX CTRLR
LIFT (ACS/AHC ONLY)
4240 LGN
SHT10/G8
2520 BLK
SHT4/B6
FLOAT SIGNAL
22
LEFT HANDLE RIGHT ROCKER UP
28
LEFT HANDLE PADDEL RIGHT
11
LEFT HANDLE PADDEL LEFT
12
D
1520 RNG/WHT
SHT3/E3
4830 LGN
4840 LGN
4810 LGN
4820 LGN
HANDLE LOCK (ACS ONLY)
E
4640 LGN
20
LEFT HANDLE RIGHT ROCKER DOWN
H
FLOAT (ACS/AHC ONLY)
A
B
RIGHT POSTION SWITCH
C
F
PADDLE
G
C410
J2A
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
739 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300789 (B)
SCHEM ELEC CTRL
Sheet 11 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 11 / 15
7300789
LIGHTS
C434-1
6100 PNK
SIG
A
37 WATT
C408
MFR HARN CONN 1 (BLACK)
2765 BLK
SHT4/F3
9
9
2735 BLK
2765 BLK
SP14
GND
2750 BLK
GND
LEFT FRONT
WORKLIGHT
B
B
50 WATT
6110 PNK
SIG
A
C434-2
C435-1
6000 PNK
1350 RED/WHT
30
6120 PNK
6000 PNK
SIG
SP23
6610 PNK
13 13
2760 BLK
GND
6130 PNK
6610 PNK
SIG
SP64
86
RC1
30
87
86
6340 PNK
SP10
6310 PNK
A
RC2
2115 BLK
A
2610 BLK
SHT4/D8
GND
2
RIGHT REAR
TAIL LIGHT
C103
TAILGATE HARN
85
RC2
SHT4/B8
Dealer Copy -- Not for Resale
6320 PNK
FRONT WORK LIGHTS
RELAY - RC2
RED/WHT
B
C435-2
2120 BLK
1330
RIGHT FRONT
WORK LIGHT
A
50 WATT
GND
2705 BLK
6630 PNK
SHT2/E1
B
85
RC1
SHT4/A8
A
37 WATT
C438
MFR HARN CONN 3 (DK GRAY)
6620 PNK
87
8
SP15
FRONT WORK LIGHTS
RELAY - RC1
SHT2/E1
8
SP49
6310 PNK
6320 PNK
SIG
1
C603
6330 PNK
SIG
1
LEFT REAR
TAIL LIGHT
GATEWAY CTRLR
5
MRKR LIGHT PWR RELAY FEEDBACK
31
REAR LIGHT RELAY
17
REAR LIGHT RELAY FEEDBACK
28
J1A
SHT2/E1
30
87
85
86
FRC1
6210 PNK
6200 PNK
E4
DESCRIPTION
H
H
SIG
1
E2
AEW
CHG NOTICE DWN
1
T17 TERMINAL (+)
6220 PNK
6200 PNK
SP96
SHEET
GND
2630 BLK
SHT4/C8
LEFT REAR
WORK LIGHT
1
T18 TERMINAL (-)
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
REV
SIG
T15 TERMINAL (+)
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
104399
1
RIGHT REAR
WORK LIGHT
FRC1
Wiring Schematic
ACS / SJC Machine
740 of 1148
GND
FRC1
REAR LIGHT
RELAY - E
E1
T16 TERMINAL (-)
2620 BLK
SHT4/D8
3440 LBL
2045 BLK
SEE SHEET 1
2
3460 LBL
1320 RED/WHT
B
GND
C602
E5
SHT4/B8
2640 BLK
SHT4/D8
6210 PNK
MRKR LIGHT PWR RELAY
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7300789 (B)
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 12 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 12 / 15
7300789
2440 BLK
GND
2
*
HVAC DUCT FAN
M
7440 WHT
SIG
*
HVAC
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
C610
2560 BLK
C
7420 WHT
*
POTENTIOMETER (TEMP
CONTROL SWITCH)
A
B
C483
7425 WHT
D
2130 BLK
*
HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
HVAC RELAY FEEDBACK
30
FRC1
FRC1
3050 LBL
2745 BLK
SHT4/F3
11 11
2745 BLK
SP16
AC SIGNAL MONITOR
7021 WHT
11
SP40
7020 WHT
5
SW10
A
M
4
2580 BLK
2100 BLK
1
*
THERMOSTAT
*
2
3
SW11
AC SWITCH
7023 WHT
7025 WHT
7024 WHT
SIG
1
D4
C350
SHT4/C6
LOW
C611
C630
B
MED
SW10
7015 WHT
AC EVAPORATOR
SWITCH
3
7410 WHT
2570 BLK
J1A
2
7510 WHT
HIGH
3
7020 WHT
12 12
7520 WHT
SW11
3
B2
86
2
1
4
1
7400 WHT
7050 WHT
HVAC RELAY SIGNAL
10 10
B4
85
B5
GATEWAY CTRLR
87
30
*
7530 WHT
C
B1
1500 RNG/WHT
SW10
BLOWER SWITCH
3
SHT2/F1
1500 RNG/WHT
*
Dealer Copy -- Not for Resale
1140 RED/WHT
C438
MFR HARN CONN 3
(DK GRAY)
1
FRC1
HVAC RELAY-B
2290 BLK
MAGNET CLUTCH
(COMPRESSOR)
2280 BLK
GND
2
C486
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
741 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300789 (B)
SCHEM ELEC CTRL
Sheet 13 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 13 / 15
7300789
#
C428
MFR HARN CONN 2 (LT GRAY)
C355
FUEL HARN
POWER BOB
CLOSE
#
1 SIG
4470 LGN
2 GND
2470 BLK
2770 BLK
SP33
C607
4480 LGN
1 SIG
POWER BOB
OPEN
2
GND
E
E
4470 LGN
B
B
2770 BLK
F
F
OPTIONS 1
4470 LGN
11 11
*
SHT4/E6
4480 LGN
4480 LGN
10 10
SW5
POWER BOBTACH SWITCH
1380 RED/WHT
2
SW5
2480 BLK
#
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
*
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
3
SW5
C606
LEFT HANDLE
LIFT (ACS/AHC ONLY)
6010 PNK
LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG)
1550 RNG/WHT
SHT3/F1
6010 PNK
13 13
1550 RNG/WHT
12 12
1405 RED/WHT
C438
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY)
1410 RED/WHT
SHT2/C1
1410 RED/WHT
1
1
SP43
SHT15/D6
1430 RED/WHT
*
X
L
1200 RED/WHT
T3
FLASHER
FLOAT (ACS/AHC ONLY)
6415 PNK
D
6515 PNK
A
TRIGGER
C103
TAILGATE HARN
C411
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
E
E
D
D
6400 PNK
2780 BLK
4450 LGN
B GND
2450 BLK
3
6530 PNK
D13
6400 PNK
4
4
4455 LGN
2780 BLK
*
4455 LGN
5
5
D3
A SIG
3
1
2
4
SHT4/C6
C423
6
5
SW6
LEFT HANDLE
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG)
C497
HORN SIGNAL
RIGHT BLINKER SIGNAL
HANDLE LOCK (ACS ONLY)
LEFT BLINKER SIGNAL
FLOAT (ACS/AHC ONLY)
HIGH FLOW SOLENOID GROUND
7200 WHT
5
C
6420 PNK
A
A
3
6520 PNK
B
B
26
2460 BRN
GND
RIGHT POSTION SWITCH
SIG
PADDLE
TRIGGER
A
1460 RED/WHT
C408
MFR HARN CONN 1
(BLACK)
SHT2/C1
7210 WHT
B
13 13
2970 BLK
2810 BLK
SHT4/E8
SIG
A
C412
2420 BLK
6540 PNK
1
*
*
7820 WHT
7830 WHT
2
2
HIGH FLOW
SOLENOID
7.5 OHM 12 V
*
1
C278
SHT10/E1
C676
RADIO CONN
3
LEFT
SPEAKER (+)
4
LEFT
SPEAKER (-)
6
2785 BLK
B
B
GND
7800 WHT
5
1885 RNG/WHT
D
F
F
B
B
C
C
A
A
C670
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
1
TWO SPEED GROUND
RIGHT
SPEAKER (+)
1
SHT10/E1
PWR
SHT10/E1
2210 BLK
GND
2
26
2350 BRN
4350 LGN
TWO SPEED SIGNAL
4
PWR
GND
5
6
C277
GND
J1A
_
L010
AIR RIDE SEAT
3
1510 RNG/WHT
C676
GATEWAY CTRLR
+
E
D
*
RIGHT
SPEAKER (-)
HORN
SHT4/E8
E
2
7810 WHT
2885 BLK
SHT10/D1
A
*
6440 PNK
C126
HORN CONNECTOR
7210 WHT
6700 PNK
C279
A
2725 BLK
2905 BLK
SHT15/D5
J2B
LEFT POSITION SWITCH
(PINS 3 & 6
INTERNALLY INSULATED)
SHT15/F4
SJC HORN/BLINKER
(SEE ADDITIONAL
OPTIONS DWG)
B
SP46
2850 BLK
SW2
SW3
SHT15/F6
C415
4460 LGN
26
5
6
SW2
4
6
RIGHT SPEAKER
J2A
HIGH FLOW SOLENOID
1
3
SW3
1
2
SW3
HAZARD SWITCH
LEFT SPEAKER
C
4
3400 LBL
2
SW6
2830 BLK
AUX CTRLR
LIFT (ACS/AHC ONLY)
*
SW2
BEACON SWITCH
6430 PNK
*
SW6
BUCKET POSITION SWITCH
3
2455 BLK
T3
D14
6500 PNK
SHT9/G8
SHT4/E3
BUCKET
POSITION
SOLENOID
9.8 OHM
6
6510 PNK
B
6410 PNK
SP22
6
3500 LBL
6570 PNK
PADDLE
6500 PNK
Dealer Copy -- Not for Resale
RIGHT POSTION SWITCH
LEFT POSITION SWITCH
SHT9/F8
SP21
SIG
2
1
TWO SPEED
SOLENOID
5.1 OHM 12 V
TRACK 2 SPEED
(SEE ADDITIONAL
OPTIONS DWG)
C441
26
J1B
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
742 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
PROPRIETARY NOTICE
WARNING
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300789 (B)
SCHEM ELEC CTRL
Sheet 14 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 14 / 15
7300789
RIDE CONTROL SW AUTO
3410 LBL
23
14 14
3410 LBL
1
7
RIDE CONTROL COIL SIGNAL
21
1
2
SP9
2040 BLK
3425 LBL
SP32
C439
2020 BLK
1
RIDE CONTROL
COIL
3475 LBL
16
29
8
2175 BRN
27
3475 LBL
7
*
2905 BLK
FRC1
8
SHT4/G8
SW13
REVERSING FAN
3
1
3470 LBL
2970 BLK
2
1555 RNG/WHT
5
3485 LBL
1
C442
SHT4/D3
RIDE CONTROL PRESSURE SENSOR SIGNAL
RIDE CONTROL SENSOR +5V PWR
2185 BRN
3455 LBL
10
5105 YEL
24
A
C
RIDE CONTROL
PRESSURE SENSOR
B
J2B
*
SW8
SIDELIGHT
1405 RED/WHT
SHT14/G3
2
1
SHT14/D3
6
P697
Wiring Schematic
ACS / SJC Machine
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
743 of 1148
B
SEE SHEET 1
REV
DESCRIPTION
104399
AEW
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
*
C672
SIDELIGHT CONN
6710 PNK
2810 BLK
2860 BLK
1
1
2
2
SHT4/E8
P697
PROPRIETARY NOTICE
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
WARNING
SHT3/D1
SW8
REVERSING
FAN COIL
25
SHT14/D3
6
4
SW8
2
J2A
REVERSING FAN SIGNAL
SHT4/C8
C440
C443
REVERSING FAN RETURN SIGNAL
FRC1
SHT3/F1
2
SHT14/D3
REVERSING FAN AUTO SIGNAL
2505 BLK
L2
2155 BLK
7
3470 LBL
1575 RNG/WHT
L1
L5
C428
MFR HARN CONN 2 (LT GRAY)
REVERSING FAN MANUAL SIGNAL
SHT4/E8
SW7
L4
3445 LBL
3435 LBL
RIDE CONTROL
COIL
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
3480 LBL
3415 LBL
2890 BLK
2
SW7
RIDE CONTROL RELAY SIGNAL
OPTIONS 2
*
SW7
RIDE CONTROL
C438
MFR HARN CONN 3 (DK GRAY)
Dealer Copy -- Not for Resale
AUX CTRLR
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7300789 (B)
SCHEM ELEC CTRL
Sheet 15 of 17
DWG. NO.
101943
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 15 / 15
7300789
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
PIN
A
B
C
D
E
F
G
H
J
K
J1-ACS
CONTROLLER
2280/BLK
4220/LGN
4275/LGN
C
+5V
E
D
B
A
G
4550/LGN
9240/PUR
9140/PUR/WHT
1740/RNG/WHT
5
3
2
7
8
1
4
6
C493
4
3
2
1
2240/BLK
J3-ACS
CONTROLLER
1170/RED/WHT
B
C
1190/RED/WHT
1180/RED/WHT
E
J
H
G
4220/LGN
2260/BLK
2270/BLK
4260/LGN
5970/YEL
2250/BRN
J2-ACS
CONTROLLER
C472
2650/BRN
4650/LGN
5650/YEL
F
B
C
A
B
C
A
GND
SIG
+5V PWR
LIFT HANDLE
HALL SENSOR
F
C469
2750/BRN
4750/LGN
5750/YEL
G
D
B
C
A
B
C
A
GND
SIG
+5V PWR
TILT HANDLE
HALL SENSOR
GND
SIG
+5V PWR
LIFT PEDAL
HALL SENSOR
SEE MANUAL CONTROL
PAGE FOR HARNESS CONN
4275/LGN
C492
HARNESS PART NUMBER
EXMF, LF
7164144
7190593
MF
2280/BLK
2240/BLK
1170/RED/WHT
MAINFRAME HARNESS
Dealer Copy -- Not for Resale
H
ACS
ACS
C467
2510/BLK
4280/LGN
3
1
2
C468
2500/BLK
4270/LGN
2
3
1
C429
4610/LGN
4600/LGN
5980/YEL
2980/BRN
3980/LBL
8
7
6
5
4
3
1
2
LIFT
SOLENOID
13 OHM
12V
FOOT PEDAL LOCK
TILT
SOLENOID
LIFT ACTUATOR
C409
C466
K
G
A
H
J
E
F
C
D
B
A
B
HANDLE
LOCK
SKI CTRL
DETENT
FLOW
TWO SPD
PWM
C410
K
D
C
B
G
F
A
J
H
E
FLOAT
SKI CTRL
SIDE
SHIFT
A
B
HANDLE
LOCK
+5V PWR
GND
SIG
C471
2660/BRN
4660/LGN
5660/YEL
J
2980/BRN
2990/BRN
K
A
B
C
D
H
E
C428
C470
2760/BRN
4760/LGN
5760/YEL
5750/YEL
5650/YEL
5970/YEL
2
3
1
GND
SIG
+5V PWR
K
4645/LGN
A
4640/LGN
TILT PEDAL
HALL SENSOR
5990/YEL
2990/BRN
3990/LBL
8
7
6
5
4
3
1
2
TILT ACTUATOR
+5V PWR
GND
SIG
5980/YEL
5990/YEL
3980/LBL
3990/LBL
Wiring Schematic
ACS / SJC Machine
744 of 1148
2
3
1
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
Printed On August 2018
7300789 (B)
Printable Version Click Here
Sheet 16 of 17
Dealer Copy -- Not for Resale
Wiring Schematic
ACS / SJC Machine
745 of 1148
S630
S550
S650
S570
S590
S595
S510
S530
T630
T550
T650
T590
T595
S/N B42T11010
AHGL12984
AHGM12591
ALJ818499
ALM416381
AR9R17222
B3NL11312
B42S11006
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
B3NK11396
through
through
through
through
throughALJ821599
B42T12000
AJZV18499
ALJU24499
B42S11023
AJDT15599
ALJG23699
B3NL12599
ALM418799
B3NK14999
AR9R18499
AHGL13799
AHGM13899
S/N ALR815171
B2L511148
B3GY11170
B2LA11412
B3GZ11234
B3H111109
ALNW13719
B2KZ12106 through
B3Z711155
through
&
through
&Above
Above
B2L511399
B3Z712000
B2LA11899
B2KZ13499
B3H112000
B3GZ12000
B3GY12000
Printed On August 2018
Printable Version Click Here
7300789 (B)
Sheet 17 of 17
Index Diagram
1
SH01 - INDEX
2
SH02 - UNSWITCHED BATT POWER
3
SH03 - SWITCHED POWER
4
SH04 - GROUND
5
SH05 - CAN BUS
6
SH06 - ENGINE
7
SH07 - ENGINE CONTROL UNIT
8
SH08 - HYDRAULICS
9
SH09 - CAB DISPLAY
10
SH10 - CAB
11
SH11 - MANUAL CONTROLS
12
SH12 - LIGHTS
13
SH13 - HVAC
14
SH14 - OPTIONS 1
15
SH15 - OPTIONS 2
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
HARNESS PART NUMBER
7331092
GROUP NUMBER RANGE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
5000 THROUGH 5999
YELLOW
YEL
6000 THROUGH 6999
PINK
PNK
CONTROLLER SUPPLY
DLX CAB
STD CAB
STD FUEL
DLX FUEL
BCT ENG
TAILGATE DOM
TAILGATE EUR
SUSP JSTK
WHL 2 SPD ADP
TRK 2 SPD
7301237
LIGHTS
7303755
7149219
7000 THROUGH 7999
WHITE
WHT
7266824
7220812
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
7267103
7217483
7163706
7159366
7243409
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
S550
S570
S590
S510
S530
T590
REV
110295
DESCRIPTION
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
Click Here For Interactive PDF
746 of 1148
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
LEGEND
CONNECTOR
1
1
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
1
1
1
1
WIRE BREAK
SHT1/F2
SHT1/F2
OTHER FUNCTIONS
Wiring Schematic
ACS / SJC Machine
0
COLOR CODE
WIRE COLOR
PARTIAL CONNECTOR
Dealer Copy -- Not for Resale
MF MFR CTRL
GROUP DESCRIPTION
ECN
WIRE #
WIRE #
SHT1/F2
SHT1/F2
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 1 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 1 / 15
7331096
UNSWITCHED
BATT POWER
1240 RED/WHT
1400 RED/WHT
C408
1450 RED/WHT
6
6
1450 RED/WHT
SHT10/D3
SP7
1420 RED/WHT
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT
FUSE 11 25 A
1070 RED
11A
11B
FUSE 13 25 A
1025 RED
13A
13B
1130 RED/WHT
1120 RED/WHT
1160 RED/WHT
SP2
SP36
SHT9/E4
SHT9/E4
SHT9/G8
2
GATEWAY CTRLR
3
J1B
1150 RED/WHT
1180 RED/WHT
3
AUX CTRLR
2
J2B
+12V BATTERY
MEGAFUSE
1
HW11
100.0 Amps
T5
C493
FUSE 15 25A
1
1270 RED
15A
T4
1170 RED/WHT
15B
1
1
2
2
FUSE 17 25 A
1280 RED
17A
1235 RED/WHT
17B
1310 RED
4A
1140 RED/WHT
4B
Dealer Copy -- Not for Resale
1010 RED
SHT6/G1
BUS BAR
FUSE 4 25 A
SHT13/E8
FUSE 3 30 A
3A
1360 RED/WHT
3B
SHT8/H8
BUS BAR
FUSE 1 15 A
1340 RED
1A
1320 RED/WHT
1B
SHT12/B8
FUSE 2 20 A
2A
SP26
1330 RED/WHT
2B
SHT12/D8
1350 RED/WHT
SHT12/F8
FUSE 9 50 A
1325 RED
1060 RED
9A
1065 RED/WHT
9B
SHT6/C3
FUSE 20 5 A
1335 RED
20A
1345 RED/WHT
20B
SHT3/G8
FUSE 16 25 A
SP1
1300 RED
16A
1035 RED/WHT
16B
SHT3/H8
RED
1445 RED/WHT
SHT6/C3
1055
FUSE 18 25 A
1190 RED
18A
1165 RED/WHT
18B
SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
1040 RED
22A
22B
1490 RED/WHT
1410 RED/WHT
SHT14/F7
SP24
FUSE 24 25 A
SP60
1290 RED
24A
24B
FRC1
1370 RED/WHT
SHT10/F8
FRC1
1050 RED
SHT3/D8
1030 RED
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
747 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
SHT6/G8
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 2 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 2 / 15
7331096
FRC1 ENGINE
ECU RELAY - G
ENG ECU CTRLR
1506 RNG/WHT
SHT2/D1
1035 RED/WHT
+12V PWR
30
G1
86
G2
87
G4
85
SP54
1540 RNG/WHT
1507 RNG/WHT
3
1508 RNG/WHT
G5
FRC1
1
5
FRC1
8005 TAN
SHT2/D1
SWITCHED
POWER
45
1345 RED/WHT
ENG ECU SW SIG
J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT
21A
1511 RNG/WHT
21B
1720 RNG/WHT
B
C404
BU ALARM-MFR HARN
B
(SEE ADDITIONAL
OPTION DWG)
A
A
BUS BAR
FUSE 5 25 A
5A
1780 RNG/WHT
1750 RNG/WHT
5B
SP50
SHT6/B7
C489
MFR ACCESSORY
FUSE 6 25 A
1760 RNG/WHT
6A
1850 RNG/WHT
6B
SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
1790 RNG/WHT
12A
1550 RNG/WHT
12B
SHT14/G7
1700 RNG/WHT
1805 RNG/WHT
14A
FRC1
SWITCHED
POWER
RELAY - A
1050 RED
30
A1
87
86
A5
85
A2
SP25
1765 RNG/WHT
A4
B3
1795 RNG/WHT
GND
FRC1
FRC1
7A
BUS BAR
SHT2/B1
+12V PWR
Dealer Copy -- Not for Resale
1520 RNG/WHT
SHT11/D2
1530 RNG/WHT
1705 RNG/WHT
1620 RNG/WHT
SHT11/G2
1940 RNG/WHT
1930 RNG/WHT
FUSE 14 5 A
1560 RNG/WHT
1570 RNG/WHT
14B
SP11
1775 RNG/WHT
22 AUX CTRLR
1960 RNG/WHT
J2B
C428
MFR HARN CONN 2
(LT GRAY)
1660 RNG/WHT
2
2
1785 RNG/WHT
1950 RNG/WHT
1660 RNG/WHT
SP42
1590 RNG/WHT
1555 RNG/WHT
FUSE 7 25 A
SP65
1730 RNG/WHT
7B
1735 RNG/WHT
SHT9/C8
SHT9/B8
SHT9/G8
SHT9/H8
SHT9/H4
SHT9/D8
SHT9/F8
SHT10/H8
SHT9/F4
SHT9/E4
SHT15/F4
SHT5/B8
1725 RNG/WHT
SHT5/C2
FUSE 8 25 A
8A
1580 RNG/WHT
8B
SHT10/F8
FUSE 23 15 A
1815 RNG/WHT
23A
1800 RNG/WHT
23B
FRC1
SHT6/G8
FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
21
SWITCHED POWER RELAY FEEDBACK
4
SWITCHED POWER RELAY SIGNAL
J1A
C428
1920 RNG/WHT
9
SP37
1920 RNG/WHT
9
1840 RNG/WHT
SHT5/E3
1830 RNG/WHT
1740 RNG/WHT
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
748 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
6
6
SHT5/F3
C492
ACS/SJC/AWS-MFR HARN
(8 PIN)
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 3 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 3 / 15
7331096
ENG ECU CTRLR
2
4
6
J7A
T32
ECU CASE GND
1
SHT15/F4
GROUND
2001 BLK
SP53
2002 BLK
2810 BLK
2004 BLK
SHT5/F3
SHT9/G8
SHT9/G4
SHT9/E4
SHT9/D4
2220 BRN
SHT8/F7
2155 BLK
3
2080 BLK
4
2070 BLK
2950 BLK
4
2695 BRN
SHT6/E7
1
T6
BATT GND
2950 BLK
10 10
2960 BLK
2250 BLK
2510 BLK
16
GATEWAY CTRLR
SP3
2110 BLK
2500 BLK
15
J1B
2765 BLK
SHT12/H8
2745 BLK
SHT13/D7
SHT15/H4
SHT9/C8
SHT9/E8
SHT14/D5
SHT9/F8
SHT14/B7
16
2860 BLK
AUX CTRLR
2890 BLK
2550 BLK
15
2065 BLK
C428
MFR HARN CONN 2 (LT GRAY)
2930 BLK
2900 BLK
2830 BLK
1
SP47
2700 BLK
SP28
J2B
2900 BLK
1
2785 BLK
2770 BLK
SHT14/H6
2200 BLK
SHT8/H4
SHT12/C4
SHT11/F8
SHT12/C4
SHT12/E4
C489
MFR ACCESSORY B
2620 BLK
2650 BLK
B
2720 BLK
C103
TAILGATE HARN
2640 BLK
2600 BLK
SP51
B
2600 BLK
B
2730 BLK
SHT10/E8
2390 BLK
1
1
2015 BLK
SHT6/F3
SP6
T8
BATT GND
2780 BLK
SHT14/E7
2090 BLK
1
2790 BLK
SHT10/D8
2540 BLK
Dealer Copy -- Not for Resale
SHT15/D4
SENSOR GROUND
2240 BLK
C408
MFR HARN CONN 1 (BLACK)
SP4
2940 BLK
17
J1B
2150 BRN
SHT6/F7
C493
2920 BLK
2230 BRN
2180 BRN
SHT6/D7
3
SP12
2190 BRN
SHT8/D7
2235 BLK
GATEWAY CTRLR
2370 BRN
SHT10/D8
C493
ACS/SJC/AWS CONN 2
SHT5/E3
2320 BRN
SHT8/F7
2003 BLK
T10
ENGINE GROUND
T1
AUX CTRLR
BATT GND
2195 BRN
SHT11/G2
2610 BLK
SP58
2995 BRN
2185 BRN
SHT15/E7
17
SENSOR GROUND
J2B
SHT12/B4
2630 BLK
SHT14/D6
SHT5/B8
SHT5/C2
SHT15/G4
SHT12/B8
SHT8/G8
SHT12/D8
SHT3/C1
SHT13/F8
SHT6/G7
SHT12/E8
2505 BLK
SHT13/B8
749 of 1148
REV
DESCRIPTION
SP27
2300 BLK
2715 BLK
2290 BLK
2035 BLK
SP55
2115 BLK
2105 BLK
2055 BLK
SHT11/D2
2030 BLK
SHT11/F2
SP5
2000 BLK
2520 BLK
2530 BLK
2005 BLK
2120 BLK
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
SEE SHEET 1
2710 BLK
2045 BLK
Wiring Schematic
ACS / SJC Machine
0
2455 BLK
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 4 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 4 / 15
7331096
CAN BUS
*
RE016
120 OHM 0.5 W RESISTOR
R3-1
GATEWAY CTRLR
CAN LO
8
CAN HI
9
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
TP-09 9260 PUR
TP-09
TP-10
9230 PUR
9160 PUR/WHT
TP-10
9130 PUR/WHT
SP31 TP-12
SP30
R3-2
J1B
9250 PUR
TP-12
9150 PUR/WHT
SP79
TP-14 9270 PUR
SP80
TP-11
TP-14
TP-16 9220 PUR
9170 PUR/WHT
SP20
TP-13
C408
MFR HARN CONN 1 (BLACK)
SP19
TP-16
9120 PUR/WHT
4
4
3
3
TP-01
SP18
9220 PUR
TP-01
TP-03
SP17
9120 PUR/WHT
TP-15
9410 PUR
TP-03
SP39
TP-05
SP38
9310 PUR/WHT
9430 PUR
TP-05
SP35 TP-07
SP34
9330 PUR/WHT
C479
LEFT PANEL (BLACK)
TP-08
9450 PUR
9360 PUR/WHT
9350 PUR/WHT
TP-04
TP-02
RE019
120 OHM 0.5 W RESISTOR
TP-07 R1 TP-08 9460 PUR
4
CAN LO
3
CAN HI
R2
TP-06
C479
C503
RH DLX PANEL
TP-15
9290 PUR
9190 PUR/WHT
TP-13
9240 PUR
9140 PUR/WHT
9340 PUR/WHT
7
7
8
8
1
1
4
*
C450
RIGHT JOYSTICK CONN
4
SHT3/B1
1830 RNG/WHT
2070 BLK
Dealer Copy -- Not for Resale
9320 PUR/WHT TP-04
9420 PUR
AUX CTRLR
TP-11
8
9180 PUR/WHT
9
J2B
CAN LO
CAN HI
14
CAN LO
20
TP-22
TP-22
9500 PUR/WHT
9600 PUR
24
1
1
2
2
3
3
4
4
2070 BLK
9560 PUR/WHT
9660 PUR
*
SHT3/B1
SHT4/G8
1840 RNG/WHT
2080 BLK
9300 PUR/WHT TP-02
9400 PUR
2
CAN HI
1
1
2
2
3
3
4
4
1
1
2
2
3
3
4
4
RIGHT JOYSTICK
+12V PWR
GND
CAN HI
CAN LO
C459
LEFT JOYSTICK
1840 RNG/WHT
2080 BLK
9540 PUR/WHT
9640 PUR
1
1
2
2
3
3
4
4
LEFT JOYSTICK
+12V PWR
GND
CAN HI
CAN LO
SUSP SEAT JOYSTICK HARNESS
R18
120 OHM 0.5W RESISTOR
R1-1
ENG ECU CTRLR
TP-17
A
A
CAN HI
B
B
CAN LO
J2B
REMOTE RUN KEY
CAN LO
C460
RIGHT JOYSTICK
1830 RNG/WHT
C449
LEFT JOYSTICK CONN
CAN HI
C426
Remote Run Tool, ACD
AUX CTRLR
4
C503
SHT4/G8
9280 PUR
TP-06
9440 PUR
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
ENG CAN LO
47
ENG CAN HI
48
9200 PUR
TP-17
9100 PUR/WHT
SP90
9215 PUR
9115 PUR/WHT
R1-2
J7A
3095 LBL
TP-18
R21
120 OHM 0.5W RESISTOR
TP-20
TP-18
SP91
R2-1
9210 PUR TP-20
9105 PUR/WHT
9110 PUR/WHT
R2-2
TP-19
GATEWAY CTRLR
B1
TP-21 9205 PUR TP-21
20
ENG CAN LO
14
ENG CAN HI
J1B
C169
ENGINE CAN
J2A
GATEWAY CTRLR
REMOTE RUN KEY
21
3090 LBL
3085 LBL
D
D
SHT3/D1
REMOTE RUN KEY
1725 RNG/WHT
1
SP93
J1B
SHT4/C6
2715 BLK
2
9155 PUR/WHT TP-19
1735 RNG/WHT
SHT3/D1
E
E
SWITCHED POWER
F
F
UNSWITCHED POWER
G
G
GROUND
9255 PUR
1165 RED/WHT
SHT2/C1
2710 BLK
SHT4/C6
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
750 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
3
ENG CAN HI
4
ENG CAN LO
C169
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 5 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 5 / 15
7331096
ENGINE
1030 RED
SHT2/B1
M1
8210 TAN
30
87
85
M5
86
FRC1
C111
MFR-BCT HARN CONN
8200 TAN
M4
M2
A
A
B
B
C
C
1
1
R
T21
S
T9
1
B
8220 TAN
3560 LBL
FRC1
1800 RNG/WHT
SHT3/C1
STARTER
T7
FRC1 STARTER
RELAY - M
2005 BLK
SHT4/B8
SHT2/E7
1800 RNG/WHT
1015 RED
GATEWAY CTRLR
7
STARTER RELAY FEEDBACK
22
3560 LBL
2150 BRN
SHT4/G3
AIR FILTER SENDER SIGNAL
AIR FILTER
SWITCH (NC)
A
FOOT THROTTLE INTDM
3695 LBL
33
2695 BRN
SHT4/G3
J1A
C355
FUEL HARN
FUEL SENDER SIGNAL
3180 LBL
12
2180 BRN
SHT4/G3
THROTTLE PRIMARY SIGNAL
IGN SW ON
C
D
D
3180 LBL
A
2180 BRN
FUEL SENDER
(30 - 270 OHM)
B
C406
3690 LBL
10
4
C
D
E
F
C116
SIG
C405
5695 YEL
SHT10/C8
THROTTLE SECONDARY SIGNAL
B
3150 LBL
16
FOOT THROTTLE
GND
8007 TAN
C
C
A
A
B
B
Dealer Copy -- Not for Resale
STARTER RELAY SIGNAL
5695 YEL
3695 LBL
2695 BRN
+5V PWR
C
SIG
A
GND
B
FOOT THROTTLE
ADAPTER
HARNESS
7217683
C110
1020 RED
ALTERNATOR
S
L
SHT4/E3
1
2015 BLK
T11
1
T12
C115
HAND THROTTLE
F
E
D
SHT10/C7
C428
MFR HARN CONN 2 (LT GRAY)
6
6
SHT10/D5
5690 YEL
+5V PWR
3690 LBL
SIG
A
2690 BRN
GND
B
C
C114
J1B
FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
IGN SW ON
19
WATER IN FUEL RETURN
34
WIF SENSOR
PRE HEATER RELAY DRIVER
2865 BRN
GND
3865 LBL
9
SIG
C100
WATER IN FUEL SENSOR
(FUEL FILTER)
2
C118
AIR INLET TEMP
35
1445 RED/WHT
C5
FRC1
C4
8525 TAN
SP77
8500 TAN
1
T14
C2
FRC1
8510 TAN
1511 RNG/WHT
SHT3/G1
28
SHT2/C1
C1
1
56
MAFS FREQU SIGNAL
1065 RED/WHT
SHT2/D1
C100
8013 TAN
8014 TAN
J7A
KL87
SHT7/B6
1
1
SHT7/C6
2
2
SHT7/G3
3
3
SHT7/F3
4
4
SHT7/H7
ENG-CROSSOVER
3420 LBL
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
751 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 6 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 6 / 15
7331096
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK
79
GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EGR VALVE DC MOTOR
1
5
3
4
64
16
72
OPEN
EXHAUST GAS TEMP SENSOR 2 RETURN
23
EXHAUST GAS TEMP SENSOR 2
6
1
2
C131
VREF 3 EGR
EGR POSITION SENSOR SIGNAL
EGR SENSOR RETURN GND
MAF SENSOR
SHT6/B5
6
92
EGR H BRIDGE POSITIVE
2
93
EGR H BRIDGE NEGATIVE
T
SHT6/B5
MASS AIR FLOW SENSOR 5V
37
MASS AIR FLOW SENSOR GND
20
C151
MAF FREQ
1
2
3
SHT6/B5
MAF TEMP
4
C136
1
45
COOLANT TEMP SENSOR RETURN
2
9
COOLANT TEMP SENSOR
OIL PRESSURE & TEMPERATURE SENSOR
OIL TEMP SENSOR
4
2
VREF 3 OIL PRESSURE
65
3
OIL PRESSURE SENSOR
11
4
OIL PRESSURE & TEMP RETURN GND
48
C149
T
FUEL TEMP SENSOR
1
10
FUEL TEMP SENSOR
2
46
FUEL TEMP SENSOR RETURN GND
1
C137
INTAKE MANIFOLD TEMPERATURE
KNOCK SENSOR 1
SHIELD-01
SHIELD-01
30
ENGINE BLOCK ACCELEROMETER #1 RETURN
2
31
ENGINE BLOCK ACCELEROMETER #1
3
28
ENGINE BLOCK ACCELEROMETER #1 SHIELD
C147
KNOCK SENSOR 2
SHIELD-02
SHIELD-02
1
2
3
33
ENGINE BLOCK ACCELEROMETER #2 RETURN
32
ENGINE BLOCK ACCELEROMETER #2
29
ENGINE BLOCK ACCELEROMETER #2 SHIELD
C146
CRANKSHAFT POSITION SENSOR
SHIELD-03
SHIELD-03
36
CRANKSHAFT SENSOR NEG
2
60
CRANKSHAFT POSITION SENSOR
3
87
CRANKSHAFT SENSOR SHIELD
1
Dealer Copy -- Not for Resale
C148
1
T
P
AIR INTAKE TEMP SENSOR RETURN
69
AIR INTAKE TEMP SENSOR
94
1
2
T
T
COOLANT TEMP SENSOR
C150
INTAKE MANIFOLD PRESSURE SENSOR
VREF 2, INTAKE PRESSURE SENSOR
61
1
INTAKE MANIFOLD PRESSURE SENSOR
12
3
INTAKE MANIFOLD PRESSURE RETURN GND
67
2
C145
P
C138
INJECTOR #1
FUEL INJECTOR #1 HSDA
27
FUEL INJECTOR #1 LSD1A
26
1
2
C139
INJECTOR #2
FUEL INJECTOR #2 HSDB
50
FUEL INJECTOR #2 LSD2B
74
1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1
SHT6/B5
2
C140
2
59
CAM SHAFT POSITION SENSOR
3
47
CAM SHAFT POSITION SENSOR RETURN
C144
INJECTOR #3
FUEL INJECTOR #3 HSDB
51
FUEL INJECTOR #3 LSD1B
75
1
RAIL PRESSURE SENSOR
P
3
38
VREF 1 RAIL PRESSURE SENSOR
1
35
RAIL PRESSURE SENSOR
2
19
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
C143
INLET METERING VALVE
VREF 1 INLET METERING VALVE
1
2
C141
FUEL INJECTOR #4 HSDA
3
FUEL INJECTOR #4 LSD2A
25
1
2
C142
SHT6/C5
77
2
C154
INLET METERING VALVE (PWM)
J7B
J7B
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
752 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 7 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 7 / 15
7331096
FRC1
TRACTION LOCK RELAY - D
HYDRAULICS
C425
+12V PWR
1360 RED/WHT
SHT2/E1
4100 LGN
D1
D5
30
87
85
86
D4
D2
B
B
A
A
C
C
A
GND
2200 BLK
SHT4/D6
2200 BLK
FRC1
FRC1
B
C308
BRAKE
SOLENOID 9.8
OHM 12 V
C308
2035 BLK
SHT4/B8
4200 LGN
TRACK 2 SPEED ADAPTER
(SEE ADDITIONAL OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
TRACTION LOCK RELAY SIGNAL
8
TRACTION LOCK RELAY FEEDBACK
13
4110 LGN
3430 LBL
SHT4/H3
2220 BRN
GND
3220 LBL
SIG
B
T
HYD TEMP SIGNAL
32
HYDRAULIC TEMPERATURE SENDER
500 - 3000 OHM (8 VOLT)
A
C108
HYD FILTER DIFF PRESS
34
SHT4/H3
3320 LBL
SIG
2320 BRN
GND
A
HYDRAULIC OIL FILTER SWITCH
(NC)
B
C112
HYDRAULIC FAN GROUND
SIG
2910 BRN
18
GND
1
Dealer Copy -- Not for Resale
4010 LGN
HYDRAULIC FAN SOLENOID
7.2 OHM 12 V
2
C446
HYD LOCK VALVE SOL GROUND
1
2410 BRN
GND
4410 LGN
SIG
2
HYDRAULIC LOCK SOLENOID
9.8 OHM 12 V
J1A
1
C420
GND
2190 BRN
SHT4/G3
SHT10/C8
3190 LBL
SIG
5190 YEL
+5 PWR
13
1
6
HYD CHARGE
PRESS SENDER
TRACTION SOLENOID
OUTPUT
HYDRAULIC CHARGE
PRESSURE 0.5-4.5V
J1B
19
HYD LOCK
SOLENOID
P
C
B
C105
4200 LGN
HYDRAULIC
FAN
A
4330 LGN
1
AUX CTRLR
FRONT ROD SOLENOID GROUND
2330 BRN
18
2
GND
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
SIG
C418
4340 LGN
GATEWAY CTRLR
2340 BRN
1
13
2
GND
FRONT BASE SOLENOID (FEMALE)
3.3 OHM PWM
SIG
C419
FRONT BASE
SOLENOID
FRONT ROD
SOLENOID
19
J2A
J2B
FRONT BASE SOLENOID GROUND
1
AUX CTRLR
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
753 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 8 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 8 / 15
7331096
CAB DISPLAY
LEFT PANEL BUZZER
1
1940 RNG/WHT
SHT3/E1
T13
1
7040 WHT
C499
PTOL CONN
T2
C479
LEFT PANEL (BLACK)
1930 RNG/WHT
SHT3/E1
2940 BLK
SHT4/F8
2920 BLK
SHT4/G8
1440 RED/WHT
SHT2/G1
1620 RNG/WHT
SHT3/E1
3500 LBL
SHT14/F4
SHT3/E1
2
GROUND
20
1
UNSWITCHED POWER
19
5
SWITCHED POWER
3030 LBL
2380 BRN
1
3030 LBL
1
2380 BRN
12 12
11
LEFT BLINKER INPUT
8
RIGHT BLINKER INPUT
24
2
PTOL OUTPUT
4
PTOL LED
8130 TAN
2
8130 TAN
2
2
START
4
RUN/ENTER SWITCH
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
J1A
1960 RNG/WHT
2700 BLK
2
22
3650 LBL
3
7
3040 LBL
3040 LBL
14 14
J1B
TRAVEL CONTROL INPUT
4
1950 RNG/WHT
SW9
SW9
9
PARK BRAKE INPUT
SW1
BRAKE SWITCH
2930 BLK
2
1
5
6
C479
SHT5/G1
4
SW1
1420 RED/WHT
SHT2/G1
3600 LBL
SW1
Dealer Copy -- Not for Resale
5
SHT3/E1
GROUND
C500
RH KEY SWITCH CONNECTOR
SHT3/D1
SHT4/E8
3
C499
SW9
TRAVEL CONTROL SWITCH(OPTIONAL)
SHT4/E8
SWITCHED POWER
C408
MFR HARN CONN 1 (BLACK)
GATEWAY CTRLR
3400 LBL
SHT14/F4
10
BUZZER
1
C480
LEFT PANEL CONN (GRAY)
1775 RNG/WHT
3620 LBL
SHT10/D3
12
3610 LBL
DOOR SIGNAL
2
PARK BRAKE OUTPUT
9
DESOX INHIBIT
4
DPF LAMP
2960 BLK
SHT4/F8
C500
C503
RH DLX PANEL
1590 RNG/WHT
SHT3/D1
1240 RED/WHT
SHT2/H1
2250 BLK
SHT4/F8
5
SWITCHED POWER
1
UNSWITCHED POWER
3
GROUND
C503
SHT5/F1
SW12
DESOX INHIBIT SWITCH(OPT KIT)
SHT4/E8
SHT3/E1
SHT3/E1
2065 BLK
1700 RNG/WHT
1705 RNG/WHT
2
4
7
9
10
8
3
8070 TAN
8050 TAN
8055 TAN
8060 TAN
SW12
SW12
5
DESOX INHIBIT LAMP
1
DPF FORCE REGEN
C480
NOT USED
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
754 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
Printable Version Click Here
7331096
SCHEM ELEC CTRL
Sheet 9 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 9 / 15
7331096
*
1785 RNG/WHT
SHT3/E1
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
2
CAB
1
*
6
2060 BLK
SHT10/D1
5
4230 LGN
SHT11/F2
SW4
4240 LGN
SHT11/D2
5
3
3
2
2
4
3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
5
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
C438
MFR HARN CONN 3 (DK GRAY)
SP29
4220 LGN
4235 LGN
4275 LGN
4550 LGN
7
7
8
8
9
9
2
2
4235 LGN
4275 LGN
*
C212
POWER SOCKET
4550 LGN
2795 BLK
1850 RNG/WHT
SHT3/F1
GND
1850 RNG/WHT
1375 RED/WHT
+12V PWR
1
2
C212
C408
MFR HARN CONN 1 (BLACK)
1370 RED/WHT
SHT2/B1
7
DOME LIGHT
SP45
1370 RED/WHT
7
1390 RED/WHT
*
1
C129
CAB ACCESSORY
1210 RED/WHT
5
2730 BLK
SHT4/E3
5
1865 RNG/WHT
2730 BLK
11 11
C428
MFR HARN CONN 2 (LT GRAY)
2790 BLK
SHT4/E3
2790 BLK
14 14
2690 BRN
2370 BRN
SHT4/H3
4
4
SEATBAR
SENSOR
SP56
GATEWAY CTRLR
SEATBAR SENSOR SIGNAL
5V PWR
11
24
3370 LBL
5
SP13
5100 YEL
5370 YEL
3
3
GND
A
SIG
B
+5V PWR
C
3370 LBL
5
5370 YEL
SP52
A
A
+12V BATT PWR
B
B
+12V SW PWR
C
C
GND
2010 BLK
SP41
1
*
T38
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SP44
SHT14/B3
2210 BLK
SHT14/B2
2885 BLK
SHT14/B3
2060 BLK
SHT10/H8
*
SHT6/D4
2375 BRN
2370 BRN
2800 BLK
2845 BLK
SHT3/D1
SP8
1580 RNG/WHT
Dealer Copy -- Not for Resale
1580 RNG/WHT
T37
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
3620 LBL
SHT9/D8
1400 RED/WHT
SHT2/G1
2840 BLK
7310 WHT
5375 YEL
C482
1
1
WIPER SWITCH, MOTOR SWITCHED POWER
4
4
DOOR SIGNAL
5
5
DOOR UNSW PWR
2
2
WIPER MOTOR GROUND
3
3
WASHER SIGNAL
J1B
SHT6/F7
SHT8/D7
SHT6/E4
5695 YEL
5690 YEL
5190 YEL
*
HARNESS WASHER PUMP
7253378
C252
B
A
2845 BLK
B
7310 WHT
A
GND
PWR
2
WASHER
MOTOR
1
C253
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
755 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 10 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 10 / 15
7331096
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3
RIGHT HANDLE LEFT ROCKER DOWN
31
RIGHT HANDLE LEFT ROCKER UP
30
A
4930 LGN
J
4940 LGN
B2
H
2195 BRN
SHT4/D3
4320 LGN
D
4300 LGN
C404
BU ALARM-MFR HARN (SEE
ADDITIONAL OPTION DWG)
A
C103
TAILGATE HARN
7100 WHT
A
C
C
SHT4/D8
RIGHT HANDLE RIGHT ROCKER UP
7100 WHT
T19
2650 BLK
1
1
F
4920 LGN
BACK UP ALARM
T20
E
2530 BLK
SHT4/B6
K
4230 LGN
SHT10/H8
PADDLE
B
4910 LGN
13
LEFT POSITION SWITCH
C
RIGHT POSITION SWITCH
TRIGGER
HANDLE LOCK (ACS ONLY)
G
C409
4980 LGN
SIG
1
C421
LIFT SPOOL LOCK
SOLENOID GROUND
2990 BRN
2
GND
3
LIFT SPOOL LOCK
7.8 OHM 12V
J1A
4990 LGN
SIG
5
LIFT SPOOL
LOCK SOLENOID
J2B
LIFT (ACS/AHC ONLY)
4240 LGN
SHT10/G8
FLOAT SIGNAL
22
LEFT HANDLE RIGHT ROCKER UP
28
LEFT HANDLE PADDEL RIGHT
11
LEFT HANDLE PADDEL LEFT
12
D
1520 RNG/WHT
4830 LGN
4840 LGN
4810 LGN
4820 LGN
HANDLE LOCK (ACS ONLY)
E
4640 LGN
20
LEFT HANDLE RIGHT ROCKER DOWN
H
2520 BLK
SHT4/B6
SHT3/E3
J1B
7
LEFT HANDLE
AUX CTRLR
1
C422
TILT SPOOL
LOCK SOLENOID
23
TILT SPOOL LOCK
7.8 OHM 12V
18
3
RIGHT HANDLE
PWM HIGH
GND
RIGHT HANDLE
PWM SIGNAL
2980 BRN
10
21
TILT SPOOL LOCK
SOLENOID GROUND
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
Dealer Copy -- Not for Resale
TILT (ACS/AHC ONLY)
FLOAT (ACS/AHC ONLY)
A
B
RIGHT POSTION SWITCH
C
F
PADDLE
G
C410
J2A
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
756 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click SCHEM
Here
ELEC CTRL
Sheet 11 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 11 / 15
7331096
LIGHTS
C434-1
6100 PNK
SIG
A
37 WATT
C408
MFR HARN CONN 1 (BLACK)
2765 BLK
SHT4/F3
9
9
2735 BLK
2765 BLK
SP14
GND
2750 BLK
GND
LEFT FRONT
WORKLIGHT
B
B
50 WATT
6110 PNK
SIG
A
C434-2
C435-1
6000 PNK
8
8
6120 PNK
6000 PNK
SIG
SP15
FRONT WORK LIGHTS
RELAY - RC1
SHT2/E1
1350 RED/WHT
30
37 WATT
C438
MFR HARN CONN 3 (DK GRAY)
6620 PNK
87
SP23
6610 PNK
13 13
2760 BLK
GND
6130 PNK
6610 PNK
SIG
SP64
86
RC1
30
87
86
6340 PNK
SP10
6310 PNK
A
RC2
2115 BLK
A
2610 BLK
SHT4/D8
GND
2
RIGHT REAR
TAIL LIGHT
C103
TAILGATE HARN
85
RC2
SHT4/B8
Dealer Copy -- Not for Resale
6320 PNK
FRONT WORK LIGHTS
RELAY - RC2
RED/WHT
B
C435-2
2120 BLK
1330
SP49
6310 PNK
6320 PNK
SIG
1
C603
6330 PNK
SIG
1
LEFT REAR
TAIL LIGHT
GATEWAY CTRLR
2640 BLK
SHT4/D8
MRKR LIGHT PWR RELAY
5
MRKR LIGHT PWR RELAY FEEDBACK
31
REAR LIGHT RELAY
17
SHT2/E1
C604
2620 BLK
SHT4/D8
3440 LBL
1320 RED/WHT
E1
6210 PNK
2
C605
30
87
85
86
6200 PNK
E4
H
H
6220 PNK
6200 PNK
2
SP96
LEFT REAR
WORK LIGHT
E2
2630 BLK
SHT4/C8
FRC1
1
FRC1
2045 BLK
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
757 of 1148
1
RIGHT REAR
WORK LIGHT
FRC1
REAR LIGHT
RELAY - E
E5
SHT4/B8
2
3460 LBL
28
J1A
GND
C602
6210 PNK
REAR LIGHT RELAY FEEDBACK
RIGHT FRONT
WORK LIGHT
A
50 WATT
GND
2705 BLK
6630 PNK
SHT2/E1
B
85
RC1
SHT4/A8
A
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 12 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 12 / 15
7331096
HVAC
*
2440 BLK
GND
2
HVAC DUCT FAN
M
7440 WHT
SIG
*
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
C610
*
2560 BLK
C
7420 WHT
POTENTIOMETER (TEMP
CONTROL SWITCH)
A
B
C483
*
7425 WHT
D
2130 BLK
HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
3
HVAC RELAY FEEDBACK
30
5
B2
86
FRC1
FRC1
3050 LBL
2745 BLK
SHT4/F3
11 11
2
1
4
2745 BLK
AC SIGNAL MONITOR
7021 WHT
11
SP40
7020 WHT
M
SW10
7410 WHT
4
C611
2580 BLK
2100 BLK
2570 BLK
J1A
7015 WHT
*
THERMOSTAT
2
3
A
7023 WHT
7025 WHT
7024 WHT
C350
SHT4/C6
SW11
AC SWITCH
SIG
1
D4
B
*
1
C630
AC EVAPORATOR
SWITCH
LOW
3
3
7020 WHT
12 12
2
7510 WHT
1
SP16
MED
7520 WHT
SW10
HIGH
1
SW11
7050 WHT
HVAC RELAY SIGNAL
10 10
B4
85
B5
GATEWAY CTRLR
87
30
7530 WHT
7400 WHT
B1
1500 RNG/WHT
*
SW10
BLOWER SWITCH
C
SHT2/F1
1500 RNG/WHT
*
Dealer Copy -- Not for Resale
1140 RED/WHT
C438
MFR HARN CONN 3
(DK GRAY)
3
FRC1
HVAC RELAY-B
2290 BLK
MAGNET CLUTCH
(COMPRESSOR)
2280 BLK
GND
2
C486
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
758 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 13 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 13 / 15
7331096
C428
MFR HARN CONN 2 (LT GRAY)
C355
FUEL HARN
#
POWER BOB
CLOSE
1 SIG
4470 LGN
2 GND
2470 BLK
2770 BLK
SP33
C607
#
4480 LGN
1 SIG
POWER BOB
OPEN
2
GND
E
E
B
B
F
F
4470 LGN
2770 BLK
OPTIONS 1
4470 LGN
11 11
SW5
POWER BOBTACH SWITCH
*
SHT4/E6
4480 LGN
4480 LGN
10 10
1380 RED/WHT
2
SW5
2480 BLK
#
DLX FUEL HARN 7266824 ONLY
(NOT IN STD FUEL HARN 7149219)
*
DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
1
3
SW5
C606
6010 PNK
LEFT HANDLE
LIFT (ACS/AHC ONLY)
LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG)
1550 RNG/WHT
SHT3/F1
6010 PNK
13 13
1550 RNG/WHT
12 12
1405 RED/WHT
C438
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY)
1410 RED/WHT
SHT2/C1
1410 RED/WHT
1
1
SP43
SHT15/D6
1430 RED/WHT
X
*
T3
FLASHER
L
1200 RED/WHT
FLOAT (ACS/AHC ONLY)
D
6515 PNK
A
TRIGGER
C103
TAILGATE HARN
C411
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG)
E
E
D
D
3
3
6500 PNK
6400 PNK
6400 PNK
2780 BLK
2780 BLK
4
4
*
4450 LGN
B GND
2450 BLK
4455 LGN
4455 LGN
5
5
D3
A SIG
1
2
4
SHT4/C6
6
5
SW6
LEFT HANDLE
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG)
RIGHT BLINKER SIGNAL
HANDLE LOCK (ACS ONLY)
LEFT BLINKER SIGNAL
FLOAT (ACS/AHC ONLY)
3
HIGH FLOW SOLENOID GROUND
7200 WHT
5
C
6420 PNK
4
6520 PNK
3
(PINS 3 & 6
INTERNALLY INSULATED)
B
B
26
RIGHT POSTION SWITCH
SIG
PADDLE
TRIGGER
A
1460 RED/WHT
C408
MFR HARN CONN 1
(BLACK)
SHT2/C1
7210 WHT
B
13 13
2810 BLK
SHT15/D5
SHT4/E8
6540 PNK
LEFT SPEAKER
SJC HORN/BLINKER
(SEE ADDITIONAL
OPTIONS DWG)
*
1
*
7820 WHT
7830 WHT
2
B
2
HIGH FLOW
SOLENOID
7.5 OHM 12 V
A
*
1
C278
SHT10/E1
3
LEFT
SPEAKER (+)
4
LEFT
SPEAKER (-)
C126
HORN CONNECTOR
6
7800 WHT
5
1885 RNG/WHT
TWO SPEED GROUND
SIG
RIGHT
SPEAKER (-)
RIGHT
SPEAKER (+)
2785 BLK
B
B
GND
F
B
B
C
C
A
A
C670
BEACON/FLASHER
EXTERIOR HARNESS
(SEE ADDITIONAL
OPTIONS DWG)
1
SHT10/E1
TWO SPEED SIGNAL
4
PWR
PWR
2210 BLK
2
C676
GND
5
GND
6
C277
26
2350 BRN
4350 LGN
+
L010
AIR RIDE SEAT
3
1
HORN
SHT4/E8
F
1510 RNG/WHT
GND
2
J1A
_
C412
D
*
SHT10/E1
A
E
D
2
7810 WHT
2885 BLK
SHT10/D1
A
C676
RADIO CONN
E
C279
GATEWAY CTRLR
7210 WHT
2420 BLK
6440 PNK
J2B
LEFT POSITION SWITCH
2970 BLK
SHT15/F4
C415
4460 LGN
26
6700 PNK
*
RIGHT SPEAKER
GND
2725 BLK
2905 BLK
SHT15/F6
2460 BRN
J2A
HIGH FLOW SOLENOID
A
SP46
2850 BLK
SW2
SW3
C
A
6
SW2
4
6
SW3
C497
HORN SIGNAL
1
5
1
2
SW3
HAZARD SWITCH
2
SW6
2830 BLK
AUX CTRLR
3400 LBL
*
SW6
BUCKET POSITION SWITCH
3
2455 BLK
C423
LIFT (ACS/AHC ONLY)
*
SW2
BEACON SWITCH
6430 PNK
SHT9/G8
SHT4/E3
BUCKET
POSITION
SOLENOID
9.8 OHM
6530 PNK
6510 PNK
6410 PNK
6415 PNK
6
T3
D14
D13
SP22
B
6
3500 LBL
6570 PNK
PADDLE
6500 PNK
Dealer Copy -- Not for Resale
RIGHT POSTION SWITCH
LEFT POSITION SWITCH
SHT9/F8
SP21
SIG
1
TWO SPEED
SOLENOID
5.1 OHM 12 V
TRACK 2 SPEED
(SEE ADDITIONAL
OPTIONS DWG)
C441
26
J1B
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
759 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 14 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 14 / 15
7331096
AUX CTRLR
RIDE CONTROL SW AUTO
3410 LBL
23
14 14
3410 LBL
1
7
RIDE CONTROL COIL SIGNAL
21
1
2
SP9
2040 BLK
3425 LBL
SP32
C439
2020 BLK
1
RIDE CONTROL
COIL
3475 LBL
16
29
FRC1
C440
8
3475 LBL
7
*
2905 BLK
8
SHT4/G8
SW13
REVERSING FAN
3
1
3470 LBL
2970 BLK
2
1555 RNG/WHT
REVERSING
FAN COIL
J2A
REVERSING FAN SIGNAL
3485 LBL
25
1
C442
SHT4/D3
RIDE CONTROL PRESSURE SENSOR SIGNAL
RIDE CONTROL SENSOR +5V PWR
2185 BRN
3455 LBL
10
5105 YEL
24
A
C
RIDE CONTROL
PRESSURE SENSOR
B
J2B
*
SW8
SIDELIGHT
1405 RED/WHT
SHT14/G3
2
1
SHT14/D3
6
P697
Wiring Schematic
ACS / SJC Machine
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
WARNING
THE EXPORT OR REEXPORT OF THIS DRAWING OR A
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
COPYRIGHT
760 of 1148
0
SEE SHEET 1
REV
DESCRIPTION
110295
PML
CHG NOTICE DWN
SHEET
C
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
SHT3/D1
SW8
Dealer Copy -- Not for Resale
2
SHT14/D3
6
4
SW8
C443
2175 BRN
27
SHT4/C8
FRC1
5
REVERSING FAN RETURN SIGNAL
SHT3/F1
2
SHT14/D3
REVERSING FAN AUTO SIGNAL
2505 BLK
L2
2155 BLK
7
3470 LBL
1575 RNG/WHT
L1
L5
C428
MFR HARN CONN 2 (LT GRAY)
REVERSING FAN MANUAL SIGNAL
SHT4/E8
SW7
L4
3445 LBL
3435 LBL
RIDE CONTROL
COIL
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
3480 LBL
3415 LBL
2890 BLK
2
SW7
RIDE CONTROL RELAY SIGNAL
OPTIONS 2
*
SW7
RIDE CONTROL
C438
MFR HARN CONN 3 (DK GRAY)
*
C672
SIDELIGHT CONN
6710 PNK
2810 BLK
2860 BLK
1
1
2
2
SHT4/E8
P697
PROPRIETARY NOTICE
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,
IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
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.
TOLERANCES:
ECN
Printed On August 2018
7331096
Printable Version Click Here
SCHEM ELEC CTRL
Sheet 15 of 17
DWG. NO.
110295
csf
WEST FARGO, NORTH DAKOTA, USA
TITLE
UNLESS OTHERWISE SPECIFIED
X ± 13
MAT
SHT 15 / 15
7331096
CONNECTOR J1-ACS
FUNCTION
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
PIN
A
B
C
D
E
F
G
H
ACS CONTROLLER
CONNECTOR J2-ACS
FUNCTION
PIN
A
B
C
D
E
F
G
H
J
K
GROUND
GROUND
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
TILT PEDAL
CONNECTOR J3-ACS
FUNCTION
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
PIN
A
B
C
D
E
F
G
H
J
K
J1-ACS
CONTROLLER
2280/BLK
4220/LGN
4275/LGN
C
+5V
E
D
B
A
G
4550/LGN
9240/PUR
9140/PUR/WHT
1740/RNG/WHT
5
3
2
7
8
1
4
6
C493
4
3
2
1
2240/BLK
J3-ACS
CONTROLLER
1170/RED/WHT
B
C
1190/RED/WHT
1180/RED/WHT
E
J
H
G
4220/LGN
2260/BLK
2270/BLK
4260/LGN
5970/YEL
2250/BRN
J2-ACS
CONTROLLER
C472
2650/BRN
4650/LGN
5650/YEL
F
B
C
A
B
C
A
GND
SIG
+5V PWR
LIFT HANDLE
HALL SENSOR
F
C469
2750/BRN
4750/LGN
5750/YEL
G
D
B
C
A
B
C
A
GND
SIG
+5V PWR
TILT HANDLE
HALL SENSOR
GND
SIG
+5V PWR
LIFT PEDAL
HALL SENSOR
SEE MANUAL CONTROL
PAGE FOR HARNESS CONN
4275/LGN
C492
HARNESS PART NUMBER
EXMF, LF
7164144
7190593
MF
2280/BLK
2240/BLK
1170/RED/WHT
MAINFRAME HARNESS
Dealer Copy -- Not for Resale
H
ACS
ACS
C467
2510/BLK
4280/LGN
3
1
2
C468
2500/BLK
4270/LGN
2
3
1
C429
4610/LGN
4600/LGN
5980/YEL
2980/BRN
3980/LBL
8
7
6
5
4
3
1
2
LIFT
SOLENOID
13 OHM
12V
FOOT PEDAL LOCK
TILT
SOLENOID
LIFT ACTUATOR
C409
C466
K
G
A
H
J
E
F
C
D
B
A
B
HANDLE
LOCK
SKI CTRL
DETENT
FLOW
TWO SPD
PWM
C410
K
D
C
B
G
F
A
J
H
E
FLOAT
SKI CTRL
SIDE
SHIFT
A
B
HANDLE
LOCK
+5V PWR
GND
SIG
C471
2660/BRN
4660/LGN
5660/YEL
J
2980/BRN
2990/BRN
K
A
B
C
D
H
E
C428
C470
2760/BRN
4760/LGN
5760/YEL
5750/YEL
5650/YEL
5970/YEL
2
3
1
GND
SIG
+5V PWR
TILT PEDAL
HALL SENSOR
K
4645/LGN
A
4640/LGN
5990/YEL
2990/BRN
3990/LBL
8
7
6
5
4
3
1
2
TILT ACTUATOR
+5V PWR
GND
SIG
5980/YEL
5990/YEL
3980/LBL
3990/LBL
Wiring Schematic
ACS / SJC Machine
761 of 1148
2
3
1
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
Printed On August 2018
7331096
Printable Version Click Here
Sheet 16 of 17
Dealer Copy -- Not for Resale
Wiring Schematic
ACS / SJC Machine
762 of 1148
S550
S570
S590
S510
S530
T590
S/N B42T12001
B3GY12001
B3GZ12001
B3H112001
B42S11024
B3Z712001 &
&
& Above
Above
Above
Printed On August 2018
7331096
Printable Version Click Here
Sheet 17 of 17
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
LIGHTS
PINK
PNK
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PARTIAL CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
CAN SHIELD
SW POWER
SHEET #
CAN LOW
CAN HIGH
GROUND
9800
CAN HIGH
D
2
C
1
B
A
GROUND
3
2700
KEY "RUN"
UNSW POWER
CAN SHIELD
SW POWER
CAN LOW
Connector
on Loader
Boom
D
F
C
E
A
B
1160
9700
1710
9600
9500
TO DLX CAB
HARNESS
1
2
C129
SIG
PWR DOOR SENSOR
A
B
C
TO CAB
HARNESS
1865/RNG/WHT
2820/BLK
SW7
REAR
WIPER
SWITCH
1
2
3
4
5
6
7170531 SPECIAL APPS DOOR HARNESS
Dealer Copy -- Not for Resale
3630/LBL
1400/RED/WHT
4
5
6
1
3
2
SENSOR SHOWN
WITH DOOR OPEN
7230/WHT T6 1
C667
DOOR HARN
5
2
3630/LBL
2860/BLK
6
R1
300 OHM RESISTOR
0.5W 5%
3635/LBL
3630/LBL
3
2860/BLK
C251
2
SIG
SENSOR SHOWN
WITH DOOR OPEN
1
GND
DOOR SENSOR
2710
9600
9500
1160
1710
PUR
1160
RED/WHT
2720
9710
PUR
9710
1730
RNG
9620
PUR
9520
PUR
2730
BLK
9
H
F
B
E
D
C
A
G
1720
9
9610
14
9510
13
F OUTPUT
G OUTPUT
H OUTPUT
C OUTPUT
D OUTPUT
A OUTPUT
M OUTPUT
ID (K TO L)
ID (K TO P)
C506
Connector
on Loader
Boom
ACD
Machine
Connector to
Engine
Compartment
SW POWER
CAN LOW
CAN HIGH
OPEN
OPEN
OPEN
1740
5100
5100
5350
5350
5400
5400
5050
5050
5300
5300
5150
5150
5250
5250
5200
5200
5910
5000
12
5510
5450
11
14-PIN
ATTACHMENT
CONNECTOR
5900
5500
C667
DOOR HARN
4
5
CAN SHIELD
2740
DELUXE ATTACHMENT
CONTROL HARNESS 6732730
REAR
WIPER
MOTOR
J1 - 8-PIN
GROUND
BOOM-MOUNTED
ACD CONNECTORS
C250
3630/LBL
1400/RED/WHT
1
2
SIG
PWR
C703
C
H
J
B
G
D
F
E
A
K
E OUTPUT
J
A
B
C
D
E
F
G
H
K
ID #1
J2 - 10-PIN BLACK
F OUTPUT
G OUTPUT
ACD
Output
Connector to
Engine
Compartment
H OUTPUT
C OUTPUT
D OUTPUT
A OUTPUT
B OUTPUT
J OUTPUT
K OUTPUT
C704
J3 - 10-PIN GRAY
ID #2
ID #3
ACD
Input
Connector to
Engine
Compartment
ID #4
ID #0
OPEN
OPEN
OPEN
OPEN
OPEN
SENSOR SHOWN
WITH DOOR OPEN
DOOR SENSOR
C251
6
C
7330/WHT
1570/RNG/WHT
CAB
HARNESS
1 1850/RNG/WHT
1410/RED/WHT
4
1400/RED/WHT
J
N
K
B
E
F
G
H
C
D
A
M
L
P
GROUND
7180207 REAR WIPER HARNESS
R2
750 OHM RESISTOR
C250
1W 5%
1 1400/RED/WHT
C705
9800
7-PIN
E OUTPUT
C426
C666
CONTROL HARNESS - 7175321
To Mainframe
Harness
C666 ATTACHMENT
CONNECTOR
SW POWER
G
7-PIN
ATTACHMENT
CONNECTOR
Connector
on Loader
Boom
C250
D
F
C
E
B
A
G
KEY "RUN"
UNSW POWER
SSL 7-PIN
CAN CONNECTOR
C667
DOOR HARN
C426
D F C E A B G
9800
SSL 7-PIN
CAN CONNECTOR
9700
CONNECTOR
3
7310/WHT
2
2840/BLK
PARK
E
3
7300/WHT
1
2
6
1860/RNG/WHT
5
4
SW8
FRONT WIPER
SWITCH
A
LOW
D
SW PWR
B
GND
WIPER
MOTOR
7155024 DOOR HARNESS
7195485 DOOR SENSOR HARNESS
TO DLX
CAB HARNESS
Printable Version Click Here
C251
1
1850/RNG/WHT
3
7310/WHT
2
2840/BLK
SW8
FRONT WIPER
SWITCH
C
7330/WHT
1570/RNG/WHT
3
1
6
4
E
7300/WHT
2
5
2850/BLK
PARK
1860/RNG/WHT
A
LOW
D
SW PWR
B
GND
WIPER
MOTOR
7171105 FORESTRY DOOR HARNESS
Printed In U.S.A.
763 of 1148
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 1 of 6
(PRINTED OCTOBER 2017)
7195572 (E)
C489-B
1510/RNG
2210/BLK
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BLK
BATTERY GROUND
2000 THROUGH 2999
BLACK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
C489-A
C220
A
C
1520/RNG
2230/BLK
6500/PNK
B
1500/RNG
2220/BLK
C103-A
G
1
2
C425
1
2
C103-B
6502/PNK
6501/PNK
G
H
B
6200/PNK
2600/BLK
H
B
D
6510/PNK
D
E
6410/PNK
E
B
A
C
TO
MAINFRAME
HARNESS
TO
MAINFRAME
HARNESS
TO
MAINFRAME
HARNESS
C427
C437
C428
2
1
2
1
2360/BRN
4360/LGN
C441
TWO SPEED
MAKEUP SOLENOID
8.8 OHM 12V
GND
SIG
C429
2
1
2
1
2350/BRN
4350/LGN
TWO SPEED
SOLENOID
5.1 OHM 12 V
GND
SIG
EXMF, LF: 7177692 2 SPD TRACK ADAPTER
EXLF: 7190709 2 SPD TRACK ADAPTER
F
F
A
6310/PNK
A
C
7100/WHT
C
BRAKE
SOLENOID
9.8 OHM
12 V
1
2
4200/LGN
2200/BLK
7110/WHT
BACK-UP ALARM
SWITCHES
C404
TO
MAINFRAME
HARNESS
7219294 - HARNESS NEUTRAL LIGHT
A
B
7100/WHT
1720/RNG/WHT
LEGEND
7175017 BACK-UP ALARM HARNESS
PARTIAL CONNECTOR
C414
A
B
Dealer Copy -- Not for Resale
C362
4440/LGN
2440/BLK
1
2
CONNECTOR
WHITE TIE STRAP
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
E
F
4430/LGN
2430/BLK
1
2
A C
SIG
GND
REAR ROD (F)
7.5 OHM 12V
1
2
4450/LGN
2450/BLK
B
SIG
GND
REAR ROD LOCK
7.5 OHM
12 V
C417
4480/LGN
2480/BLK
1
2
GREEN TIE STRAP
SIG
GND
4440/LGN
2440/BRN
1
2
WHITE TIE STRAP
J2B PIN 7
AUX CTRLR J2A PIN 10
4430/LGN
2430/BRN
J2B PIN 4
2450/BLK
YELLOW TIE STRAP
4480/LGN
J2B PIN 6
GREEN TIE STRAP
REAR BASE
7.5 OHM 12V
SIG
GND
REAR ROD
7.5 OHM 12V
SIG
GND
C417
1
2
2480/BLK
SIG
GND
C416
1
2
4450/LGN
2725/BLK
SIG
GND
REAR ROD LOCK
7.5 OHM
12 V
REAR BASE LOCK
9.8 OHM
12 V
7191339 or 7201414 REAR AUX HARNESS
Printed In U.S.A.
764 of 1148
B D
2780/BLK
TO
MAINFRAME
HARNESS
A
6515/PNK
86
87
C
7200/WHT
TO
MAINFRAME
HARNESS
(2 WAY LH)
86
87
2790/BLK
85
30 6010/PNK
6020/PNK
2770/BLK
C412
87
B
2785/BLK
A
1420/RED/WHT
85
30
C489-2
TO
C489-1
MAINFRAME
B
2720/BLK
HARNESS
A
1720/RNG
(ACCESSORY
POWER)
2740/BLK
B
A
ADDITIONAL
ACCESSORY
POWER
CONNECTOR
7151940 SJC/AWS/SCPA HRN/BLINKER HARNESS
C413
1
2
BROWN TIE STRAP
TO
C489-1
MAINFRAME
B
2720/BLK
HARNESS
A
1780/RNG/WHT
(ACCESSORY
POWER)
C489-2
ADDITIONAL
A
ACCESSORY
POWER
B
CONNECTOR
6510/PNK
6415/PNK
86
C414
AUX CTRLR
E
TO
MAINFRAME
HARNESS
(5 WAY LH)
6410/PNK
REAR BASE LOCK
9.8 OHM
12 V
7173271 REAR AUX HARNESS
AUX CTRLR J2B PIN 5
AUX CTRLR J2A PIN 2
C497
C416
YELLOW TIE STRAP
G
H
C411
C413
BROWN TIE STRAP
TO
MAINFRAME
HARNESS
REAR BASE (M)
7.5 OHM 12V
6000/PNK
C
D
SIG
GND
Printable Version Click Here
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 2 of 6
(PRINTED OCTOBER 2017)
7195572 (E)
85
30
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
LBL
MONITORING
3000 THROUGH 3999
LIGHT BLUE
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
ENGINE
8000 THROUGH 8999
TAN
TAN
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
PARTIAL CONNECTOR
CONNECTOR
C129
CAB ACCESSORY
POWER CONN
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
A
SHEET #
TO STANDARD
CAB HARNESS
DLX CAB:
TO DLX CAB HARNESS
2775/BLK
1
2
1
2
2785/BLK
6440/PNK
6540/PNK
3
6718872 EXTERIOR CAB HARNESS
2785/BLK
2795/BLK
2790/BLK
7169753 4 WAY FLASHER HARNESS
6340/PNK
A
6340/PNK
2670/BLK
B
2670/BLK
TO EURO
TAILGATE
HARNESS
C603
C103
D
6510/PNK
C407-A
H
B
6200/PNK
2600/BLK
C407-B
A
A
6320/PNK
6510/PNK
6610/PNK
6430/PNK
2610/BLK
BREAK CONNECTION
FOR ROADLIGHT KIT
E
F
A
C
B
D
7100/WHT
6600/PNK
E
6410/PNK
F
A
+
-
6700/PNK
2420/BLK
C250
3620/LBL
1400/RED/WHT
DOOR SENSOR
1850/RNG/WHT
2840/BLK
1570
2814
5
4
6
3
1
2
HT
0/W
3
3
7
HT
7 300/W
C
PARK
A
LOW
E
HIGH
D
SW PWR
B
GND
7305/WHT
1860/RNG/WHT
INTERMITTENT WIPER
SWITCH
2842/BLK
-
2650/BLK
+
NOTE: SPLICE ADDED BEFORE
CONNECTOR INSTEAD OF AT PIN.
C602
6410/PNK
6620/PNK
6330/PNK
2640/BLK
E
F
A
C
B
D
2630/BLK
6210/PNK
6310/PNK
6310/PNK
Taillight Left
7104671
Taillight Left
7104671
BLU
RED
YEL
BLK
+
6310/PNK
6250/PNK
SP24
+
7217483 - HARNESS EUR TAILGATE
(HARNESS SAME AS 7175287
EXCEPT AS SHOWN ABOVE)
TO EXTERIOR
CAB HARNESS
SENSOR SHOWN
WITH DOOR OPEN
7310/WHT
1
2
SIG
PWR
E
D
C
A
F
B
C251
3
CAB
HARNESS
1
2
7231771 INTERMITTENT WIPER DOOR HARNESS
7175287 - HARNESS EUR TAILGATE
765 of 1148
4
5
6
7153090 HARNESS LICENSE LIGHT
6210/PNK
WITHOUT ROADLIGHT
KIT: TO MAINFRAME
HARNESS
C
G
C670
2850/BLK
6440/PNK
6540/PNK
C667
DOOR HARN
REGISTRATION
(LICENSE PLATE)
LAMP
BLU
RED
YEL
BLK
Backup Alarm
6660294
WITH ROADLIGHT KIT:
TO ROADLIGHT KIT
HARNESS
2780/BLK
7169130 ACC HARNESS
(STD CAB HARNESS ONLY)
Taillight Right
7104670
2620/BLK
6210/PNK
SW2
BEACON
SWITCH
2725/BLK 6
5
4
1
2
3
INSULATED)
LEFT
FLASHER
LIGHT
6540/PNK
C800
Printed In U.S.A.
SW3
4 WAY FLASHER
SWITCH
1
6570/PNK
2
3
4
(PINS 3 & 6
5
INTERNALLY
6
RIGHT
FLASHER
LIGHT
6440/PNK
T3
FLASHER CONN
2780/BLK
C669
STROBE
BEACON
X
L
C609
6700/PNK
2780/BLK
Dealer Copy -- Not for Resale
STD CAB:
TO ACC HARNESS
E
D
C
A
F
B
1200/RED/WHT
1430/RED/WHT
B
C
C670
1410/RED/WHT
Printable Version Click Here
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 3 of 6
(PRINTED OCTOBER 2017)
7195572 (E)
WIPER
MOTOR
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BATTERY GROUND
2000 THROUGH 2999
BLACK
BLK
BRN
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
YEL
PINK
PNK
LIGHTS
6000 THROUGH 6999
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
TAN
TAN
ENGINE
8000 THROUGH 8999
COMMUNICATION
9000 THROUGH 9999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
TO EURO
TAILGATE
HARNESS
T01
85
4210/LGN
85
2020/BLK
86
7210/WHT
6330/WHT
2
2310/BLK
B
2120/BLK
6
7230/WHT
C
6120/LGN
5
7270/WHT
D
6340/RED
4
85
86
1510/RNG
A
2210/BLK
B
A
1520/RNG
1500/RNG
A
2730/BLK
C
2230/BLK
2200/BLK
B
6600/PNK
B
6500/PNK
F
F
6420/PNK
A
7210/WHT
E
6440/PNK
D
7250/WHT
6510/PNK
E
6220/PNK
C
2110/BLK
B
7260/WHT
B
7200/WHT
C
7220/WHT
7240/WHT
A
2300/BLK
2320/BLK
D
7200/WHT
2030/BLK
Brake Light
Rear Turn Light
ADDITIONAL
ACCESSORY
POWER
CONNECTOR
HARNESS
T02
2120/BLK
B
2300/BLK
E
F
6330/PNK
A
7210/WHT
6120/PNK
C
7220/WHT
7240/WHT
6340/PNK
D
7250/WHT
7260/WHT
6520/PNK
E
7200/WHT
F
TO
SJC/AWS/SCPA
CONTROLS HARNESS
(1 PIN CONN)
A
B
Rear Position Light
C
Brake Light
2320/BLK
D
7210/WHT
A
6330/WHT
2
7270/WHT
D
6340/RED
4
E
7175581 - SJC BRAKE HARNESS
(ONLY FOR SJC OPTION)
HARNESS
6010/PNK
6320/PNK
H
B
2000/BLK
6530/PNK
2010/BLK
G
D
6210/PNK
6230/PNK
D
E
6110/PNK
6130/PNK
E
F
Position Light
3
7230/WHT
C
6120/LGN
5
2310/BLK
B
2120/BLK
6
F
H
Front Turn Light
6310/PNK
30
1730/RNG
86
1
Relay1
Right Side Lights
6410/PNK
87
6400/PNK
6300/PNK
87A
3
A
Position Light
6430/PNK
30
10.0 Amps
30
1
SHEET #
Relay2
Left Side Lights
87
1400/RED/WHT
1010/RED
87
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
F
E
C407-B
1410/RED/WHT
10.0 Amps
CONNECTOR
Dealer Copy -- Not for Resale
1020/RED
PARTIAL CONNECTOR
1
B
F
G
A
6000/PNK
6000/PNK
A
C
7100/WHT
7100/WHT
C
HARNESS
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Printable Version Click Here
Sheet 4 of 6
(PRINTED OCTOBER 2017)
Printed In U.S.A.
766 of 1148
7195572 (E)
LEGEND
PARTIAL CONNECTOR
** HARNESS
STVB 04
1
2
CONNECTOR
** HARNESS
HEIGHT ADJUSTMENT
L4/RD
STVB 92
STVB 02
1
STVB A
L1/BK
2
3
COMPRESSOR
(SUSPENSION)
STVB B
L2/RD
SHEET #
S1
(MOMENTARY)
4
1
2
C277
1
2
5
L3/BK
6
L2/VT
L4/BK
L13/BRN
L1/RD
L12/BLK
4
1
2
Dealer Copy -- Not for Resale
HARNESS
L10/RED
STVB 03
L7/BK
STVB xx
STVB 03
** HARNESS
L5/RD
3
HEATING MAT SEAT
YEL
L3/RD
L6/BK
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
STVB H1
1
2
60°C / 50°C
BRN
HEATING SWITCH
STVB H2
S2
STVB H3
L14/BRN
YEL
STVB H5
HEATING MAT BACK
STVB xx
1
2
L11/BLK
60°C / 50°C
BRN
7308952 HEATED SEAT
Printable Version Click Here
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 5 of 6
(PRINTED OCTOBER 2017)
Printed In U.S.A.
767 of 1148
7195572 (E)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
GROUP NUMBER RANGE
WIRE COLOR
COLOR CODE
BATT FEED, GENERAL
1000 THROUGH 1499
RED
RED
BATT FEED, FUSED
1000 THROUGH 1499
RED/WHITE
RED/WHT
BATT FEED, SWITCHED
1500 THROUGH 1999
ORANGE/WHITE
RNG/WHT
BLK
BATTERY GROUND
2000 THROUGH 2999
BLACK
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
BROWN
BRN
MONITORING
3000 THROUGH 3999
LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN
LGN
YEL
CONTROLLER SUPPLY
5000 THROUGH 5999
YELLOW
LIGHTS
6000 THROUGH 6999
PINK
PNK
OTHER FUNCTIONS
7000 THROUGH 7999
WHITE
WHT
TAN
TAN
ENGINE
8000 THROUGH 8999
PURPLE
PUR
COMMUNICATION
9000 THROUGH 9999
COMMUNICATION
9000 THROUGH 9999
PURPLE/WHITE
PUR/WHT
SHEET #
MACHINE CONN
2
4
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
C678
1
3
CONNECTOR
Dealer Copy -- Not for Resale
C001
CALAMP TELEMATICS CONN
PARTIAL CONNECTOR
9502/PUR/WHT/18
9602/PUR/18
4
3
5
6
7
8
CAN HI
CAN LO
9
10
1167/RED/WHT/18
1
11
2712/BLK/18
2
12
UNSWITCHED POWER
7335305 & 7335295 NON-TELEMATIC JUMPER
CAN GROUND
Printable Version Click Here
7300058 CALAMP ADP TELEMATICS HARNESS
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 6 of 6
(PRINTED OCTOBER 2017)
Printed In U.S.A.
768 of 1148
7195572 (E)
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
SYMBOL
DESCRIPTION
COMPONENTS
CONNECTIONS
A
3520
C
B
3510
C107
3500
A
3500
C
B
3510
3520
C107
A
C
B
3500
3520
3510
A
C
B
3500
3520
3510
DESCRIPTION
CONNECTOR - Harness - Used for
connecting 2 harnesses together or a
harness to a component. The
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
pins can be numbered alphabetical
(shown) or numerical (1, 2, 3 etc.).
The harness wires numbers are
called out next to the connector
(Example: 3500).
GROUND - Frame - Used to
represent an component that is
internally grounded.
LIGHT -
SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector.
SWITCH - Single Pole - Sing