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 2 of 1148 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 3 of 1148 1-1 S530 Service Manual Dealer Copy -- Not for Resale CORRECT Dealer Copy -- Not for Resale 4 of 1148 1-2 S530 Service Manual 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 5 of 1148 1-3 S530 Service Manual Dealer Copy -- Not for Resale SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 Dealer Copy -- Not for Resale 6 of 1148 1-4 S530 Service Manual 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 7 of 1148 1-5 S530 Service Manual Dealer Copy -- Not for Resale SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Dealer Copy -- Not for Resale 8 of 1148 1-6 S530 Service Manual 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 9 of 1148 1-7 S530 Service Manual Dealer Copy -- Not for Resale 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 10 of 1148 1-8 S530 Service Manual 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 11 of 1148 1-9 S530 Service Manual Dealer Copy -- Not for Resale 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 12 of 1148 1-10 S530 Service Manual 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 13 of 1148 1-11 S530 Service Manual Dealer Copy -- Not for Resale 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 14 of 1148 1-12 S530 Service Manual 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. 15 of 1148 1-13 S530 Service Manual 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. 16 of 1148 1-14 S530 Service Manual 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. 17 of 1148 1-15 S530 Service Manual Dealer Copy -- Not for Resale 16 Dealer Copy -- Not for Resale 18 of 1148 1-16 S530 Service Manual 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 of 1148 10-01 10-90-1 10-90-1 10-90-1 10-90-3 10-90-4 S530 Service Manual 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 20 of 1148 10-02 S530 Service Manual Dealer Copy -- Not for Resale 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 21 of 1148 10-03 S530 Service Manual Dealer Copy -- Not for Resale 22 of 1148 10-04 S530 Service Manual 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 23 of 1148 10-10-1 S530 Service Manual 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.) 25 of 1148 10-20-1 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 S530 Service Manual 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. 27 of 1148 10-20-3 S530 Service Manual Dealer Copy -- Not for Resale 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 S530 Service Manual 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. 35 of 1148 10-40-1 S530 Service Manual Dealer Copy -- Not for Resale 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 10-50-1 S530 Service Manual Dealer Copy -- Not for Resale 38 of 1148 10-50-2 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 10-60-3 S530 Service Manual Dealer Copy -- Not for Resale 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 43 of 1148 10-60-5 S530 Service Manual 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 10-61-1 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 48 of 1148 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 10-61-5 S530 Service Manual 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 10-61-6 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. 51 of 1148 10-61-7 S530 Service Manual Dealer Copy -- Not for Resale 52 of 1148 10-61-8 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 53 of 1148 10-70-1 S530 Service Manual Dealer Copy -- Not for Resale 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 54 of 1148 10-70-2 S530 Service Manual Dealer Copy -- Not for Resale 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]. 56 of 1148 10-80-2 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 57 of 1148 10-90-1 S530 Service Manual Dealer Copy -- Not for Resale 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 10-90-2 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 10-90-5 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 10-90-6 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 10-100-3 S530 Service Manual Dealer Copy -- Not for Resale 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 10-110-2 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 10-120-1 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 10-120-3 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 10-120-4 S530 Service Manual Dealer Copy -- Not for Resale 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.) 76 of 1148 10-120-6 S530 Service Manual Dealer Copy -- Not for Resale 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. 77 of 1148 10-120-7 S530 Service Manual Dealer Copy -- Not for Resale 78 of 1148 10-120-8 S530 Service Manual 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 79 of 1148 10-130-1 S530 Service Manual Dealer Copy -- Not for Resale 1 Dealer Copy -- Not for Resale 80 of 1148 10-130-2 S530 Service Manual 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. 81 of 1148 10-140-1 S530 Service Manual Dealer Copy -- Not for Resale 82 of 1148 10-140-2 S530 Service Manual 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 83 of 1148 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 Dealer Copy -- Not for Resale 84 of 1148 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]. 85 of 1148 10-150-1 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]. 86 of 1148 10-150-2 S530 Service Manual Dealer Copy -- Not for Resale 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]. 87 of 1148 10-150-3 S530 Service Manual Dealer Copy -- Not for Resale 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]. 88 of 1148 10-150-4 S530 Service Manual 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. 89 of 1148 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 90 of 1148 10-160-2 S530 Service Manual 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. 91 of 1148 10-170-1 S530 Service Manual Dealer Copy -- Not for Resale 92 of 1148 10-170-2 S530 Service Manual 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. 93 of 1148 Dealer Copy -- Not for Resale LOADER STORAGE AND RETURN TO SERVICE Dealer Copy -- Not for Resale 94 of 1148 10-180-2 S530 Service Manual 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. 95 of 1148 10-190-1 S530 Service Manual Dealer Copy -- Not for Resale Figure 10-190-3 Dealer Copy -- Not for Resale 96 of 1148 10-190-2 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 Dealer Copy -- Not for Resale ————————————————————————————————————————————————————— 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. 98 of 1148 10-200-2 S530 Service Manual Dealer Copy -- Not for Resale 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]. 99 of 1148 10-200-3 S530 Service Manual Dealer Copy -- Not for Resale 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]. 100 of 1148 10-200-4 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. 101 of 1148 10-210-1 S530 Service Manual Dealer Copy -- Not for Resale 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 102 of 1148 10-210-2 S530 Service Manual 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 20-30-5 103 of 1148 20-01 S530 Service Manual Dealer Copy -- Not for Resale 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30 104 of 1148 20-02 S530 Service Manual Dealer Copy -- Not for Resale 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 20-120-3 105 of 1148 20-03 S530 Service Manual Dealer Copy -- Not for Resale 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 of 1148 20-04 S530 Service Manual 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). 124 of 1148 20-10-2 S530 Service Manual Dealer Copy -- Not for Resale 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. 125 of 1148 20-10-3 S530 Service Manual Dealer Copy -- Not for Resale 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). 126 of 1148 20-10-4 S530 Service Manual 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. 127 of 1148 20-10-5 S530 Service Manual Dealer Copy -- Not for Resale 128 of 1148 20-10-6 S530 Service Manual 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. 129 of 1148 20-20-1 S530 Service Manual Dealer Copy -- Not for Resale 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 130 of 1148 20-20-2 S530 Service Manual Dealer Copy -- Not for Resale 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. 131 of 1148 20-20-3 S530 Service Manual Dealer Copy -- Not for Resale 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. 132 of 1148 20-20-4 S530 Service Manual Dealer Copy -- Not for Resale 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. 133 of 1148 20-20-5 S530 Service Manual 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 134 of 1148 20-20-6 S530 Service Manual 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]. 135 of 1148 20-20-7 S530 Service Manual Dealer Copy -- Not for Resale 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]. 136 of 1148 20-20-8 S530 Service Manual 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. 137 of 1148 20-20-9 S530 Service Manual Dealer Copy -- Not for Resale 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]. 138 of 1148 20-20-10 S530 Service Manual Dealer Copy -- Not for Resale 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. 139 of 1148 20-20-11 S530 Service Manual Dealer Copy -- Not for Resale 140 of 1148 20-20-12 S530 Service Manual 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. 141 of 1148 20-21-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 142 of 1148 20-21-2 S530 Service Manual 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]. 143 of 1148 20-21-3 S530 Service Manual Dealer Copy -- Not for Resale 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 144 of 1148 20-21-4 S530 Service Manual 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. 145 of 1148 20-21-5 S530 Service Manual Dealer Copy -- Not for Resale 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]. 146 of 1148 20-21-6 S530 Service Manual 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. 147 of 1148 20-21-7 S530 Service Manual Dealer Copy -- Not for Resale 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]. 148 of 1148 20-21-8 S530 Service Manual Dealer Copy -- Not for Resale 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. 149 of 1148 20-21-9 S530 Service Manual 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. 150 of 1148 20-21-10 S530 Service Manual 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. 151 of 1148 20-22-1 S530 Service Manual Dealer Copy -- Not for Resale 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 152 of 1148 20-22-2 S530 Service Manual 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. 153 of 1148 20-22-3 S530 Service Manual 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. 154 of 1148 20-22-4 S530 Service Manual Dealer Copy -- Not for Resale • 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. 155 of 1148 20-22-5 S530 Service Manual Dealer Copy -- Not for Resale 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 156 of 1148 20-22-6 S530 Service Manual 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. 157 of 1148 20-22-7 S530 Service Manual Dealer Copy -- Not for Resale 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. 158 of 1148 20-22-8 S530 Service Manual Dealer Copy -- Not for Resale 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. 159 of 1148 20-22-9 S530 Service Manual Dealer Copy -- Not for Resale 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. 160 of 1148 20-22-10 S530 Service Manual Dealer Copy -- Not for Resale 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. 161 of 1148 20-22-11 S530 Service Manual Dealer Copy -- Not for Resale 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]. 162 of 1148 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. 163 of 1148 20-23-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 164 of 1148 20-23-2 S530 Service Manual 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]. 165 of 1148 20-23-3 S530 Service Manual Dealer Copy -- Not for Resale 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 166 of 1148 20-23-4 S530 Service Manual 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 20-23-5 S530 Service Manual 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 20-23-6 S530 Service Manual 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. 169 of 1148 20-23-7 S530 Service Manual Dealer Copy -- Not for Resale 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. 170 of 1148 20-23-8 S530 Service Manual Dealer Copy -- Not for Resale 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. 171 of 1148 20-23-9 S530 Service Manual Dealer Copy -- Not for Resale 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. 172 of 1148 20-23-10 S530 Service Manual 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). 173 of 1148 20-24-1 S530 Service Manual Dealer Copy -- Not for Resale 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. 174 of 1148 20-24-2 S530 Service Manual 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 175 of 1148 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]. 176 of 1148 20-24-4 S530 Service Manual Dealer Copy -- Not for Resale 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. 177 of 1148 20-24-5 S530 Service Manual Dealer Copy -- Not for Resale 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 S530 Service Manual 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. 179 of 1148 20-24-7 S530 Service Manual Dealer Copy -- Not for Resale 180 of 1148 20-24-8 S530 Service Manual 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. 181 of 1148 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. 183 of 1148 20-30-3 S530 Service Manual Dealer Copy -- Not for Resale 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. 184 of 1148 20-30-4 S530 Service Manual 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]. 185 of 1148 20-30-5 S530 Service Manual Dealer Copy -- Not for Resale Clean the area around the control valve. Dealer Copy -- Not for Resale 186 of 1148 20-30-6 S530 Service Manual 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. 187 of 1148 20-40-1 S530 Service Manual 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. 189 of 1148 20-40-3 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. 190 of 1148 20-40-4 S530 Service Manual Dealer Copy -- Not for Resale 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. 191 of 1148 20-40-5 S530 Service Manual 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. 194 of 1148 20-40-8 S530 Service Manual Dealer Copy -- Not for Resale 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 20-40-10 S530 Service Manual 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]. 200 of 1148 20-40-14 S530 Service Manual 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. 201 of 1148 20-40-15 S530 Service Manual Dealer Copy -- Not for Resale 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]. 202 of 1148 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. 203 of 1148 20-40-17 S530 Service Manual Dealer Copy -- Not for Resale 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. 204 of 1148 20-40-18 S530 Service Manual Dealer Copy -- Not for Resale 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]. 205 of 1148 20-40-19 S530 Service Manual Dealer Copy -- Not for Resale 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. 206 of 1148 20-40-20 S530 Service Manual Dealer Copy -- Not for Resale 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. 207 of 1148 20-40-21 S530 Service Manual Dealer Copy -- Not for Resale 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]. 208 of 1148 20-40-22 S530 Service Manual Dealer Copy -- Not for Resale 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. 209 of 1148 20-40-23 S530 Service Manual Dealer Copy -- Not for Resale 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. 210 of 1148 20-40-24 S530 Service Manual Dealer Copy -- Not for Resale 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]. 211 of 1148 20-40-25 S530 Service Manual Dealer Copy -- Not for Resale 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. 212 of 1148 20-40-26 S530 Service Manual Dealer Copy -- Not for Resale 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. 213 of 1148 20-40-27 S530 Service Manual 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. 214 of 1148 20-40-28 S530 Service Manual Dealer Copy -- Not for Resale 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. 215 of 1148 20-40-29 S530 Service Manual Dealer Copy -- Not for Resale 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. 216 of 1148 20-40-30 S530 Service Manual 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. 217 of 1148 20-40-31 S530 Service Manual Dealer Copy -- Not for Resale Remove the O-ring (Item 1) [Figure 20-40-106]. Dealer Copy -- Not for Resale 218 of 1148 20-40-32 S530 Service Manual 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 219 of 1148 20-41-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 220 of 1148 20-41-2 S530 Service Manual Dealer Copy -- Not for Resale 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. 221 of 1148 20-41-3 S530 Service Manual 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. 223 of 1148 20-41-5 S530 Service Manual 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.) 224 of 1148 20-41-6 S530 Service Manual 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. 225 of 1148 20-41-7 S530 Service Manual 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]. 226 of 1148 20-41-8 S530 Service Manual 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]. 227 of 1148 20-41-9 S530 Service Manual 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]. 228 of 1148 20-41-10 S530 Service Manual 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. 230 of 1148 20-41-12 S530 Service Manual 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. 231 of 1148 20-41-13 S530 Service Manual Dealer Copy -- Not for Resale 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. 233 of 1148 20-41-15 S530 Service Manual Dealer Copy -- Not for Resale 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. 234 of 1148 20-41-16 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 20-41-17 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 20-41-18 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 20-41-19 S530 Service Manual Dealer Copy -- Not for Resale 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 20-41-20 S530 Service Manual 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 20-41-22 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 S530 Service Manual 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. 242 of 1148 20-41-24 S530 Service Manual Dealer Copy -- Not for Resale 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]. 243 of 1148 20-41-25 S530 Service Manual Dealer Copy -- Not for Resale 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 20-41-27 S530 Service Manual Dealer Copy -- Not for Resale 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]. 246 of 1148 20-41-28 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. 247 of 1148 20-41-29 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. 248 of 1148 20-41-30 S530 Service Manual 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. 249 of 1148 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. 250 of 1148 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. 251 of 1148 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 252 of 1148 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. 253 of 1148 20-60-1 S530 Service Manual 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. 254 of 1148 20-60-2 S530 Service Manual Dealer Copy -- Not for Resale 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.) 257 of 1148 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.) 258 of 1148 20-60-6 S530 Service Manual 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.) 259 of 1148 20-60-7 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.) 260 of 1148 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. 261 of 1148 20-60-9 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]. 262 of 1148 20-60-10 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 263 of 1148 20-60-11 S530 Service Manual 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. 264 of 1148 20-60-12 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 265 of 1148 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]. 267 of 1148 20-80-1 S530 Service Manual 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. 268 of 1148 20-80-2 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.) 269 of 1148 20-90-1 S530 Service Manual Dealer Copy -- Not for Resale 270 of 1148 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]. 272 of 1148 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. 273 of 1148 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. 274 of 1148 20-100-4 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. 275 of 1148 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 276 of 1148 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. 277 of 1148 20-110-1 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. 279 of 1148 20-110-3 S530 Service Manual Dealer Copy -- Not for Resale 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]. 280 of 1148 20-110-4 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]. 281 of 1148 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. 282 of 1148 20-110-6 S530 Service Manual Dealer Copy -- Not for Resale 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. 283 of 1148 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. 284 of 1148 20-110-8 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. 286 of 1148 20-120-2 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. 287 of 1148 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. 289 of 1148 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]. 292 of 1148 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). 296 of 1148 20-121-2 S530 Service Manual 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. 297 of 1148 20-121-3 S530 Service Manual 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 298 of 1148 20-121-4 S530 Service Manual 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. 299 of 1148 20-121-5 S530 Service Manual 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. 300 of 1148 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. 301 of 1148 20-121-7 S530 Service Manual Dealer Copy -- Not for Resale 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. 302 of 1148 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. 303 of 1148 20-121-9 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 20-121-10 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. 305 of 1148 20-130-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 306 of 1148 20-130-2 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. 307 of 1148 20-130-3 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. 308 of 1148 20-130-4 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. 309 of 1148 20-130-5 S530 Service Manual Dealer Copy -- Not for Resale 310 of 1148 20-130-6 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. 311 of 1148 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 20-140-4 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. 315 of 1148 20-140-5 S530 Service Manual Dealer Copy -- Not for Resale 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. 316 of 1148 20-140-6 S530 Service Manual 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. 317 of 1148 20-140-7 S530 Service Manual Dealer Copy -- Not for Resale 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. 318 of 1148 20-140-8 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 30-40-6 319 of 1148 30-01 S530 Service Manual Dealer Copy -- Not for Resale 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 320 of 1148 30-02 S530 Service Manual Dealer Copy -- Not for Resale 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. 321 of 1148 30-10-1 S530 Service Manual 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. 322 of 1148 30-10-2 S530 Service Manual Dealer Copy -- Not for Resale 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.) 323 of 1148 30-20-1 S530 Service Manual 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. 324 of 1148 30-20-2 S530 Service Manual 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. 325 of 1148 30-20-3 S530 Service Manual 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 326 of 1148 30-20-4 S530 Service Manual 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. 327 of 1148 30-20-5 S530 Service Manual Dealer Copy -- Not for Resale 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. 328 of 1148 30-20-6 S530 Service Manual 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]. 330 of 1148 30-20-8 S530 Service Manual 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. 331 of 1148 30-21-1 S530 Service Manual 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. 392 of 1148 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. 393 of 1148 30-40-5 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. 394 of 1148 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. 395 of 1148 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.) 397 of 1148 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). 398 of 1148 30-50-4 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 400 of 1148 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. 404 of 1148 30-50-10 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. 405 of 1148 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 30-50-20 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 30-51-3 S530 Service Manual Dealer Copy -- Not for Resale 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.) 419 of 1148 30-51-5 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 30-51-6 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 30-51-9 S530 Service Manual Dealer Copy -- Not for Resale 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 441 of 1148 30-51-27 S530 Service Manual 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. 443 of 1148 30-60-1 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 445 of 1148 30-60-3 S530 Service Manual Dealer Copy -- Not for Resale 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]. 446 of 1148 30-60-4 S530 Service Manual 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]. 447 of 1148 30-60-5 S530 Service Manual 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. 448 of 1148 30-60-6 S530 Service Manual 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. 449 of 1148 30-70-1 S530 Service Manual Dealer Copy -- Not for Resale • 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]. 450 of 1148 30-70-2 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]. 451 of 1148 30-80-1 S530 Service Manual Dealer Copy -- Not for Resale 452 of 1148 30-80-2 S530 Service Manual 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 of 1148 40-01 S530 Service Manual Dealer Copy -- Not for Resale 454 of 1148 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. 455 of 1148 40-10-1 S530 Service Manual Dealer Copy -- Not for Resale 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 456 of 1148 40-10-2 S530 Service Manual Dealer Copy -- Not for Resale 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 40-20-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 459 of 1148 40-20-3 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.) 460 of 1148 40-20-4 S530 Service Manual Dealer Copy -- Not for Resale 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]. 461 of 1148 40-20-5 S530 Service Manual Dealer Copy -- Not for Resale 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]. 462 of 1148 40-20-6 S530 Service Manual 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]. 463 of 1148 40-20-7 S530 Service Manual Dealer Copy -- Not for Resale 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 40-20-8 S530 Service Manual 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 40-20-9 S530 Service Manual 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 40-20-10 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 50-01 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 50-150-3 473 of 1148 50-03 S530 Service Manual 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1 474 of 1148 50-04 S530 Service Manual 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). 475 of 1148 50-10-1 S530 Service Manual Dealer Copy -- Not for Resale 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. 476 of 1148 50-10-2 S530 Service Manual 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. 477 of 1148 50-10-3 S530 Service Manual Dealer Copy -- Not for Resale 478 of 1148 50-10-4 S530 Service Manual 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). 479 of 1148 50-20-1 S530 Service Manual Dealer Copy -- Not for Resale 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. 480 of 1148 50-20-2 S530 Service Manual 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 S530 Service Manual Dealer Copy -- Not for Resale 482 of 1148 50-20-4 S530 Service Manual 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. 483 of 1148 50-30-1 S530 Service Manual Dealer Copy -- Not for Resale 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. 484 of 1148 50-30-2 S530 Service Manual Dealer Copy -- Not for Resale 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. 485 of 1148 50-31-1 S530 Service Manual Dealer Copy -- Not for Resale 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. 486 of 1148 50-31-2 S530 Service Manual 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. 487 of 1148 50-31-3 S530 Service Manual 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 50-31-4 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]. 489 of 1148 50-31-5 S530 Service Manual Dealer Copy -- Not for Resale 490 of 1148 50-31-6 S530 Service Manual 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]. 491 of 1148 50-40-1 Dealer Copy -- Not for Resale 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. 492 of 1148 50-40-2 S530 Service Manual 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]. 493 of 1148 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. 494 of 1148 50-40-4 S530 Service Manual Dealer Copy -- Not for Resale 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. 495 of 1148 50-40-5 S530 Service Manual Dealer Copy -- Not for Resale 496 of 1148 50-40-6 S530 Service Manual 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. 497 of 1148 50-41-1 S530 Service Manual Dealer Copy -- Not for Resale 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]. 498 of 1148 50-41-2 S530 Service Manual 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. 499 of 1148 50-41-3 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]. 500 of 1148 50-41-4 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 50-41-5 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 50-41-6 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 50-50-1 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. 504 of 1148 50-50-2 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 50-50-3 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 50-50-4 S530 Service Manual Dealer Copy -- Not for Resale 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. 507 of 1148 50-50-5 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. 508 of 1148 50-50-6 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 50-60-2 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 50-70-1 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 50-70-2 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 50-70-3 S530 Service Manual 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 50-70-4 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 50-80-1 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 50-80-2 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 50-80-3 S530 Service Manual Dealer Copy -- Not for Resale 518 of 1148 50-80-4 S530 Service Manual 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 50-90-1 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 50-90-2 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 50-90-3 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 50-90-4 S530 Service Manual 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 50-91-1 S530 Service Manual 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 50-91-2 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 50-91-3 S530 Service Manual Dealer Copy -- Not for Resale 526 of 1148 50-91-4 S530 Service Manual 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 50-100-1 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 50-100-9 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 50-100-10 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 50-160-1 S530 Service Manual 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 S530 Service Manual 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 50-170-1 S530 Service Manual 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. 585 of 1148 50-170-3 S530 Service Manual 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). 587 of 1148 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 50-190-1 S530 Service Manual 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 50-190-2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13 591 of 1148 60-01 S530 Service Manual Dealer Copy -- Not for Resale 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 60-02 60-100-1 60-100-1 60-100-2 S530 Service Manual Dealer Copy -- Not for Resale 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 597 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 598 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 599 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 600 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 601 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 602 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 603 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 604 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 605 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 606 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 607 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 608 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 609 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 610 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 611 of 1148 Dealer Copy -- Not for Resale Printable Version Click Here 612 of 1148 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 Printed In U.S.A. 704 of 1148 (PRINTED NOVEMBER 2016) 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) Printable Version Click Here 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) 7253420 (0) Printed In U.S.A. 706 of 1148 # 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) Printable Version Click Here Sheet 17 of 18 Printed In U.S.A. 709 of 1148 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
