Service Manual: Skid-Steer Loader [PDF]

Zitiervorschau

Dealer Copy -- Not for Resale

Service Manual

Skid-Steer Loader S/N A3NV11001 & Above S/N A3NW11001 & Above S/N 1MLS11001 & Above

6987168enUS (09-20) (T)

1 of 1311

Printed in U.S.A.

©2020 Bobcat Company. All rights reserved. NA iT4 EU S3A

2 of 1311

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.

P-90216

Never service the Bobcat SkidSteer Loader without instructions.

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.

WRONG

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.

CORRECT

CORRECT

NA1694

Use the correct procedure to lift or lower operator cab.

NA1693

Cleaning and maintenance are required daily.

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. Replace it if damaged.

NA1680

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

NA1683

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. MSW39-0820

3 of 1311

Dealer Copy -- Not for Resale

CORRECT

4 of 1311

Dealer Copy -- Not for Resale

CONTENTS SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

5 of 1311

1-3

S650 Service Manual

Dealer Copy -- Not for Resale

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

Dealer Copy -- Not for Resale 6 of 1311

1-4

S650 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 1311

1-5

S650 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 1311

1-6

S650 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. SYSTEM A general inspection of the following items must be made after the loader has had service or repair: 9. The parking brake function correctly.

2. Check that ROPS mounting hardware is tightened and is Bobcat approved.

10. Enclosure door latches must DRIVE 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.

5. Check lift arm support, 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

must

machine

oil

HVAC

fluid

or

FW SSL-0820 SM

9 of 1311

1-7

S650 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-0820 SM

10 of 1311

1-8

S650 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 1311

1-9

S650 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 1311

1-10

S650 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 1311

1-11

S650 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 1311

1-12

S650 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 it may be necessary to use a different procedure in doing a specific service operation.

Figure 3

Loader Serial Number Figure 1 1

P-90466

1

Dealer Copy -- Not for Resale

The engine serial number is located on the side of the engine (Item 1) [Figure 3] behind the alternator.

P109923C

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 P-90175 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 which the loader is produced.

15 of 1311

1-13

S650 Service Manual

DELIVERY REPORT Figure 4

B-16315

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 1311

1-14

S650 Service Manual

LOADER IDENTIFICATION OPERATION & MAINTENANCE MANUAL AND OPERATOR’S HANDBOOK

FRONT LIGHTS

GRAB HANDLES OPERATOR SEAT with SEAT BELT AND SEAT BAR TILT CYLINDERS

FRONT AUXILIARY QUICK COUPLERS

BUCKET STEPS LIFT CYLINDER

Dealer Copy -- Not for Resale

[1] BUCKET STEP

[2] OPERATOR CAB (ROPS AND FOPS)

LIFT ARM SUPPORT DEVICE

REAR GRILLE LIFT ARM BACK-UP ALARM

REAR LIGHT REAR DOOR

TAILLIGHT

[3] TIRES

NA1667 NA1668

[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader. [2] ROPS - Roll-Over Protective Structure per ISO 3471 and FOPS - Falling-Object Protective Structure per ISO 3449, Level I. Level II is available. [3] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.

17 of 1311

1-15

S650 Service Manual

Dealer Copy -- Not for Resale 18 of 1311

1-16

S650 Service Manual

SAFETY & MAINTENANCE LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2 10-30-1 10-30-1 10-30-2 10-30-3 10-30-4 10-30-5 10-30-5 10-30-6 10-30-6

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 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 of 1311

10-01

10-90-1 10-90-1 10-90-1 10-90-2 10-90-4 10-90-6 10-90-6

S650 Service Manual

Dealer Copy -- Not for Resale

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Application Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . .

10-100-1 10-100-1 10-100-1 10-100-2 10-100-3 10-100-3

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2 Hydraulic / Hydrostatic Filter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4 Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) . . . 10-120-5 Removing And Replacing Hydraulic / Hydrostatic Filter (Square Head Filter Cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6 Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) . . . . . 10-120-7 Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-8 Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-10 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2 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

SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

20 of 1311

10-02

S650 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-210-1 10-210-1 10-210-1 10-210-1 10-210-2 10-210-2 10-210-2

Dealer Copy -- Not for Resale

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

21 of 1311

10-03

S650 Service Manual

Dealer Copy -- Not for Resale 22 of 1311

10-04

S650 Service Manual

LIFTING AND BLOCKING THE LOADER

Figure 10-10-2

Procedure Figure 10-10-1

P-85985

NOTE: Make sure the jack stands do not touch the tires. Make sure tires clear floor or any obstacles.

WARNING

Figure 10-10-3 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

Always park the loader on a level surface. P-90556 P-85425

WARNING

Lift the rear of the loader and install jack stands [Figure 10-10-3].

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

23 of 1311

10-10-1

S650 Service Manual

Dealer Copy -- Not for Resale

Lift the front of the loader and put jack stands under the axle tubes [Figure 10-10-2].

B-7023A

Dealer Copy -- Not for Resale 24 of 1311

10-10-2

S650 Service Manual

LIFT ARM SUPPORT DEVICE

Figure 10-20-1

Installing

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. 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

P-85463A

P100009

Put jack stands under the rear corners of the loader frame (Inset) [Figure 10-20-1].

DANGER

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. Figure 10-20-2

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

Remove attachment from the loader. P-90567

Have a second person install the lift arm support device over the rod of one of the lift cylinders [Figure 10-20-2]. The lift arm support device must be tight against the cylinder rod.

25 of 1311

10-20-1

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the lift arm support device (Item 1) [Figure 1020-1] from the storage position.

LIFT ARM SUPPORT DEVICE (CONT’D)

Removing

Installing (Cont’d)

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.

Figure 10-20-3

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.

P100005A

Have a second person remove the lift arm support device after the lift arms are all the way up. Lower the lift arms all the way and stop the engine. P100005

26 of 1311

Remove the jackstands.

10-20-2

Dealer Copy -- Not for Resale

Lower the lift arms slowly until the lift arm support device is held between the lift arms and the lift cylinder [Figure 10-20-3]. The tabs of the lift arm support device must go past the end of the cylinder (Inset) [Figure 10-20-3].

Return the lift arm support device to the storage position and secure with clamping knobs.

S650 Service Manual

OPERATOR CAB Description The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. The seat belt must be worn for rollover protection. Inspect the cab, mounting and hardware for damage. Never modify the cab. Replace the cab and hardware if damaged. ROPS - Roll Over Protective Structure per ISO 3471, and FOPS - Falling Object Protective Structure per ISO 3449, Level I. Level II is available. Level I

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. Level II Protection from falling trees, rocks: for machines involved in site clearing, overhead demolition or forestry.

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

27 of 1311

10-30-1

S650 Service Manual

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 10-30-1

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

P-85463A

Install jack stands under the rear of the loader frame [Figure 10-30-1]. Figure 10-30-2

Hardware Installed

P-90564A

Hardware Removed

Lift on the grab handles and bottom of the operator cab [Figure 10-30-3] slowly until the operator cab is all the way up and the latching mechanism engages.

P-90512A

P-90511A

Remove the nuts and washers [Figure 10-30-2] (both sides) at the front corners of the operator cab.

28 of 1311

10-30-2

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 10-30-3

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 10-30-4]. 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 10-30-4 PINCH POINT CAN CAUSE INJURY Remove your hand from the latching mechanism when the cab is past the latch stop. W-2469-0803

Figure 10-30-5

N-20120

Hardware Installed

P-90565A

Pull down on the bottom of the operator cab until it stops at the latching mechanism [Figure 10-30-4]. NOTE: The weight of the operator cab increases when equipped with options and accessories such as cab door, heater, air conditioning, etc. In these cases, the operator cab may need to be raised slightly from the latch to be able to release the latch.

P-90511A

P-90512A

Install the washers and nuts (both sides) [Figure 10-305]. Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.

WARNING

Remove the jackstands.

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

29 of 1311

10-30-3

S650 Service Manual

Dealer Copy -- Not for Resale

Hardware Removed

OPERATOR CAB (CONT’D)

Figure 10-30-8

Cab Door Sensor This machine may be equipped with a Cab Door Sensor. Figure 10-30-6

P-76461Q

The LIFT AND TILT VALVE light (Item 1) [Figure 10-307] will be ON when the door is open, the key switch is turned to RUN or the RUN button is pressed, the seat bar is lowered and the PRESS TO OPERATE LOADER button is pressed.

1

[DOOR] will appear in the data display [Figure 10-30-8].

Dealer Copy -- Not for Resale

P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6] installed which deactivates the lift and tilt valves when the door is open. Figure 10-30-7

1

P-90726L

The LIFT AND TILT VALVE light (Item 1) [Figure 10-307] will be OFF when the door is closed, the key switch is turned to RUN or the RUN button is pressed, the seat bar is lowered and the PRESS TO OPERATE LOADER button is pressed.

30 of 1311

10-30-4

S650 Service Manual

OPERATOR CAB (CONT'D)

Special Applications Kit Inspection And Maintenance

Special Application 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.

10-30-5

S650 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 and Top Guard (if applicable) to provide added operator protection in these applications. W-2737-0917

Dealer Copy -- Not for Resale

Figure 10-30-9

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 10-30-9]. Polycarbonate top window (standard item) must be installed for special applications to restrict material from entering cab openings.

31 of 1311

OPERATOR CAB (CONT’D)

Forestry Door And Window Kit Inspection And Maintenance

Forestry Door And Window Kit • •

Figure 10-30-10

• • • • • •

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 10-30-11

Must be used as part of the Forestry Applications Kit to prevent flying debris and objects from entering the loader. Kit includes 19,1 mm (0.75 in) thick laminated polycarbonate front door, polycarbonate side windows and polycarbonate rear window [Figure 10-30-10].

1

Polycarbonate top window (standard item) must be installed as part of the Forestry Applications Kit to restrict material from entering cab openings. P-100984

•

32 of 1311

•

Inspect both emergency exit levers (Item 1) [Figure 10-30-11], linkages and hardware for loose or damaged parts. Repair or replace if necessary.

10-30-6

S650 Service Manual

Dealer Copy -- Not for Resale

NA1819

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.

P107253

P-85615A

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.)

P-90561A

Alternate Rear Tie-Down

Alternate Front Tie-Down

P-85717A

P-85466 P-85599A

1 P-90560A

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 clarity.) (Some models have two front tie-down locations on the transmission.) 5. Fasten each end of the chain to the transport vehicle. 6. Use chain binders to tighten the chains.

33 of 1311

10-40-1

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 10-40-1

Dealer Copy -- Not for Resale 34 of 1311

10-40-2

S650 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.)

35 of 1311

10-50-1

S650 Service Manual

Dealer Copy -- Not for Resale 36 of 1311

10-50-2

S650 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.

37 of 1311

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

S650 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

2 2 1 1

P-85728

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.

38 of 1311

10-60-2

S650 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 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.

39 of 1311

10-60-3

S650 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 1

P-85728

Figure 10-60-11 P-85729

1

2 1 P-85726

Connect the Remote Start Tool to the engine harness connector (Item 1) [Figure 10-60-10].

P-85728

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).

40 of 1311

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

S650 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 10-60-13] is used to turn traction lock ON or OFF. Push the switch to the override position. The switch will illuminate to indicate traction lock OVERRIDE, in this position the wheels are able to turn. 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

41 of 1311

10-60-5

S650 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

P-85311

42 of 1311

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].

S650 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.

43 of 1311

10-61-1

S650 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.

44 of 1311

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

S650 Service Manual

Dealer Copy -- Not for Resale

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-2] has five buttons.

REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT'D)

Figure 10-61-5 2

Loader Service Tool Harness - 6689747 Figure 10-61-3

1 1

P-85725

2

P-76678

The Loader Service Tool Harness (Item 1) [Figure 1061-3] is used to connect the Remote Start Tool (Service Tool) (Item 2) [Figure 10-61-3] 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).

45 of 1311

10-61-3

S650 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 2

1 1

3

2 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 (Item 1) [Figure 1061-7] is required to connect Remote Start Tool (Service Tool) to the Service PC (Item 2) [Figure 10-61-7].

Dealer Copy -- Not for Resale

P-85726

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

46 of 1311

10-61-4

S650 Service Manual

Raise the operator cab (if required by the procedure).

REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT'D)

Open the rear door of the loader. Remote Start Procedure Figure 10-61-9

WARNING 1 UNAUTHORIZED AND UNEXPECTED ENGINE START-UP CAN CAUSE SERIOUS INJURY OR DEATH

W-2457-1110

The tool listed will be needed to do the following procedure: 7217666: Remote Start Tool (Service Tool) Kit Figure 10-61-8

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). 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 2

1

1

P-76450 P-85725

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.

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].

Lift and block the loader. Raise the lift arms (if required by the procedure) and install an approved lift arm support device.

47 of 1311

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.

10-61-5

S650 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.

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

2 1

1 3 P-76439

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

48 of 1311

10-61-6

S650 Service Manual

Dealer Copy -- Not for Resale

P-85726

REMOTE START TOOL (SERVICE TOOL) KIT 7217666 (CONT'D)

Figure 10-61-14

Remote Start Procedure (Cont'd) Figure 10-61-13

1

2 P-85311

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.

49 of 1311

10-61-7

S650 Service Manual

Dealer Copy -- Not for Resale 50 of 1311

10-61-8

S650 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 radiator, hydraulic fluid cooler, air conditioning condenser (if equipped), and rear grille. Check coolant level COLD and add premixed coolant as needed. Fuel Filter - Remove the trapped water. Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges - Lubricate with multipurpose lithium based grease. Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks - Check the condition of seat belt. Clean or replace seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris from moving parts. Bobcat Interlock Control Systems (BICS™) - Check for correct function. Lift and Tilt functions MUST NOT operate with seat bar raised. Front Horn / Back-up Alarm - Check for proper function. Tires - Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the tire. Operator Cab - Check the fastening bolts, washers, and nuts. Check the condition of the cab. Indicators and Lights - Check for correct operation of all indicators and lights. Wheel Nuts - Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts and tighten to correct torque. Safety Signs and Safety Treads - Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn. Hydraulic Fluid - Check fluid level and add as needed. Heater and Air Conditioning Filters (if equipped) - Clean or replace filters as needed. SS SSL LF EXLF T3 MF EXMF iT4-0118

51 of 1311

10-70-1

S650 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 • • •

Spark Arrester - Empty spark chamber. Battery - Check cables and connections. Engine Oil and Filter - Perform every 100 hours when operating under severe conditions. Replace oil and filter.

• • • • •

Fuel Filter - Replace filter. Engine / Hydrostatic Drive Belt - Check for wear or damage. Adjust or replace as needed. Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed. Bobcat Interlock Control System (BICS™) - Check the function of the lift arm bypass control. Engine Oil and Filter - Replace oil and filter.

Every 500 Hours or Every 12 Months • •

Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap - Replace the charge filter and the reservoir breather cap. Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator. Clean the plenum drains.

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 24 Months •

Coolant - Replace the coolant. SS SSL LF EXLF T3 MF EXMF iT4-0118

52 of 1311

10-70-2

S650 Service Manual

Dealer Copy -- Not for Resale

Every 250 Hours or Every 12 Months

AIR CLEANER SERVICE

Outer Filter

Replacing Filter Elements

Figure 10-80-2

Figure 10-80-1 2

1

3

2

1

NA3271 P100072

Open the latches (Item 1) and remove the dust cover (Item 2) [Figure 10-80-2]. Figure 10-80-3

Dealer Copy -- Not for Resale

It is important to change the air filter element only when necessary. The service indicator (Item 1) will FLASH. Press the information button (Item 3) until the display screen (Item 2) 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 change is necessary. Replace the inner filter every third time the outer filter is replaced or as indicated.

1

P-90523A

Pull the outer filter element (Item 1) [Figure 10-80-3] out and discard. NOTE: Make sure all sealing surfaces are free of dirt and debris. Do not use compressed air. Install the new outer filter element. Push all the way in until it contacts the base of the housing. Install the dust cover and secure the latches [Figure 1080-2].

53 of 1311

10-80-1

S650 Service Manual

AIR CLEANER SERVICE (CONT’D)

Figure 10-80-5

Replacing Filter Elements (Cont’d) Inner Filter Only replace the inner filter element under the following conditions: •

Replace the inner filter element every third time the outer filter is replaced.

•

After the outer element has been replaced, start the engine and run at full rpm. If service code [M0117] (Air Filter Plugged) is still displayed in the data display, replace the inner filter element.

Remove the dust cover [Figure 10-80-2] and the outer filter element [Figure 10-80-3].

1

2

P100072

Install the dust cover (Item 2) and secure the latches (Item 1) [Figure 10-80-5].

Dealer Copy -- Not for Resale

Figure 10-80-4

1

P-90524A

Remove the inner filter element (Item 1) [Figure 10-804]. NOTE: Make sure all sealing surfaces are free of dirt and debris. Do not use compressed air. Install new inner filter element. Push all the way in until it contacts the base of the housing. Install the outer filter element [Figure 10-80-3].

54 of 1311

10-80-2

S650 Service Manual

ENGINE COOLING SYSTEM

Cooling System Identification

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

NOTE: Identification of the cooling system used on your machine is necessary to perform the correct cleaning procedure.

Maintenance Platform Figure 10-90-2 Figure 10-90-1 Earlier Model

Later Model

1 P109009B

P109569A

Dealer Copy -- Not for Resale

Earlier models have a square coolant tank. Later models have a rectangular coolant tank [Figure 10-90-2].

P100040A

A maintenance platform (Item 1) [Figure 10-90-1] is available to facilitate access when cleaning the engine cooling system.

WARNING 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

55 of 1311

10-90-1

S650 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Figure 10-90-4

Cleaning (Earlier Models) 1

Open the rear door. (See REAR DOOR (TAILGATE) on Page 50-70-1.) Remove the rear grille. (See REAR GRILLE on Page 5060-1.) Loaders With Air Conditioning

2

Figure 10-90-3

1

NOTE: Be careful when raising and lowering the air conditioning condenser so that the air conditioning condenser does not fall on the oil cooler and damage the fins.

2 3

Raise the air conditioning condenser (Item 1) and use low air pressure or water pressure to clean the top of the oil cooler (Item 2) [Figure 10-90-4]. Lower the air conditioning condenser (Item 1) [Figure 1090-4]. Install the brackets (Item 3) [Figure 10-90-3] and the bolts (Item 2) [Figure 10-90-3].

P107097

Use low air pressure or water pressure to clean the top of the air conditioning condenser (Item 1) [Figure 10-90-3]. The area between the air conditioning condenser and the oil cooler will require occasional cleaning. Remove the bolts (Item 2) and the brackets (Item 3) [Figure 10-90-3].

56 of 1311

10-90-2

S650 Service Manual

Dealer Copy -- Not for Resale

2

P107097A

ENGINE COOLING SYSTEM (CONT’D)

All Loaders

Cleaning (Earlier Models) (Cont’d)

Unhook the two rubber straps (Item 2) [Figure 10-90-5].

Loaders Without Air Conditioning

Figure 10-90-6

Figure 10-90-5

1

1

2 3

2 P100181

Use low air pressure or water pressure to clean the top of the oil cooler (Item 1) [Figure 10-90-5].

Raise the oil cooler (Item 1) until the bar (Item 2) drops into position to support the oil cooler. Use low air pressure or water pressure to clean the top of the radiator (Item 3) [Figure 10-90-6]. Raise the bar (Item 2) [Figure 10-90-6] slightly and lower the oil cooler. Fasten the two rubber straps. Check the cooling system for leaks. Install the rear grille and close the rear door.

57 of 1311

10-90-3

S650 Service Manual

Dealer Copy -- Not for Resale

P100179

ENGINE COOLING SYSTEM (CONT’D)

Figure 10-90-8

Cleaning (Later Models) 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.)

2 3

WARNING

W-2019-0907

Loaders With Air Conditioning

P109572

Pivot the air conditioning condenser (Item 1) up and rotate the support bar (Item 2) into position. Use low air pressure or water pressure to clean the top of the hydraulic fluid cooler and radiator assembly (Item 3) [Figure 10-90-8]. Return the support bar to storage position and lower the air conditioning condenser.

Figure 10-90-7 Figure 10-90-9 1 1

2

2 P121162

Ensure the air conditioning condenser is installed into the two slotted brackets [Figure 10-90-9]. (Left side shown.)

P109573

Use low air pressure or water pressure to clean the top of the air conditioning condenser (Item 1) [Figure 10-90-7].

Ensure the clips (Item 1) are properly installed over the two slotted brackets (Item 2) [Figure 10-90-9]. (Left side shown.)

Unhook the two rubber straps (Item 2) [Figure 10-90-7]. Fasten the two rubber straps (Item 2) [Figure 10-90-7]. NOTE: The air conditioning condenser fits into two slotted brackets mounted on the hydraulic fluid cooler and radiator assembly. Ensure the air conditioning condenser remains connected to the brackets when raising and lowering.

58 of 1311

NOTE: The air conditioning condenser can be lifted out of the two slotted brackets by removing the clips. This allows greater access to clean the hydraulic fluid cooler and radiator assembly.

10-90-4

S650 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.

ENGINE COOLING SYSTEM (CONT’D)

All Loaders

Cleaning (Later Models) (Cont’d)

Check the cooling system for leaks.

Loaders Without Air Conditioning

Install the rear grille and close the rear door.

Figure 10-90-10

1

Dealer Copy -- Not for Resale

P109717

Use low air pressure or water pressure to clean the top of the hydraulic fluid cooler and radiator assembly (Item 1) [Figure 10-90-10].

59 of 1311

10-90-5

S650 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Removing And Replacing Coolant

Checking Level

For the service interval for replacing the engine coolant (See SERVICE SCHEDULE on Page 10-70-1.)

Open the rear door and raise the rear grille. Open the rear door and remove the rear grille. Figure 10-90-11 Remove the coolant fill cap (Item 1) [Figure 10-90-11]. Earlier Model

Later Model Figure 10-90-12 1

1 1

2

P109009B

P109570A

Check coolant level using the level markers (Item 2) [Figure 10-90-11] on the tank. Coolant must be between top and bottom level markers when the engine is cold. 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.

P-85606

Disconnect the coolant hose (Item 1) [Figure 10-90-12] from the oil filter assembly. Drain the coolant into a container. Connect the coolant hose to the oil filter assembly. Recycle or dispose of coolant in an environmentally safe manner. Mix new coolant in a separate container. (See Capacities on Page SPEC-10-5.)

Lower the rear grille and close the rear door.

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.

IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Add premixed coolant, 47% water and 53% propylene glycol to the coolant tank until the coolant level reaches the lower marker on the tank [Figure 10-90-11].

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

Install the coolant fill cap.

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

NOTE: When installing the coolant fill cap, the cap must be tightened until it clicks. Run the engine until it is at operating temperature. Stop the engine. Check the coolant level when cool. Add coolant as needed. Install the rear grille and close the rear door.

I-2124-0497

60 of 1311

10-90-6

S650 Service Manual

Dealer Copy -- Not for Resale

2

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. At a minimum, low sulfur diesel fuel must be used in this machine. Low sulfur is defined as 500 mg/kg (500 ppm) sulfur maximum.

•

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 which can cause corrosion and plugging of fuel system components.

•

Use of biodiesel blend fuel may result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

•

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 five percent 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. Ultra low sulfur diesel fuel may also be used in this machine. Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur maximum. The following is one suggested blending guideline that should prevent fuel gelling during cold temperatures: TEMPERATURE

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%

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.

Use only clean, high quality diesel fuel that meets the specifications listed below:

•

Do not exceed engine oil change interval. Extended oil change intervals can cause engine damage.

•

Low sulfur diesel fuel defined as 500 mg/kg (500 ppm) sulfur maximum

•

•

Diesel fuel with cetane number of 51.0 and above.

Before vehicle storage; drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel may also be used in this machine. Biodiesel blend fuel must contain no more than five percent 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)

Clean, high quality diesel fuel that meets the EN590 specification may also be used.

NOTE: Biodiesel blend fuel does not have long term stability and should not be stored for more than three months.

NOTE: Biodiesel blend fuel may also be used in this machine. Biodiesel blend fuel must contain no more than seven percent 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.

61 of 1311

10-100-1

S650 Service Manual

Dealer Copy -- Not for Resale

FUEL SYSTEM

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

Open the rear door.

NA1684

Figure 10-100-1

1

Install and tighten the fuel cap (Item 1) [Figure 10-1001]. Close the rear door.

WARNING P100006

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

62 of 1311

10-100-2

S650 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)

Removing Air From The Fuel System

Fuel Filter

After replacing the filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

For the service interval for removing water from, or replacing the fuel filter (See SERVICE SCHEDULE on Page 10-70-1.)

WARNING

Removing Water Figure 10-100-3

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. W-2072-0807

2

1 P-85508

Loosen the drain (Item 1) [Figure 10-100-3] at the bottom of the filter element to remove water from the filter.

1

2

Replacing Element Remove the filter element (Item 2) [Figure 10-100-3]. Clean the area around the filter housing. Put clean oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove air from the fuel system. (See on Page 10-1003.)

P-85507

Open the vent (Item 2) [Figure 10-100-4] on the fuel filter housing. Squeeze the hand pump (priming bulb) (Item 1) [Figure 10-100-4] until fuel flows from the vent with no air bubbles.

WARNING

Close the vent (Item 2) [Figure 10-100-4].

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

63 of 1311

10-100-3

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 10-100-4

Dealer Copy -- Not for Resale 64 of 1311

10-100-4

S650 Service Manual

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

Figure 10-110-1

P-85506

Park the machine on level ground. 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.

Refer to temperature range anticipated before next oil change Must use API Category CI-4 or better, or ACEA E7 or better Do not use API Category FA-4 engine oil [1] Bobcat Synthetic Oil – SAE 5W-40 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 CI4 or better, or ACEA E7 or better [Figure 10-110-2].

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

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

65 of 1311

10-110-1

S650 Service Manual

Dealer Copy -- Not for Resale

1

ENGINE LUBRICATION SYSTEM (CONT’D)

Later Models

Removing And Replacing Oil And Filter

Figure 10-110-4

Follow the service interval for replacing the engine oil and filter (See SERVICE SCHEDULE on Page 10-70-1.) Run the engine until it is at operating temperature. Stop the engine. Open the rear door. Earlier Models

1

Figure 10-110-3

2

P109086B

1

Remove the cover mounting bolts (Item 1) and remove the cover (Item 2) [Figure 10-110-4]. Figure 10-110-5

2 3

P-90497A P-90499A

The oil drain hose is located behind a cover under the right rear corner of the loader (Inset) [Figure 10-110-3]. Remove two cover mounting bolts (Item 1) [Figure 10110-3]. Loosen one cover mounting bolt (Item 2) and slide the cover (Item 3) [Figure 10-110-3] to the rear of the loader.

1

2 P-109087

Remove the oil drain hose (Item 1) from the storage location and route through the opening (Item 2) [Figure 10-110-5].

66 of 1311

10-110-2

S650 Service Manual

Dealer Copy -- Not for Resale

The oil drain hose is located behind a cover under the right rear corner of the loader (Inset) [Figure 10-110-4].

ENGINE LUBRICATION SYSTEM (CONT’D)

Figure 10-110-7

Removing And Replacing Oil And Filter (Cont’d) Figure 10-110-6 2

3

1

P-85506

1

Open the rear door, remove the oil filter (Item 3) [Figure 10-110-7] and clean the filter housing surface.

P-90498A

Put oil on the new filter gasket, install the filter and hand tighten. Remove the oil fill cap (Item 1) [Figure 10-110-7].

Install and tighten the oil drain cap [Figure 10-110-6]. (Earlier Models) - Install the cover and the cover mounting bolts [Figure 10-110-3]. Tighten all bolts.

Put oil in the engine. For the correct quantity (See Capacities on Page SPEC-10-5.) Do not overfill. Start the engine and let it run for several minutes. Stop the engine and check for leaks at the filter.

OR (Later Models) - Remove the oil drain hose from the opening and return to storage location [Figure 10-1105]. Install the cover and the cover mounting bolts [Figure 10-110-4]. Tighten all bolts.

Remove the dipstick (Item 2) [Figure 10-110-7] and check the oil level. Add oil as needed if it is not at the top mark on the dipstick. Install the dipstick 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. W-2103-0508

67 of 1311

10-110-3

S650 Service Manual

Dealer Copy -- Not for Resale

Use genuine Bobcat filter only. Remove the oil drain cap (Item 1) [Figure 10-110-6] from the oil drain hose and drain the oil into a container. Recycle or dispose of used oil in an environmentally safe manner.

Dealer Copy -- Not for Resale 68 of 1311

10-110-4

S650 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM

Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid

HYDRAULIC / HYDROSTATIC FLUID RECOMMENDED ISO VISCOSITY GRADE (VG) AND VISCOSITY INDEX (VI) Figure 10-120-3

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 place 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] VG 100; Minimum VI 130 [2] VG 46; Minimum VI 150 [3] BOBCAT All-Season Fluid [4] BOBCAT Synthetic Fluid [5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid (Unlike biodegradable fluids that are vegetable based, Bobcat biodegradable fluid is formulated to prevent oxidation and thermal breakdown at operating temperatures.)

1

P100010

Check the fluid level in the sight gauge (Item 1) [Figure 10-120-1]. Keep the fluid level within the operating range. Stop the engine, open the rear door and remove the rear grille. (See REAR GRILLE on Page 50-60-1.)

Use only recommended fluid in the hydraulic system [Figure 10-120-3]. (See Hydraulic System on Page SPEC-10-4.)

Figure 10-120-2

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

P100055

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 (Item 1) [Figure 10-120-2], the rear grille and close the rear door.

69 of 1311

10-120-1

S650 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 For the correct service interval SCHEDULE on Page 10-70-1.)

(See

SERVICE 1

Replace the fluid if it becomes contaminated or after major repair.

2 Always replace the hydraulic / hydrostatic filter and the hydraulic charge filter whenever the hydraulic fluid is replaced. (See Hydraulic / Hydrostatic Filter Identification on Page 10-120-4.) Remove the rear grille. (See REAR GRILLE on Page 5060-1.)

P100179

(Earlier Models with Square Coolant Tank) - Raise the oil cooler (Item 1) until the bar (Item 2) [Figure 10-120-5] drops into the last position to support the oil cooler. This will aid in draining the hydraulic fluid.

Figure 10-120-4

Dealer Copy -- Not for Resale

Figure 10-120-6 1 1

P100055

P100007

Remove the right side access cover bolts (Item 1) [Figure 10-120-6] and remove the cover. (Lift arms shown raised for visual clarity.) 2 P100181

Remove the hydraulic fill cap (Item 1) [Figure 10-120-4]. (Earlier Models with Square Coolant Tank) - unhook the two rubber straps (Item 2) [Figure 10-120-4].

70 of 1311

10-120-2

S650 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Figure 10-120-8

Removing And Replacing Hydraulic Fluid (Cont’d) NOTE: The hose used to drain the hydraulic reservoir is located under the fan motor on earlier models and behind the fan motor on later models. 1

Figure 10-120-7 Earlier Model

Later Model

1 P-90506

2

2 P109760A

P115442A

Remove the clamp (Item 1). Pinch off the hose (Item 2) [Figure 10-120-7] 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. Recycle or dispose of used fluid in an environmentally safe manner.

WARNING

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. Install the rear grille. Close the rear door. Start the engine and operate the loader hydraulic controls. Stop the engine and check for leaks.

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.

Check the fluid level in the reservoir and add as needed. (See Checking And Adding Fluid on Page 10-120-1.)

W-2103-0508

Install the side access cover. (Earlier Models with Square Coolant Tank) - Raise the bar supporting the oil cooler and lower the oil cooler. Fasten the two rubber straps.

71 of 1311

10-120-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove and clean the hydraulic fill screen (Item 1) [Figure 10-120-8]. Use low air pressure to dry the screen.

1

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Figure 10-120-10 Square Head Filter Cap

Hydraulic / Hydrostatic Filter Identification The filter housing is located behind the hydraulic fluid reservoir. NOTE: Identification of the hydraulic / hydrostatic filter used on your machine is necessary to perform the correct filter replacement procedure. Figure 10-120-9 Hex Head Filter Cap

This model has a square head on the filter cap [Figure 10-120-10]. (See Removing And Replacing Hydraulic / Hydrostatic Filter (Square Head Filter Cap) on Page 10120-6.) Figure 10-120-11 Bolt-on Filter Cap P-90500

This model has a hex head on the filter cap [Figure 10120-9]. (See Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) on Page 10-1205.)

P121075

This model has a filter cap held in place by two bolts [Figure 10-120-11]. (See Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) on Page 10-120-7.)

72 of 1311

10-120-4

S650 Service Manual

Dealer Copy -- Not for Resale

P109922

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

WARNING

Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) 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.)

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

Clean the top of the filter housing. Install the rear grille and close the rear door. Figure 10-120-12 Start the engine and operate the loader hydraulic controls.

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

P-90500

W-2072-0807

Remove the filter (Item 1) [Figure 10-120-12] using a socket wrench.

Stop the engine and check for leaks at the filter. Figure 10-120-13 Check the fluid level in the reservoir and add as needed. (See Checking And Adding Fluid on Page 10-120-1.)

1

P-85478

Discard the entire filter (Item 1) [Figure 10-120-13]. Clean the surface of the filter housing where the filter seal contacts the housing. Install new filter and tighten to 61 N•m (45 ft-lb) torque.

73 of 1311

10-120-5

S650 Service Manual

Dealer Copy -- Not for Resale

WARNING

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Install new filter element ensuring that element is fully seated in the housing.

Removing And Replacing Hydraulic / Hydrostatic Filter (Square Head Filter Cap)

Install the filter cap and tighten to 25 N•m (18 ft-lb) torque.

See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 10-70-1.)

WARNING

Stop the engine, open the rear door, and remove the rear grille. (See REAR GRILLE 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.

Clean the top of the filter housing. Figure 10-120-14

W-2103-0508

Install the rear grille and close the rear door.

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.

P100047

Remove the filter cap (Item 1) [Figure 10-120-14]. Figure 10-120-15

W-2072-0807

1

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.)

2

P100044

P100046

Remove the filter element (Item 1) [Figure 10-120-15] and discard. Remove the O-ring (Item 2) [Figure 10-120-15] and discard. Install new O-ring and lubricate with clean oil.

74 of 1311

10-120-6

S650 Service Manual

Dealer Copy -- Not for Resale

Start the engine and operate the loader hydraulic controls.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Install new filter element ensuring that element is fully seated in the housing.

Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap)

Remove the filter cap O-rings (Item 3) [Figure 10-12017] 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 the bolts [Figure 10-120-16]. Alternate tightening the bolts to draw the cap down evenly. Tighten the bolts to 27 - 41 N•m (20 - 30 ft-lb) torque.

Figure 10-120-16

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 P121075

Install the rear grille and close the rear door. Remove the bolts (Item 1) and slowly pry the filter cap (Item 2) [Figure 10-120-16] off the housing by hand.

Start the engine and operate the loader hydraulic controls.

Figure 10-120-17 1

WARNING 2

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

W-2072-0807 P121072A

P115686B

Stop the engine and check for leaks at the filter.

Remove the filter element (Item 2) [Figure 10-120-17] and discard.

Check the fluid level in the reservoir and add as needed. (See Checking And Adding Fluid on Page 10-120-1.)

Lubricate the O-ring (Item 1) [Figure 10-120-17] on new filter element with clean oil.

75 of 1311

10-120-7

S650 Service Manual

Dealer Copy -- Not for Resale

WARNING

1

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Earlier Models

Removing And Replacing Hydraulic Charge Filter

Figure 10-120-20

The hydraulic charge filter is located under the operator cab. For the correct service interval (See SERVICE SCHEDULE on Page 10-70-1.) Raise the operator cab. (See Raising on Page 10-30-2.) 1

Figure 10-120-18

P-85489B

1

2

Dealer Copy -- Not for Resale

Place a suitable container below the filter housing and remove the filter housing (Item 1) [Figure 10-120-20] using a socket wrench. Figure 10-120-21 P115884

Unhook the three rubber straps (Item 1) and remove the lower fan duct (Item 2) [Figure 10-120-18]. NOTE: Identification of the hydraulic charge filter used on your machine is necessary to perform the correct replacement procedure.

1

Figure 10-120-19 Earlier Model

Later Model P-85489A

Remove and discard the filter element (Item 1) [Figure 10-120-21]. Clean the surface of the filter housing and the filter base where they contact the filter element seal. P109622B

Put clean oil on the seal of the new filter element. Install the element on the filter base.

P115441A

Earlier models use a separate filter housing and filter element. Later models use a spin-on filter [Figure 10120-19].

76 of 1311

Install and tighten the filter housing to 65 - 70 N•m (48 52 ft-lb) torque.

10-120-8

S650 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 10-120-22

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 lower fan duct [Figure 10-120-18].

Lower the operator cab. (See Lowering on Page 10-303.)

P115441

Put a suitable container below the filter, remove the filter (Item 1) [Figure 10-120-22], and clean the filter base.

Start the engine and operate the loader hydraulic controls.

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.

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

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.)

77 of 1311

10-120-9

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Failure to install the lower fan duct correctly may result in decreased cooling.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap See the SERVICE SCHEDULE for the correct replacement interval. (See SERVICE SCHEDULE on Page 10-70-1.) Stop the engine and open the rear door. Remove the rear grille. (See REAR GRILLE on Page 5060-1.) Figure 10-120-23

Dealer Copy -- Not for Resale

1

P100055

Remove the breather cap (Item 1) [Figure 10-120-23] and discard. Install new breather cap. Install the rear grille. Close the rear door.

78 of 1311

10-120-10

S650 Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Fluid The chaincase contains the final drive sprockets and chains and uses the same type of fluid as the hydraulic / hydrostatic system. (See Hydraulic System on Page SPEC-10-4.) Stop the loader on a level surface and stop the engine. Figure 10-130-1

Dealer Copy -- Not for Resale

1

P107956

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

79 of 1311

10-130-1

S650 Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE) (CONT’D)

WARNING

Removing And Replacing Fluid Figure 10-130-2

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

P-85745

Dealer Copy -- Not for Resale

Remove the check plug (Item 1) [Figure 10-130-2] from the front of the chaincase housing. Figure 10-130-3

P107281

Pump the fluid out of the chaincase [Figure 10-130-3]. Recycle or dispose of the environmentally safe manner.

used

fluid

in

an

Add fluid through the check plug hole until the fluid flows from the hole.

80 of 1311

10-130-2

S650 Service Manual

BOB-TACH (HAND LEVER)

Figure 10-140-2

Inspection And Maintenance 1 Figure 10-140-1 2

Wedge must contact lower edge of hole in the attachment mounting frame. P-31233A

P-31233

Move the Bob-Tach levers down to engage the wedges [Figure 10-140-1]. The levers and wedges must move freely.

The spring loaded wedge (Item 1) must contact the lower edge of the holes in the attachment mounting frame (Item 2) [Figure 10-140-2]. If the wedges do not contact the lower edge of the holes [Figure 10-140-2], the attachment will be loose and can come off the Bob-Tach.

WARNING 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

81 of 1311

10-140-1

S650 Service Manual

Dealer Copy -- Not for Resale

The wedges (Item 1) [Figure 10-140-2] must extend through the holes in the attachment mounting frame.

P-85513A

BOB-TACH (HAND LEVER) (CONT’D) Inspection And Maintenance (Cont’d)

Dealer Copy -- Not for Resale

Figure 10-140-3

NA13065S

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. Inspect for cracked welds. Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1.) (See LUBRICATING THE LOADER on Page 10-150-1.)

82 of 1311

10-140-2

S650 Service Manual

BOB-TACH (POWER)

Figure 10-141-2

This machine may be equipped with a Power Bob-Tach. 1 Inspection And Maintenance Figure 10-141-1

2

Wedge must contact lower edge of hole in the attachment mounting frame.

1

P-31233A

P-31233

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].

P-85320A

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.

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.

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

83 of 1311

10-141-1

S650 Service Manual

Dealer Copy -- Not for Resale

The wedges (Item 1) [Figure 10-141-2] must extend through the holes in the attachment mounting frame.

2

BOB-TACH (POWER) (CONT’D) Inspection And Maintenance (Cont’d)

Dealer Copy -- Not for Resale

Figure 10-141-3

NA13065S

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. Inspect for cracked welds. Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1.) and (See LUBRICATING THE LOADER on Page 10-150-1.)

84 of 1311

10-141-2

S650 Service Manual

LUBRICATING THE LOADER

Figure 10-150-2

Lubrication Locations Lubricate the loader as specified for the best performance of the loader. (See SERVICE SCHEDULE on Page 10-70-1.) Record the operating hours each time you lubricate the Bobcat loader. 2

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.

P-90572A

Tilt the Bob-Tach forward until it contacts the ground. (Not required on later models with Bob-Tach wedge grease fittings that are accessible from the side.)

2. Base End Lift Cylinder (Both Sides) (2) [Figure 10150-2].

Stop the engine.

Figure 10-150-3

Figure 10-150-1 3

1

P-90543A

3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-3]. P100011

1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10150-1].

85 of 1311

10-150-1

S650 Service Manual

Dealer Copy -- Not for Resale

Lubricate the following:

LUBRICATING THE LOADER (CONT’D)

Figure 10-150-6

Lubrication Locations (Cont’d) Figure 10-150-4 6 4

P-85720

6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10150-6].

P-90542A

Figure 10-150-7 Figure 10-150-5

5 7

P-85719

7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-1507].

P-85484

5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10150-5].

86 of 1311

10-150-2

S650 Service Manual

Dealer Copy -- Not for Resale

4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-4].

LUBRICATING THE LOADER (CONT’D)

Figure 10-150-10

Lubrication Locations (Cont’d) Earlier Models 9

Figure 10-150-8

8 P100012

9. Rear Control Link (Both Sides) (2) [Figure 10-15010].

Later Models Figure 10-150-9

10

8

P-90544A

10. Front Control Link (Both Sides) (2) [Figure 10-15011]. P-31308A

8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8] or [Figure 10-150-9].

87 of 1311

10-150-3

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 10-150-11

P-85487

Dealer Copy -- Not for Resale 88 of 1311

10-150-4

S650 Service Manual

TIRE MAINTENANCE

Rotating

Wheel Nuts

Check the tires regularly for wear, damage and pressure.

Figure 10-160-1

Figure 10-160-2

P-85479

See your SERVICE SCHEDULE for the correct interval to check the wheel nuts [Figure 10-160-1]. (See SERVICE SCHEDULE on Page 10-70-1.)

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].

When installing wheel nuts, tighten to 217 N•m (160 ft-lb) torque.

It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

When checking wheel nut torque, set the torque wrench to 190 N•m (140 ft-lb) to prevent over-tightening.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for correct pressure before operating the loader.

89 of 1311

10-160-1

S650 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 which 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 1311

10-160-2

S650 Service Manual

SPARK ARRESTER MUFFLER

Figure 10-170-1

Cleaning Procedure See the SERVICE SCHEDULE for service interval for cleaning the spark arrester muffler. (See SERVICE SCHEDULE on Page 10-70-1.) 1

Do not operate the loader with a defective exhaust system.

P-85509

IMPORTANT

•

•

WITH MUFFLER The muffler spark chamber must be emptied every 100 hours of operation to keep it in working condition. WITH SELECTIVE CATALYST REDUCTION (SCR) AND / OR DIESEL OXIDATION CATALYST (DOC) Do not remove or modify the DOC or SCR. The SCR must be maintained according to the instructions in the Operation & Maintenance Manual for proper function.

•

WITH DIESEL PARTICULATE FILTER (DPF) The DPF must be maintained according to the instructions in the Operation & Maintenance Manual for proper function.

(If this machine is operated on flammable forest, brush or grass cover land, the engine must be equipped with a spark arrester and maintained in working order. Failure to do so will be in violation of California state law section 4442 PRC. Refer to local laws and regulations for spark arrester requirements.) I-2350-1114

Stop the engine and open the rear door.

Remove the plug (Item 1) [Figure 10-170-1] from the bottom of the muffler.

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. W-2006-1209

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. This will force contaminants out through the cleanout hole. Stop the engine. Install and tighten the plug. Close the rear door.

WARNING AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning. W-2050-0807

WARNING

WARNING

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

W-2068-1285

W-2011-1285

91 of 1311

10-170-1

S650 Service Manual

Dealer Copy -- Not for Resale

This machine is factory equipped with a U.S.D.A. Forestry Service Approved spark arrester exhaust system that must be maintained for proper function.

Dealer Copy -- Not for Resale 92 of 1311

10-170-2

S650 Service Manual

PIVOT PINS Inspection And Maintenance Figure 10-180-1

1

P100004

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 10-180-1]. Check that the locknuts are tightened to 48 - 54 N•m (35 40 ft-lb) torque.

93 of 1311

10-180-1

S650 Service Manual

Dealer Copy -- Not for Resale 94 of 1311

10-180-2

S650 Service Manual

Return To Service

Storage

After the Bobcat loader has been in storage, it is necessary to follow a list of items to return the loader to service.

Sometimes it may be necessary to store your Bobcat loader for an extended period of time. Below is a list of items to perform before storage.

•

Check the engine and hydraulic oil levels; check coolant level.

Thoroughly clean the loader including the engine compartment.

•

Install a fully charged battery.

•

Lubricate the loader.

•

Remove grease from exposed cylinder rods.

•

Replace worn or damaged parts.

•

Check all belt tensions.

•

Park the loader in a dry protected shelter.

•

Be sure all shields and guards are in place.

•

Lower the lift arms all the way and put the bucket flat on the ground.

•

Lubricate the loader.

• •

Put blocks under the frame to remove weight from the tires.

Check tire inflation and remove blocks from under frame.

•

Remove cover from exhaust pipe opening.

•

Put grease on any exposed cylinder rods. •

•

Put fuel stabilizer in the fuel tank and run 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.

10-190-1

S650 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 run 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.

95 of 1311

Dealer Copy -- Not for Resale

LOADER STORAGE AND RETURN TO SERVICE

Dealer Copy -- Not for Resale 96 of 1311

10-190-2

S650 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.

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 60-200-2.) or (See Password Lockout Feature on Page 60-201-1.) Figure 10-200-3

Figure 10-200-1

Exit the loader using grab handles, safety tread and steps (maintaining a 3-point contact) [Figure 10-200-3].

P-90525B

Push the engine speed control fully down to decrease the engine speed [Figure 10-200-1].

WARNING

Engage the parking brake. Figure 10-200-2 1

1

2

P-90688A

P-90214C

P-90214A

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.

Turn the key switch to the STOP position (Item 1) or press the STOP button (Item 2) [Figure 10-200-2].

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.

NOTE: If the loader lights are ON, they will remain ON for approximately 90 seconds after turning the loader OFF.

W-2463-1110

Raise the seat bar and make sure the lift and tilt functions are deactivated. Unbuckle the seat belt. Remove the key from the switch (Standard Key Panel) to prevent operation of the loader by unauthorized personnel.

97 of 1311

10-200-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-85735A

P-85737A

Dealer Copy -- Not for Resale 98 of 1311

10-200-2

S650 Service Manual

EMERGENCY EXIT The front opening on the operator cab and rear window provide exits. Rear Window Identification Figure 10-210-1

There are two different procedures for removing the rear window from your machine:

Latches

Rubber Cord 1. This window is equipped with latches (Item 1) [Figure 10-210-1]. 2 2. This window is equipped with a rubber cord and tag (Item 2) [Figure 10-210-1].

1 P-85309B

NOTE: Use these procedures to remove the rear window only under emergency conditions. Damage to machine may occur.

P-64994G

Rear Window Removal (Latches)

Rear Window Removal (Rubber Cord)

Figure 10-210-2

Figure 10-210-4 1

P-85309A

P-64994F

Turn both latches (Item 1) [Figure 10-210-2] in until they disengage from the window frame.

Pull on the tag on the top of the rear window to remove the rubber cord [Figure 10-210-4].

Push the rear window out of the rear of the operator cab.

Push the rear window out of the rear of the operator cab.

Figure 10-210-3

Figure 10-210-5

P-90676

P-90676

Exit through rear of the operator cab [Figure 10-210-3].

Exit through rear of the operator cab [Figure 10-210-5].

99 of 1311

10-210-1

S650 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 10-210-6 Figure 10-210-8 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 10-210-6] counterclockwise until the latches disengage from the window frame. Pull the top of the window away from the cab and lift up to remove. OR

Pull both handles (Item 1) [Figure 10-210-8] up and out to remove the rear window. Front Door This machine may be equipped with a front door.

Figure 10-210-7

NOTE: Use this procedure to remove the front door only under emergency conditions. Damage to machine may occur.

1

Figure 10-210-9

1

P-90669C

A kit is available to allow removal of the latch equipped rear window from outside the machine without tools. P-90725

Turn both knobs (Item 1) [Figure 10-210-7] counterclockwise until the latches disengage from the window frame. Pull the top of the window away from the cab and lift up to remove.

Turn both latches (Item 1) [Figure 10-210-9] down until they disengage from the door frame. Push the door out of the operator cab door frame and exit through the opening.

100 of 1311

10-210-2

S650 Service Manual

Dealer Copy -- Not for Resale

P13982

EMERGENCY EXIT (CONT’D)

Figure 10-210-12

Front Door (Cont’d) Front Door Reassembly 2 Reassemble the front door using the following instructions if the door was opened using the emergency exit procedure. Figure 10-210-10

1

1

P-90685

Orient the latches as shown (Item 1) and install the door hinges (Item 2) [Figure 10-210-12] on the door. (Bottom hinge shown.) 2

Dealer Copy -- Not for Resale

Figure 10-210-13

1

P-85781A

NOTE: Later models route the washer fluid hose differently and will not require this step.

2

Disconnect electrical connector (Item 2) and washer fluid hose (Item 1) (if equipped) [Figure 10-210-10]. Figure 10-210-11

P-90686A

2 3

Install cast washers (Item 2) on door hinges taking care to match rectangular surfaces. Hold cast washer firmly against door and rotate latch (Item 1) [Figure 10-210-13] up to lock cast washer into position. (Bottom hinge shown.) (Plastic cap shown removed for visual clarity.) 1 Install door on loader.

P-85588A

Install the gas spring socket on the ball stud fitting. Install the clip into the hole in the gas spring socket. Rotate the clip (Item 1) to lock into position [Figure 10-210-11].

P-85589A

Rotate and pull the clip (Item 1) out of the gas spring socket. Pull the gas spring socket (Item 3) straight off the ball stud fitting (Item 2) [Figure 10-210-11].

Connect electrical connector (Item 2) and washer fluid hose (Item 1) (if equipped) [Figure 10-210-10].

Remove the door hinges from the loader.

101 of 1311

10-210-3

S650 Service Manual

Dealer Copy -- Not for Resale 102 of 1311

10-210-4

S650 Service Manual

SEAT BELT

Figure 10-220-1

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.

2

4

Any seat belt system that shows cuts, fraying, extreme or unusual wear, significant discoloration 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. B-22283

The items below are referenced in [Figure 10-220-1]. 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, deformed or 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. See your dealer for seat belt system replacement parts for your machine.

103 of 1311

10-220-1

S650 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 104 of 1311

10-220-2

S650 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 (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-21-1 20-21-1 20-21-2 20-21-4 20-21-5 20-21-6 20-21-7 20-21-9

CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-22-1 20-22-1 20-22-2 20-22-3 20-22-4 20-22-5

MAIN RELIEF VALVE (EARLIER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-30-1 20-30-1 20-30-2 20-30-4 20-30-5

MAIN RELIEF VALVE (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-31-1 20-31-1 20-31-2 20-31-4 20-31-4 20-31-5 20-31-6

105 of 1311

20-01

S650 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 (STANDARD) (LATER MODELS) . . . . . . . . . . . . . . . . 20-41-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2 Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7 Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8 Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-41-9 Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-10 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-10 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-11 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-11 Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12 Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14 Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15 End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15 Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26 Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28 Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29 Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31 Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31 Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32 Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32

106 of 1311

20-02

S650 Service Manual

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12 Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13 End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14 Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27 Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30 Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31 Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33 Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33 Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34

107 of 1311

20-03

S650 Service Manual

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) . . . . . . . . . . . 20-42-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1 Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-5 Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-10 Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11 Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11 Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-42-12 Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-42-13 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-42-13 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-42-14 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-42-14 Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-15 Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-16 End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-17 Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-17 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-22 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24 Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-26 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-27 Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-28 Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-29 Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-29 Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1 Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2 Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6 Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10

108 of 1311

20-04

S650 Service Manual

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) . . . . . . . . . . . . . 20-43-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-5 Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-6 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-9 Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10 Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10 Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-43-11 Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-43-12 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-43-12 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-43-13 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-43-13 Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14 Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-16 End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17 Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17 Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-19 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-20 Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-22 Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-23 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-24 Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-25 Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-27 Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-27 Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-28 Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-28

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2 Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3 Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5 High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7 High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8 Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10 Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-14

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 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 20-100-2 20-100-2 20-100-4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-120-1 20-120-1 20-120-1 20-120-3 20-120-7

109 of 1311

20-05

S650 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 A3NV25242 AND A3NW13834 & ABOVE) . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 of 1311

20-06

S650 Service Manual

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH NO OPTIONS S650 (S/N A3NV11001 AND ABOVE) (S/N A3NW11001 AND ABOVE) (PRINTED NOVEMBER 2010) V-1348legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal)

2

SIGHT GUAGE

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 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

7

RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 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

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY

11

LOAD CHECK VALVE

16 FILTER - BICS CONTROL VALVE (SCREEN)

33

17 CHECK VALVE With 100 kPa 1,0 bar (14.5 psi) Spring

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

34

HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle

35

VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP

36

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi)

37

RELIEF VALVE - CHARGE INLET: 3206 kPa (32,0 bar) (465 PSI) at High Engine Idle With 60 ° C (140 ° F) Fluid

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

22 PROPORTIONAL RELIEF VALVE – Dealer Copy -- Not for Resale (Fan Speed Regulator): 10797-12300 kPa 38 CHECK VALVE – COLD WEATHER BY-PASS (108 - 123 bar) (1566 - 1784 psi) With 345 kPa (3,45 bar) (50 psi) Spring 23 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 24 FIXED CAPACITY DISPLACEMENT HYDRAULIC MOTOR 25 FILTER - HYDRAULIC (CANISTER) 26 SENSOR – CHARGE PRESSURE – Fan Filter 27 ANTICAVITATION VALVE 28 SENSOR – HYD. TEMPERATURE

12

FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE

29 RESTRICTION - 1,5 mm (0.06 in)

13

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL

30 CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring

14

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL

31 DRIVE MOTOR SHUTTLE VALVE

15

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL

32 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

Printed in U.S.A. 111 of 1311

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1348legend (12-2-10)

INTEGRATED COUPLER BLOCK

12 Male DRIVE MOTOR OUT

31

Male

HYDRAULIC CONTROL VALVE

L

29 12

30

Female

9 10 10 Auxiliary Spool

32 A

TILT CYLINDERS

8

B

11 BICS CONTROL VALVE

HYDROSTATIC PUMP

Tilt Spool

35

8

38

13

27 11 M4

M 3

D

C

14

Lift Spool

36

36

Dealer Copy -- Not for Resale 8

Charge Inlet

37

36

LIFT CYLINDERS

18

20 11

16

16

17

A

B

?

IN

7

M1

M 2

15

2

6

36 1

19

T

35 VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

34

Oil Cooler

3

2

RESERVOIR (VENTED)

5 1

33

23

25

4

26

A

B

PUMP SUPPLY WORKING CIRCUIT PILOT PRESSURE DRAIN / RETURN

HYDRAULIC FILTER

24

32

21 P

DR

22

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH NO OPTIONS S650 (S/N A3NV11001 & ABOVE) (S/N A3NW11001 & ABOVE)

28

30 29

31

L

DRIVE MOTOR

DRAIN / RETURN MANIFOLD

(PRINTED NOVEMBER 2010) 112 of 1311

PRINTED IN U.S.A.

7170812

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH ALL OPTIONS S650 (S/N A3NV11001 – A3NV12444) (S/N A3NW11001 – A3NW11129) (PRINTED NOVEMBER 2010) V-1349legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal)

19

2

SIGHT GUAGE

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed

20 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP 21 ANTICAVITATION VALVE

4

FILTER - HYDRAULIC (CANISTER)

5

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi)

6

DIAGNOSTIC COUPLER

7

RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)

8 9

10 11 12 13 14 15 16

RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL): 27579 kPa (276 bar) (4000 psi) SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY LOAD CHECK VALVE FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF 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

22 PROPORTIONAL RELIEF VALVE – (Fan Speed Regulator): 10797-12300 kPa (108 - 123 bar) (1566 - 1784 psi)

26 SENSOR – CHARGE PRESSURE – Fan Filter 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) FLOW DIVIDER ADJUSTMENT VALVE 28 29 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 30 CHECK VALVE - BUCKET POSITION VALVE 31

32

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH FILTER - BOB-TACH VALVE

17 CHECK VALVE - With 100 kPa 1,0 bar (14.5 psi) Spring

34

RESTRICTION - 2,26 mm (0.089 in)

18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

35

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

113 of 1311

RELIEF VALVE: 8274 kPa (83 bar) (1200 psi)

57

HIGH PRESSURE SHUTTLE

37

CHECK VALVE - With 552 kPa (5,5 bar) (80 psi) Spring RELIEF VALVE: 13790 kPa (137 bar) (2000 psi)

58

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR – 2 SPEED

59

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

60

HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR)

61

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – 2 SPEED

62

CHECK VALVE

63

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – MAKE-UP

38 39

CHECK VALVE - With 2068 kPa (20,7 bar) (300 psi) Spring And With 0,33 mm (0.013 in) Orifice

40

RESTRICTION - 0,6 mm (0.025 in)

41

SENSOR – HYD. TEMPERATURE

42 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 23 SPRING LOADED FILTER BY-PASS VALVE: L/min (23.0 U.S. gpm) at High Engine Idle 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 43 CHARGE PUMP 24 FIXED CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle Dealer Copy -- Not for Resale HYDRAULIC MOTOR 44 PILOT ACTIVATED DIRECTIONAL 25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - REAR AUXILIARY

33

Printed in U.S.A.

36

45

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

64

FILTER - BRAKE

46

65

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE

47

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

66

48

LOAD SHUTTLE VALVE - BLEED OFF

HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gpm) at High Engine Idle

67

RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)

68

DUMP VALVE – ON / OFF

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi) RELIEF VALVE - CHARGE INLET: 3206 kPa (32,0 bar) (465 PSI) at High Engine Idle With 60 ° C (140 ° F) Fluid

69

CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi) Spring

70

ANTICAVITATION VALVE

71

RIDE CONTROL VALVE

72

HIGH PRESSURE CHAMBER

73

LOW PRESSURE CHAMBER

74

FILTER – BOB-TACH VALVE

54

RESTRICTION - 1,5 mm (0.06 in)

75

55

CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring

CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring

49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 50 51 52 53

56

DRIVE MOTOR SHUTTLE VALVE

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1349legend (12-1-10)

INTEGRATED COUPLER BLOCK

12 Male TWO SPEED DRIVE MOTOR (OPTIONAL) L

56

Male

54

12

55 Female

HIGH FLOW VALVE (OPTIONAL)

BUCKET POSITIONING VALVE (OPTIONAL)

68

OUT

69 X

D

HYDRAULIC CONTROL VALVE

29

30 31

67

28 ?

57 W

9

REAR AUXILIARY COUPLERS (OPTIONAL)

58

FEMALE

MALE

27

10

60

C

A

10

59

?

Auxiliary Spool

Z Base ?

A

Rod

B

6

?

48 TILT CYLINDERS

B

50

8 11

49 HYDROSTATIC PUMP

46 ?

51

BICS CONTROL VALVE

?

Tilt Spool

75 47 8 45

M4

M 3

D

C

13

70 11

44 52

REAR AUXILIARY VALVE (OPTIONAL)

52 Charge Inlet

LIFT CYLINDERS

14

P - in

T

P - out

Dealer Copy --Lift Spool Not for Resale 8

BOB-TACH CYLINDER (OPTIONAL)

53

M1

M 2

BOBTACH VALVE (OPTIONAL)

74

A

B

37

74

38

16

16

17

15

?

IN

7

36

RIDE CONTROL (OPTIONAL)

18

20 11

2

6

71 DUAL STAGE ACCUMULATOR

52

52 51

35

19

?

34

73

40

PP

DR T P1

Oil Cooler

3

5

2

RESERVOIR (VENTED)

1

P2

42

33

43

32

4

VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

2-SPEED & SAPR BRAKE VALVE (OPTIONAL)

64

1

39 ?

HYDRAULIC FILTER

66

B1

65

23

25

B

60

64

PUMP SUPPLY WORKING CIRCUIT

26

B

A

63

PILOT PRESSURE

Z

62

C

P

24

59

58

D W

62 ?

P

61

DRAIN / RETURN

21 DR

22

57 A

X

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH ALL OPTIONS S650 (S/N A3NV11001 - A3NV12444) (S/N A3NW11001 - A3NW11129)

A1 T

41 55 54

56

L

DRAIN / RETURN MANIFOLD

(PRINTED NOVEMBER 2010)

TWO SPEED DRIVE MOTOR (OPTIONAL)

7170812

114 of 1311 PRINTED IN U.S.A.

Printable Version Click Here

72

Printable Version Click Here

(PRINTED MAY 2014) V-1419legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . . 41,6 L (11.0 U.S. gal)

19

2

SIGHT GUAGE

38

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed

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)

40

RESTRICTION - 0,51 mm (0.020 in)

41

SHUTTLE VALVE

4

FILTER - HYDRAULIC (CANISTER)

5

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi)

6

DIAGNOSTIC COUPLER

7

RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 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 14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL 16 FILTER - BICS CONTROL VALVE (SCREEN) 17 CHECK VALVE - With 100 kPa (1,0 bar) (14.5 psi) Spring

115 of 1311

57

36

RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)

37

58 CHECK VALVE - With 552 kPa) (5,5 bar) (80 psi) Spring RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 59

39

CHECK VALVE - With 2068 kPa (20,7 bar) (300 psi) Spring And With 0,40 mm (0.016 in) Orifice

42 RESTRICTION - 0,51 mm (0.020 in) 23 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 43 HYDRAULIC PUMP . . . . . . . Gear Type 24 FIXED CAPACITY DISPLACEMENT 87,1 L/min (23.0 U.S. gpm) at High Engine Idle Dealer Copy -- Not for Resale HYDRAULIC MOTOR 44 PILOT ACTIVATED DIRECTIONAL 25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - REAR AUXILIARY 26 SENSOR – CHARGE PRESSURE – Fan Filter 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) FLOW DIVIDER ADJUSTMENT VALVE 28 29 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 30 CHECK VALVE - BUCKET POSITION VALVE 31

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL

32

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – HYDRAULIC POWERED BOB-TACH With Build-up Valve 207 kPa (2,07 bar) (30 psi)

33

FILTER - BOB-TACH VALVE

34

RESTRICTION - 2,08 mm (0.08 in)

35

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

Printed in U.S.A.

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

DRIVE MOTOR SHUTTLE VALVE FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR)

60

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed

61

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

62

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

63

HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gal) at High Engine Idle

64

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

45

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

65

DUMP VALVE – ON / OFF

46

66

CHECK VALVE - With 34,5 kPa (0,34 bar) (5.0 psi) Spring

47

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

67

48

LOAD SHUTTLE VALVE - BLEED OFF

68

FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE SENSOR – HYD. TEMPERATURE

69

RIDE CONTROL VALVE

70

HIGH PRESSURE CHAMBER

71

LOW PRESSURE CHAMBER

72 73

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE FILTER – BRAKE VALVE

74

CHECK VALVE

49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Female 50 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Male 51 VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP 52 RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi) 53 RELIEF VALVE - CHARGE INLET: 3206 kPa (32, bar) (465 psi) at High Engine Idle With 60 ° C (140 ° F) Fluid 54 CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring 55 RESTRICTION - 1,5 mm (0.06 in) 56

CHECK VALVE - With 1379 kPa 13,8 bar (200 psi) Spring

75 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift 76 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Make-up NOTE: Unless otherwise specified springs have NO significant pressure value. V-1419legend (5-21-14)

INTEGRATED COUPLER BLOCK

TWO SPEED DRIVE MOTOR (OPTIONAL)

Male

56

L

67

57

Male

55 66

Female

RIDE CONTROL (OPTIONAL)

OUT

HYDRAULIC CONTROL VALVE (SPOOL VALVE)

X

71

70

LIFT CYLINDERS

60 W

61

REAR QUICK COUPLERS

58

FEMALE

69 MALE

59

10

10 Z A

48

B

Auxiliary Spool

9

50 49

8

6

46

11 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

HYDROSTATIC PUMP

BUCKET POSITIONING VALVE (OPTIONAL) E2

E1

47

A1

E3

Tilt Spool

51

28

B

8 45

13

29

12 M4

B

11

M3

76 A

REAR AUXILIARY VALVE (OPTIONAL)

D

72

P in

P out

30

Dealer Copy -- Not for Resale Lift Spool

POWER BOBTACH VALVE (OPTIONAL)

P

A1

73

74

C

D2

T

31

8

POWER BOBTACH CYLINDER (OPTIONAL)

B1

30

14

52

52

53

T

27

44

C

D

2-SPEED & SAPR BRAKE VALVE (OPTIONAL)

A2

R

B

20

11 37

B

A

M2

M1

75

C2

C1

16

16

17

41

39

36

15 18

IN

7

D1

2

6

74 38

TILT CYLINDERS

52

52

1

Oil Cooler

54

51

19

42

35 34

D

40

FILTER

HYDRAULIC RESERVOIR (VENTED)

T

43

4

33

2

1

32

5

62 VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

64

3

65

25

23

63

26

WORKING CIRCUIT CHARGE PRESSURE

59

DRAIN / RETURN

B

A

21

24

Z

61

58

P

DR

22

W

DRAIN/RETURN MANIFOLD

60 X

68

55

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC WITH ALL OPTIONS S650 (S/N A3NV12445 - A3NV18826) (S/N A3NW11130 - A3NW12750)

57

56 L

(PRINTED MAY 2014)

TWO SPEEDDRIVE MOTOR (OPTIONAL)

116 of 1311 PRINTED IN U.S.A.

7170812 (C)

Printable Version Click Here

(S/N A3NV18227 - A3NV25735) (S/N A3NW12751 - A3NW13963) (S/N 1MLS11001 AND ABOVE) (PRINTED JULY 2017) V-1470legend

LEGEND

28

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle 40 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle LIFT CYLINDER SPOOL - MADE TO 41 VARIABLE CAPACITY DISPLACEMENT RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP DOWN BUT NOT DURING BOOM UP 42 RELIEF/REPLENISHING VALVE - HIGH RELIEF VALVE - 24132 kPa (241 bar) PRESSURE: 36500 kPa (365 bar) (5294 psi) (3500 psi) (If Equipped) 43 RELIEF VALVE - CHARGE INLET: ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) (440 +/- 50 psi) at High Engine Idle PROPORTIONAL RELIEF VALVE – With 60 ° C (140 ° F) Fluid (Fan Speed Regulator): 10797 – 12300 kPa (108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) SPRING LOADED FILTER BY-PASS VALVE: (50 psi) Spring Dealer Copy -- Not for Resale 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) FRONT AUXILIARY MANUAL PRESSURE 45 FIXED CAPACITY DISPLACEMENT BLEED-OFF VALVE HYDRAULIC MOTOR 46 PILOT ACTIVATED DIRECTIONAL FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – HYDRAULIC SENSOR – CHARGE PRESSURE – POWERED BOB-TACH With Build-up Fan Filter Valve: 276 kPa (2,76 bar) (40 psi) SENSOR – HYD. TEMPERATURE 47 FILTER - BOB-TACH VALVE

29

RESTRICTION - 1,5 mm (0.06 in)

48

RESTRICTION - 1,17 mm (0.46 in)

30

CHECK VALVE - With 1379 kPa 13,8 bar (200 psi) Spring DRIVE MOTOR SHUTTLE VALVE

49

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

50

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option

1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . . 41,6 L (11.0 U.S. gal)

19

2

SIGHT GUAGE

20

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER)

4 5 6 7

8 9

10

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi) DIAGNOSTIC COUPLER RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers NOTE - If Equipped With Ref. 21: 25855 kPa (258 bar) (3750 psi) RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi) RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL): 27579 kPa (276 bar) (4000 psi)

21 22 23

24 25 26 27

11

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY LOAD CHECK VALVE

31

12

ANTICAVITATION VALVE

32

13

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL 16 FILTER - BICS CONTROL VALVE (SCREEN) 17 CHECK VALVE - With 100 kPa (1,0 bar) (14.5 psi) Spring 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) Printed in U.S.A. 117 of 1311

33 34 35 36 37 38

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR) SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE FILTER – BRAKE VALVE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift

39

51

ACCUMULATOR – Ride Control Option

52

ORIFICE WITH CHECK VALVE: 2,54 mm (0.10 in)

53

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

54

RESTRICTION - 0,254 mm (0.010 in)

55

CHECK VALVE

56

ORIFICE: 1,60 mm (0.063 in)

57 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 58 FLOW DIVIDER ADJUSTMENT VALVE 59 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 60 CHECK VALVE - BUCKET POSITION VALVE 61 62

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE – UNLOADING SPOOL HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gal) at High Engine Idle

63

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

64

DUMP VALVE – ON / OFF

65

CHECK VALVE - With 34,5 kPa (0,34 bar) (5.0 psi) Spring

66

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY

67

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

68 69

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

70

LOAD SHUTTLE VALVE - BLEED OFF

71 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 72 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD 73

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Fan Reversing Option

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1470legend (7-25-17)

INTEGRATED COUPLER BLOCK

DRIVE MOTOR

Male L

30

31

45

29

Male

OUT

65

HYDRAULIC CONTROL VALVE

45 Female X

9 RIDE CONTROL (FIELD INSTALLED OPTION)

75

32

74

9

33

34 FEMALE

REAR QUICK COUPLERS

NOTE: CUSHIONED LIFT CYLINDERS ON LATER MODELS ONLY

10

MALE

35

10

LIFT CYLINDERS

Z

Auxiliary Spool A

70

B

73 72

21

71 6

68

HYDROSTATIC PUMP

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

11

8

R

41

TILT BASE

T E1 TILT ROD

69 X

13 67 11

36

14

66 M T

M C

D M

43

P in

REAR AUXILIARY VALVE (OPTION)

P out

59 LIFT BASE

Lift Spool

42

Dealer Copy -- Not for Resale

8

C2

C1

M

B1

61

POWER BOBTACH VALVE (OPTIONAL)

A

B

53

55

11

15

37 IN

7 42

BUCKET POSITIONING VALVE (OPTIONAL)

18

2

16

6

49

D1

16

20

M

42

D2

12

T

POWER BOBTACH CYLINDER (OPTIONAL)

P

60

57

LIFT ROD

A

A2

58

B

42 X

38 B

A1

Tilt Spool

8 2-SPEED & SAPR BRAKE VALVE (OPTIONAL)

E2

E3

17

54

TILT CYLINDERS 1

Oil Cooler

D

41

19

48

44

47 T

5

2

RESERVOIR (VENTED)

1

R

40

46

39 VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

3

4

HYDRAULIC FILTER

62 63

64 24

26

WORKING CIRCUIT

27 22 B

35

CHARGE PRESSURE DRAIN / RETURN

A

25 Z

33

P

34

DR

23

32

HYDRAULIC/HYDROSTATIC SCHEMATIC MANUAL WITH ALL OPTION S650 (S/N A3NV18827 - A3NV25735) (S/N A3NW12751 - A3NW13963) (S/N 1MLS11001 AND ABOVE)

X

28

30

Printable Version Click Here

29

31 L

DRIVE MOTOR

DRAIN / RETURN MANIFOLD

(PRINTED MAY 2018) 7170813 (G)

118 of 1311

PRINTED IN U.S.A.

Printable Version Click Here

(PRINTED JULY 2017) V-1642legend

LEGEND

28

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle 40 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle LIFT CYLINDER SPOOL - MADE TO 41 VARIABLE CAPACITY DISPLACEMENT RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP DOWN BUT NOT DURING BOOM UP 42 RELIEF/REPLENISHING VALVE - HIGH RELIEF VALVE - 24132 kPa (241 bar) PRESSURE: 36500 kPa (365 bar) (5294 psi) (3500 psi) (If Equipped) 43 RELIEF VALVE - CHARGE INLET: ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) (440 +/- 50 psi) at High Engine Idle PROPORTIONAL RELIEF VALVE – With 60 ° C (140 ° F) Fluid (Fan Speed Regulator): 10797 – 12300 kPa (108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) SPRING LOADED FILTER BY-PASS VALVE: (50 psi) Spring Dealer Copy -- Not for Resale 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) FRONT AUXILIARY MANUAL PRESSURE 45 FIXED CAPACITY DISPLACEMENT BLEED-OFF VALVE HYDRAULIC MOTOR 46 PILOT ACTIVATED DIRECTIONAL FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – HYDRAULIC SENSOR – CHARGE PRESSURE – POWERED BOB-TACH With Build-up Fan Filter Valve: 276 kPa (2,76 bar) (40 psi) SENSOR – HYD. TEMPERATURE 47 FILTER - BOB-TACH VALVE

29

RESTRICTION - 1,5 mm (0.06 in)

48

RESTRICTION - 1,17 mm (0.46 in)

30

CHECK VALVE - With 1379 kPa 13,8 bar (200 psi) Spring DRIVE MOTOR SHUTTLE VALVE

49

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

50

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option

1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . . 41,6 L (11.0 U.S. gal)

19

2

SIGHT GUAGE

20

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER)

4 5 6 7

8 9

10

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi) DIAGNOSTIC COUPLER RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers NOTE - If Equipped With Ref. 21: 25855 kPa (258 bar) (3750 psi) RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi) RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL): 27579 kPa (276 bar) (4000 psi)

21 22 23

24 25 26 27

11

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY LOAD CHECK VALVE

31

12

ANTICAVITATION VALVE

32

13

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL 16 FILTER - BICS CONTROL VALVE (SCREEN) 17 CHECK VALVE - With 100 kPa (1,0 bar) (14.5 psi) Spring 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) Printed in U.S.A. 119 of 1311

33 34 35 36 37 38

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR) SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE FILTER – BRAKE VALVE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift

39

51

ACCUMULATOR – Ride Control Option

52

ORIFICE WITH CHECK VALVE: 2,54 mm (0.10 in)

53

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

54

RESTRICTION - 0,254 mm (0.010 in)

55

CHECK VALVE

56

ORIFICE: 1,60 mm (0.063 in)

57 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 58 FLOW DIVIDER ADJUSTMENT VALVE 59 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 60 CHECK VALVE - BUCKET POSITION VALVE 61 62

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE – UNLOADING SPOOL HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gal) at High Engine Idle

63

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

64

DUMP VALVE – ON / OFF

65

CHECK VALVE - With 34,5 kPa (0,34 bar) (5.0 psi) Spring

66

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY

67

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

68 69

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

70

LOAD SHUTTLE VALVE - BLEED OFF

71 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 72 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD 73

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Fan Reversing Option

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1642legend (7-24-17)

INTEGRATED COUPLER BLOCK

DRIVE MOTOR

Male L

30

31

45

29

Male

OUT

65

HYDRAULIC CONTROL VALVE

45 Female X

51

RIDE CONTROL (OPTION)

9

T2

ACC

52

T

32

56 9

33

34 FEMALE

REAR QUICK COUPLERS

35

50

10

LIFT CYLINDERS

Z

Auxiliary Spool A

72

CR

CR2

70

B

NOTE: CUSHIONED LIFT CYLINDERS ON LATER MODELS ONLY

P

10

MALE

CB

CB2

21

71 6

68

HYDROSTATIC PUMP

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

11

8

R

41

TI LT BASE

T E1 TI LT ROD

69 X

E2

A1

Tilt Spool

8

58

B

42

2-SPEED & SAPR BRAKE VALVE (OPTIONAL)

13

X

67 11

36

14

66

A

M T

D M

43

P in

REAR AUXILIARY VALVE (OPTION)

M C

P out

59 LI FT BASE

Lift Spool

42

M

B1

61

Dealer Copy -- Not for Resale

8

53

55

11

15

37 IN

7 42

BUCKET POSITIONING VALVE (OPTIONAL)

18

2

16

6

49

D1

16

20

M

C2

C1

POWER BOBTACH VALVE (OPTIONAL)

A

B

42

D2

12

T

POWER BOBTACH CYLINDER (OPTIONAL)

P

60

57

LI FT ROD

38 B

A2

E3

17

54

TILT CYLINDERS D

41

1

Oil Cooler

19

48

44 47 T

5

2

RESERVOIR (VENTED)

1

R

40

46

39 VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

3

4

HYDRAULIC FILTER

62 63

64

24

26 27

WORKING CIRCUIT

1 B

35

22

4

CHARGE PRESSURE DRAIN / RETURN

A

3

2

25 73 Z

33

34

DR

23

P

32

Printable Version Click Here

X

28

30

HYDRAULIC/HYDROSTATIC SCHEMATIC MANUAL WITH ALL OPTION S650 (S/N A3NV23736 AND ABOVE) (S/N A3NW13964 AND ABOVE)

29

31 L

DRIVE MOTOR

DRAIN / RETURN MANIFOLD

(PRINTED MAY 2018) 7170812 (K)

120 IN of 1311 PRINTED U.S.A.

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH NO OPTIONS S650 (S/N A3NV11001 AND ABOVE) (S/N A3NW11001 AND ABOVE) (PRINTED NOVEMBER 2010) V-1350legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal)

14

2

SIGHT GUAGE

15

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed

4

FILTER - HYDRAULIC (CANISTER)

LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP

28 SENSOR – CHARGE PRESSURE – Fan Filter 29 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL

30 CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

16 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 17

31 VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL

32 RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi)

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi)

18 FILTER - BICS CONTROL VALVE (SCREEN)

6

DIAGNOSTIC COUPLER

19 CHECK VALVE - With 100 kPa 1,0 bar (14.5 psi) Spring

7

RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers

20 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

34

SERVO PISTON – Swash Plate

21 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

35

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE

36

FILTER

37

CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring

38

RESTRICTION – 1,5 mm (0.06 in)

39

CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring

40

DRIVE MOTOR SHUTTLE VALVE

41

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

5

8

9

10

11 12 13

RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)

33 RELIEF VALVE - CHARGE INLET: 2654 kPa (26,5 bar) (385 psi) at High Dealer Copy -- Not for Resale Engine Idle With 60 ° C (140 ° F) Fluid

22 SENSOR – HYD. TEMPERATURE

RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL): 27579 kPa (276 bar) (4000 psi)

23 ANTICAVITATION VALVE

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY

24 PROPORTIONAL RELIEF VALVE – (Fan Speed Regulator): 10797-12300 kPa (108 - 123 bar) (1566 - 1784 psi)

LOAD CHECK VALVE FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE ANTICAVITATION VALVE

25 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 26 FIXED CAPACITY DISPLACEMENT HYDRAULIC MOTOR 27 FILTER - HYDRAULIC (CANISTER)

NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A. 121 of 1311

V-1350legend (12-1-10)

INTEGRATED COUPLER BLOCK

Male

12

TWO SPEED DRIVE MOTOR (OPTIONAL)

39

L

40

Male

OUT

38

HYDRAULIC CONTROL VALVE (SPOOL VALVE)

12 Female

9

10 10

41

A

6

B

8

31

TILT CYLINDERS

37

11

R

TANDEM HYDROSTATIC DRIVE PUMP

BICS CONTROL VALVE

T

35

36

X

34

15 8

X

11

16

LIFT CYLINDERS

13

36

M

M B

A M

32

32

Dealer Copy 8 -- Not for Resale

Charge G Inlet

33

20

B

A

14

M

36

M

11

19 18

18

17

IN

32

7

2

6

?

32

?

X

VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

34

1

X

?

36 35

27

25 OIL COOLER

T

3

2

RESERVOIR (VENTED)

21

28

31 R

1

5

29

4

23

30

26 P

B

HYDRAULIC FILTER

Printable Version Click Here

22

40 39

38 L

DRIVE MOTOR

PRINTED IN U.S.A.

24

A

41

122 of 1311

DR

PUMP SUPPLY WORKING CIRCUIT PILOT PRESSURE DRAIN / RETURN

DRAIN/RETURN MANIFOLD

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH NO OPTION S650 (S/N A3NV11001 AND ABOVE) (S/N A3NW11001 AND ABOVE) (PRINTED NOVEMBER 2010) 7170813

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH ALL OPTIONS S650 (S/N A3NV11001 – A3NV12444) (S/N A3NW11001 – A3NW11129) (PRINTED NOVEMBER 2010) V-1351legend

LEGEND 1

2 3

4 5 6 7

8 9

10 11 12

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal) SIGHT GUAGE DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER) SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi) DIAGNOSTIC COUPLER RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers 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 FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE

13

ANTICAVITATION VALVE

14

LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP

15 16 17 18 19

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) CHECK VALVE With 100 kPa 1,0 bar (14.5 psi) Spring

Printed in U.S.A. 123 of 1311

60

CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring

61

RESTRICTION - 1,5 mm (0.06 in)

62

CHECK VALVE - - With 2068 kPa (20,7 bar) (300 psi) Spring And With 0,33 mm (0.013 in) Orifice 63

CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring DRIVE MOTOR SHUTTLE VALVE

43

RESTRICTION - 0,6 mm (0.025 in)

64

HIGH PRESSURE SHUTTLE

44

SENSOR – HYD. TEMPERATURE

65

45

HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle

46

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR – 2 SPEED FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

20 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

39

21 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

40

CHECK VALVE - With 552 kPa (5,5 bar) (80 psi) Spring FILTER – BOB-TACH VALVE

41

RELIEF VALVE : 13790 kPa (137 bar) (2000 psi)

22 RIDE CONTROL VALVE

42

23 ANTICAVITATION VALVE 24 PROPORTIONAL RELIEF VALVE – (Fan Speed Regulator): 10797-12300 kPa (108 - 123 bar) (1566 - 1784 psi) 25 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 26 FIXED CAPACITY DISPLACEMENT HYDRAULIC MOTOR 27 FILTER - HYDRAULIC (CANISTER)

Dealer Copy --47NotPILOT for Resale ACTIVATED DIRECTIONAL

28 SENSOR – CHARGE PRESSURE – Fan Filter SOLENOID ACTIVATED DIRECTIONAL 29 CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 30 FLOW DIVIDER ADJUSTMENT VALVE 31 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL CHECK VALVE - BUCKET POSITION 32 VALVE 33 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL 34 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH 35

FILTER - BOB-TACH VALVE

36

RESTRICTION - 2,26 mm (0.089 in)

37

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

38

RELIEF VALVE : 8274 kPa (83 bar) (1200 psi)

CONTROL VALVE - REAR AUXILIARY

66

67

HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR) SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – 2 SPEED CHECK VALVE

68

50

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 inch)

51

LOAD SHUTTLE VALVE - BLEED OFF

71

52

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD

72

VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP

74

RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)

75

DUMP VALVE – ON / OFF

76

CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi) Spring

77

HIGH PRESSURE CHAMBER

78

LOW PRESSURE CHAMBER

48 49

53 54 55 56

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi) RELIEF VALVE - CHARGE INLET: 2654 kPa (26,5 bar) (385 psi) at High Engine Idle With 60 ° C (140 ° F) Fluid

57

SERVO PISTON – Swash Plate

58

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE FILTER

59

69 70

73

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – MAKE-UP FILTER - BRAKE SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gpm) at High Engine Idle

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1351legend (12-1-10)

INTEGRATED COUPLER BLOCK

Male

TWO SPEED DRIVE MOTOR (OPTIONAL)

12

62

L

Male

61

63

12 Female

HIGH FLOW VALVE (OPTIONAL)

74

75

BUCKET POSITIONING VALVE (OPTIONAL)

OUT

31

HYDRAULIC CONTROL VALVE (SPOOL VALVE)

X

D

32

33 30

?

65

64

W

9

76

C

A

REAR QUICK COUPLERS

66

10

67

10 FEMALE

?

MALE

Z ?

A

6

?

51

B

29 B

54

60

TILT CYLINDERS

11

52

R

TANDEM HYDROSTATIC

8

53 ?

49

?

BICS CONTROL VALVE

T

58

59

X

50 57

15 8

X

11

48

16

47 59

M

M B

A

REAR AUXILIARY VALVE (OPTIONAL)

T

P out

Dealer Copy -- Not for Resale

M

55

LIFT CYLINDERS

13

P in

55 8

Charge G Inlet

56

BOBTACH CYLINDER (OPTIONAL)

20

22

B

A

14

M

POWER BOBTACH VALVE (OPTIONAL)

40

59

M

39 55

18

18

17

IN

40

38

11

19

41

7

?

2

6

?

55 X

57 1

X

42

?

59

37

58

?

?

36

43

DR

PP

P1

P2

OIL COOLER

T

54 R

2

RESERVOIR (VENTED)

21 78

77

1

45

34

35

46

5

VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER HYDRAULIC FILTER

2-SPEED & SAPR BRAKE VALVE

71

3

4

B1

73

72

27 B

25

PUMP SUPPLY WORKING CIRCUIT PILOT PRESSURE DRAIN / RETURN

67

71

28 B

70

69

A

Z C

P

23 W

68 69

26

66

D

P

64

?

A

X

T

44

63 62

61 L

TWO SPEED DRIVE MOTOR (OPTIONAL)

PRINTED IN U.S.A.

24

DRAIN/RETURN MANIFOLD

A1

124 of 1311

DR

65

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH ALL OPTION S650 (S/N A3NV11001 - A3NV12444) (S/N A3NW11001 - A3NW11129) (PRINTED NOVEMBER 2010) 7170813

Printable Version Click Here

Printable Version Click Here

(PRINTED MAY 2014) V-1420legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal)

2

SIGHT GUAGE

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER)

4 5

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi)

6

DIAGNOSTIC COUPLER

7

RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers RELIEF/ANTICAVITATION VALVE PORT: 27579 kPa (276 bar) (4000 psi)

8 9

10 11 12 13 14

15 16 17 18 19

RELIEF/ANTICAVITATION VALVE PORT (OPTIONAL): 27579 kPa (276 bar) (4000 psi) SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY LOAD CHECK VALVE FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE ANTICAVITATION VALVE LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP 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) CHECK VALVE - With 100 kPa 1,0 bar (14.5 psi) Spring

Printed in U.S.A. 125 of 1311

62

40

CHECK VALVE - With 552 kPa (5,5 bar) (80 psi) Spring SHUTTLE VALVE

CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring

63

41

RELIEF VALVE: 13790 kPa (137 bar) (2000 psi)

64

42

CHECK VALVE - With 2068 kPa (20,7 bar) (300 psi) Spring And With 0,33 mm (0.013 in) Orifice

DRIVE MOTOR SHUTTLE VALVE FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

65

HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR)

66

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed

67

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR – 2 Speed HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle

20 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

39

21 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS 22 RIDE CONTROL VALVE 23 ANTICAVITATION VALVE

43

RESTRICTION - 0,51 mm (0.020 in)

44

RESTRICTION - 0,51 mm (0.020 in)

45

SENSOR – HYD. TEMPERATURE

25 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)

46

NOT USED FOR THIS MODEL

26 FIXED CAPACITY DISPLACEMENT HYDRAULIC MOTOR

47

24 PROPORTIONAL RELIEF VALVE – (Fan Speed Regulator): 10797-12300 kPa (108 - 123 bar) (1566 - 1784 psi)

27 FILTER - HYDRAULIC (CANISTER)

PILOT ACTIVATED DIRECTIONAL CONTROL Dealer Copy -- Not for ResaleVALVE - REAR AUXILIARY 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

28 SENSOR – CHARGE PRESSURE – Fan Filter SOLENOID ACTIVATED DIRECTIONAL 29 CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 30 FLOW DIVIDER ADJUSTMENT VALVE PILOTED ACTIVATED DIRECTIONAL 31 CONTROL VALVE - FLOW CONTROL SPOOL CHECK VALVE - BUCKET POSITION 32 VALVE 33 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL 34 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH 35

FILTER - BOB-TACH VALVE

36

RESTRICTION - 2,08 mm (0.08 in)

37

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

38

RELIEF VALVE: 8274 kPa (83 bar) (1200 psi)

50

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

51

LOAD SHUTTLE VALVE - BLEED OFF

52

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Female SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Male

49

53 54 55 56

VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa (365 bar) (5294 psi) RELIEF VALVE - CHARGE INLET: 2654 kPa (26,5 bar) (385 psi) at High Engine Idle With 60 ° C (140 ° F) Fluid

57

SERVO PISTON – Swash Plate

58

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE FILTER

59 60 61

CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring RESTRICTION – 1,5 mm (0.06 in)

68 69

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

70

HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gpm) at High Engine Idle FILTER - BRAKE

71

73

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE CHECK VALVE

74

RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)

75

DUMP VALVE – ON / OFF

76

CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi) Spring SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift

72

77 78

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Make-up

79

HIGH PRESSURE CHAMBER

80

LOW PRESSURE CHAMBER NOTE: Unless otherwise specified springs have NO significant pressure value. V-1420legend (5-21-14)

INTEGRATED COUPLER BLOCK

Male

TWO SPEED DRIVE MOTOR (OPTIONAL)

12

62

L

Male

61

63

12 Female

HIGH FLOW VALVE (OPTIONAL)

74

75

BUCKET POSITIONING VALVE (OPTIONAL)

OUT

31

HYDRAULIC CONTROL VALVE (SPOOL

D

32

33

X

30

67

66

W

9

76

C

A

REAR QUICK COUPLERS

64

10

65

10 FEMALE

MALE

Z A

6

51

B

29 B

54

60

TILT CYLINDERS

11

52 49

R

TANDEM HYDROSTATIC

8

53

BICS CONTROL VALVE

T

58

59

X

50

57

15 8

X

11

48

16

47 M

M B

A M

55

59

P in REAR AUXILIARY VALVE (OPTIONAL)

LIFT CYLINDERS

13 T

P out

Dealer Copy -- Not for Resale

55 Charge G Inlet

56

20

BOBTACH VALVE (OPTIONAL)

M

59

M

8

POWER BOBTACH CYLINDER (OPTIONAL)

B

A

14

11 39

55

7

55

18

17 2

6

42

38

X

18

IN

40

22

19

41

57

37 1

X

59 58 T

54

44 36

D

OIL COOLER

43

2

RESERVOIR (VENTED)

80 34

VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER HYDRAULIC FILTER

2-SPEED & SAPR BRAKE VALVE B1

70

72

27 B

25

PUMP SUPPLY WORKING CIRCUIT PILOT PRESSURE DRAIN / RETURN

65

71

28 B

78

A

Z C

P

79

4

69

73

21

1

5

35

68

71

3

R

23 26

64

D W

77

73

P

66 A

DR

24

67

X

DRAIN/RETURN MANIFOLD

A1 T

45

63

62

61

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH ALL OPTION S650 (S/N A3NV12445 - A3NV18826) (S/N A3NW11130 - A3NW12750)

L

TWO SPEED DRIVE MOTOR (OPTIONAL)

126 of 1311

PRINTED IN U.S.A.

(PRINTED MAY 2015) 7170813 (C)

Printable Version Click Here

Printable Version Click Here

- A3NV25735) - A3NW13963) (PRINTED JULY 2017) V-1471legend

LEGEND 1

2 3 4 5 6 7

8 9

10 11 12 13 14

15

RESERVOIR: Capacity at sight gauge . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . 41,6 L (11.0 U.S. gal) SIGHT GUAGE DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER) SPRING LOADED FILTER BY-PASS VALVE: 172 kPa 1,7 bar (25 psi) DIAGNOSTIC COUPLER RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers NOTE - If Equipped With Ref. 81: 25855 kPa (258 bar) (3750 psi) 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

CHECK VALVE - With 1379 kPa (13,8 bar) (200 psi) Spring

63

41

RELIEF VALVE: 13790 kPa (137 bar) (2000 psi)

64

42

CHECK VALVE - With 2068 kPa (20,7 bar) (300 psi) Spring And With 0,33 mm (0.013 in) Orifice

DRIVE MOTOR SHUTTLE VALVE FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR

65

HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR)

39

21 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS 22 RIDE CONTROL VALVE 23 ANTICAVITATION VALVE

43

RESTRICTION - 0,51 mm (0.020 in)

24 PROPORTIONAL RELIEF VALVE – (Fan Speed Regulator): 10797-12300 kPa (108 - 123 bar) (1566 - 1784 psi)

44

RESTRICTION - 0,51 mm (0.020 in)

66

HIGH PRESSURE SHUTTLE With INNER MAKE-UP SPOOL

45

SENSOR – HYD. TEMPERATURE

67

25 SPRING LOADED FILTER BY-PASS VALVE: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)

46

NOT USED FOR THIS MODEL

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR – 2 Speed HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle

26 FIXED CAPACITY DISPLACEMENT HYDRAULIC MOTOR 27 FILTER - HYDRAULIC (CANISTER)

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY Dealer Copy -- Not for Resale 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

28 SENSOR – CHARGE PRESSURE – Fan Filter SOLENOID ACTIVATED DIRECTIONAL 29 CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 30 FLOW DIVIDER ADJUSTMENT VALVE

FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE ANTICAVITATION VALVE

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL CHECK VALVE - BUCKET POSITION 32 VALVE

LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP

33 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 16 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 17 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL 18 FILTER - BICS CONTROL VALVE (SCREEN) 19 CHECK VALVE - With 100 kPa 1,0 bar (14.5 psi) Spring Printed in U.S.A.

62

40

CHECK VALVE - With 552 kPa (5,5 bar) (80 psi) Spring SHUTTLE VALVE

20 RESTRICTION . . . . . . . 2,0 mm (0.079 in)

31

47

50

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

51

LOAD SHUTTLE VALVE - BLEED OFF

52

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Female SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Male VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP

49

53 54 55 56

34 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH 35

FILTER - BOB-TACH VALVE

36

RESTRICTION - 2,08 mm (0.08 in)

57

37

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)

58

38

RELIEF VALVE: 8274 kPa (83 bar) (1200 psi)

59 60 61

127 of 1311

68 69

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle

70

HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gpm) at High Engine Idle FILTER - BRAKE

71

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 36500 kPa(365 bar) (5294 psi) RELIEF VALVE - CHARGE INLET: (S/N A3NV11001 – A3NV23845) and (S/N A3NW11001 – A3NW13328) 2654 kPa (26,5 bar) (385 psi) (S/N A3NV23846 & ABOVE), (S/N A3NW13329 & ABOVE) and (S/N 1MLS11001 & ABOVE) 3413 kPa (34,1 bar) (495 psi) SERVO PISTON – Swash Plate SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE FILTER CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) (50 psi) Spring RESTRICTION – 1,5 mm (0.06 in)

73

SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE NOT USED ON THIS MODEL

74

RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)

75

DUMP VALVE – ON / OFF

76

CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi) Spring SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift

72

77 78

NOT USED ON THIS MODEL

79

HIGH PRESSURE CHAMBER

80

LOW PRESSURE CHAMBER

81

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi) (If Equipped) NOTE: Unless otherwise specified springs have NO significant pressure value. V-1471legend (5-21-14)

INTEGRATED COUPLER BLOCK

Male

12 TWO SPEED DRIVE MOTOR (OPTIONAL)

62 Male

L

63

61 OUT

12 Female

HYDRAULIC CONTROL VALVE (SPOOL HIGH FLOW VALVE (OPTIONAL)

74

BUCKET POSITIONING VALVE (OPTIONAL)

75

31

D

32

33

9

X

30

60

9

76 67

C

A

REAR QUICK COUPLERS

10 10

65

FEMALE

Z

MALE

64 A

6

51

B

29

53

B

52 54

TILT CYLINDERS

60

81 8

49

R

TANDEM HYDROSTATIC

11

BICS CONTROL VALVE

T

58

59

X

50 8

15

57 X

11

48

47 M

M B

A M

59

P in REAR AUXILIARY VALVE (OPTIONAL)

Charge Inlet

56

B

20

BOBTACH VALVE (OPTIONAL)

M

59

M

8

POWER BOBTACH CYLINDER (OPTIONAL)

G A

11 IN

40

55

7

6

42

38

X

41

57

22

14

39

55

LIFT CYLINDERS

Dealer Copy -- Not for Resale

55

55

16

13 T

P out

18 17 2

18

19

37 1

X

59

58 T

54

44 36

D

OIL COOLER

43

3

2 5

35

68

RESERVOIR (VENTED)

37 80

R

79

1

34

4

69

VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER HYDRAULIC FILTER

70

27

25

65

2-SPEED & SAPR BRAKE VALVE

28

71

A

B

B1

72

Z B

71

23

26

64 P

77

P

DR

24

Printable Version Click Here

67

60 A

PUMP SUPPLY WORKING CIRCUIT PILOT PRESSURE DRAIN / RETURN

X

DRAIN/RETURN MANIFOLD

A1 T

45 62

63

61

L

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH ALL OPTION S650 (S/N A3NV18827 - A3NV25735) (S/N A3NW12751 - A3NW13963) (S/N 1MLS11001 AND ABOVE) (PRINTED MAY 2018)

TWO SPEED DRIVE MOTOR (OPTIONAL)

7170813 (G)

128 of 1311

PRINTED IN U.S.A.

Printable Version Click Here

(PRINTED JULY 2017) V-1643legend

LEGEND 1

RESERVOIR: Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) System Capacity . . . . . . . 41,6 L (11.0 U.S. gal)

19

2

SIGHT GUAGE

20

3

DIFFERENTIAL PRESSURE SWITCH: 103 kPa (1,03 bar) (15 psi) Normally Closed FILTER - HYDRAULIC (CANISTER)

4 5 6 7

8 9

10

SPRING LOADED FILTER BY-PASS VALVE: 172 kPa (1,7 bar) (25 psi) DIAGNOSTIC COUPLER RELIEF VALVE - MAIN: 24132 kPa (241 bar) (3500 psi) at Front Quick Couplers NOTE - If Equipped With Ref. 21: 25855 kPa (258 bar) (3750 psi) 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 14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL 16 FILTER - BICS CONTROL VALVE (SCREEN) 17 CHECK VALVE - With 100 kPa (1,0 bar) (14.5 psi) Spring 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) Printed in U.S.A. 129 of 1311

21 22 23

24 25

CHARGE PUMP 51,1 L/min (13.5 U.S. gpm) at High Engine Idle 40 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min (23.0 U.S. gpm) at High Engine Idle LIFT CYLINDER SPOOL - MADE TO 41 VARIABLE CAPACITY DISPLACEMENT RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP DOWN BUT NOT DURING BOOM UP 42 RELIEF/REPLENISHING VALVE - HIGH RELIEF VALVE - 24132 kPa (241 bar) PRESSURE: 36500 kPa (365 bar) (5294 psi) (3500 psi) (If Equipped) 43 RELIEF VALVE - CHARGE INLET: ANTICAVITATION VALVE 3413 +/- 172 kPa (34,1 +/- 1,7 bar) (495 +/- 25 psi) at High Engine Idle PROPORTIONAL RELIEF VALVE – With 60 ° C (140 ° F) Fluid (Fan Speed Regulator): 10797 – 12300 kPa (108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER BY-PASS With 345 kPa (3,45 bar) SPRING LOADED FILTER BY-PASS VALVE: (50 psi) Spring Dealer Copy -- Not for Resale 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 45 SERVO PISTON SWASH PLATE FIXED CAPACITY DISPLACEMENT PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS

HYDRAULIC MOTOR 26 FILTER - HYDRAULIC (CANISTER) 27 SENSOR – CHARGE PRESSURE – Fan Filter 28 SENSOR – HYD. TEMPERATURE 29

RESTRICTION - 1,7 mm (0.067 in)

30

CHECK VALVE - With 1379 kPa 13,8 bar (200 psi) Spring DRIVE MOTOR SHUTTLE VALVE

31 32 33 34 35 36 37 38

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR HYDRAULIC BRAKE – SPRING APPLIED – PRESSURE RELEASE (SAPR) SOLENOID ACTIVATED DIRECECTIONAL CONTROL VALVE – BRAKE FILTER – BRAKE VALVE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – 2 Speed Shift

39

46 47

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Forward / Reverse FILTER

50

FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – HYDRAULIC POWERED BOB-TACH With Build-up Valve: 276 kPa (2,76 bar) (40 psi) FILTER - BOB-TACH VALVE

51

RESTRICTION - 1,17 mm (0.46 in)

52

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option

48 49

53 54

ACCUMULATOR – Ride Control Option

55

ORIFICE With Check Valve: 2,54 mm (0.10 in)

56

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

57

RESTRICTION - 0,254 mm (0.010 in)

58

CHECK VALVE

59

ORIFICE: 1,6 mm (0.063 in)

60 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 61 FLOW DIVIDER ADJUSTMENT VALVE 62 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 63 CHECK VALVE - BUCKET POSITION VALVE 64 65

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE – UNLOADING SPOOL HIGH FLOW HYDRAULIC PUMP Gear Type 28,4 L/min (7.5 U.S. gal) at High Engine Idle

66

RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)

67

DUMP VALVE – ON / OFF

68

CHECK VALVE - With 34,5 kPa (0,34 bar) (5.0 psi) Spring

69

PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY

70

RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)

71 72

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL RESTRICTOR - 0,8 mm (0.031 in)

73

LOAD SHUTTLE VALVE - BLEED OFF

74 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 75 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD 76

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Reversing Fan Option

NOTE: Unless otherwise specified springs have NO significant pressure value. V-1643legend (7-25-17)

INTEGRATED COUPLER BLOCK

DRIVE MOTOR

Male L

30

48

29

31

Male

OUT

68

HYDRAULIC CONTROL VALVE

48 Female X RIDE CONTROL (OPTION)

54

9 T2

ACC

55

T

32 59

9

33

34 FEMALE

REAR QUICK COUPLERS

10

MALE

35

NOTE: CUSHIONED LIFT CYLINDERS ON LATER MODELS ONLY

P

10

LIFT CYLINDERS

53

Z

Auxiliary Spool A

73

B

CR2

75

CR

CB

CB2

21

74 6

71

HYDROSTATIC PUMP

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

11

8

R

41

TILT BASE

T E1

46 47

X

TILT ROD

72

E2

A1

Tilt Spool

8 13

X

70 11

36

14

69

A

M T

M B

A M

43

47

P in

REAR AUXILIARY VALVE (OPTION)

63

60

LIFT ROD

38 B

61

B

45

42

2-SPEED & SAPR BRAKE VALVE (OPTIONAL)

P out

D2

12

T

62 LIFT BASE

Lift Spool

42 POWER BOBTACH CYLINDER (OPTIONAL)

Dealer Copy -- Not for Resale

8

64

G P

A2

E3

B

A

M

B1

56

58

11

15

37 IN

7 42

42

BUCKET POSITIONING VALVE (OPTIONAL)

18

2

16

6

52

X

D1

16

20

47

M

C2

C1

POWER BOBTACH VALVE (OPTIONAL)

17

57 45

TILT CYLINDERS 1

46

X

47

41

Oil Cooler

D

19

51

44

50 T

5

2

RESERVOIR (VENTED)

1

R

40

49

39 VARIABLE SPEED HYDRAULIC FAN MOTOR W/ INTEGRATED FILTER

3

4

HYDRAULIC FILTER

65 66

27

67 26

24 WORKING CIRCUIT

1 B

35

22

4

CHARGE PRESSURE DRAIN / RETURN

A

3

2

25 76 Z

33

DR

34

23

P

32

Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC SJC WITH ALL OPTION S650 (S/N A3NV25736 AND ABOVE) (S/N A3NW13964 AND ABOVE)

X

28

30

29

31 L

DRIVE MOTOR

130 of 1311

PRINTED IN U.S.A.

DRAIN / RETURN MANIFOLD

(PRINTED MAY 2018) 7170813 K)

HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic / Hydrostatic Symbols SYMBOL DESCRIPTION

SYMBOL

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). CONNECTED JUNCTION OF OIL LINES (Flow Line Connection).

OIL LINES Connected).

CROSSING

(NOT

COUPLER - Quick - Acting Coupling (uncoupled, closed by non-return valve).

TEMPERATURE CONTROL (Indication of temperature).

-

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). OIL COOLER (heat exchanger) - The arrows in the diamond indicate the extraction of heat (heat dissipation). PRESSURE SENSOR electric signal with pressure.

Varies

DIFFERENTIAL PRESSURE SWITCH - Switch activates when pressure difference reaches specified level. PRESSURE SWITCH - Switch activates when pressure reaches specified level. MUFFLER noise.

131 of 1311

20-10-1

(silencer)

-

Reduces

S650 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).

132 of 1311

20-10-2

S650 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.

133 of 1311

20-10-3

S650 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).

134 of 1311

20-10-4

S650 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 Arm Bypass Control valve stuck.

12

Lift Arm Bypass Control valve stem bent or broke.

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 SPEC40-1.) 8. Exceeding the loader’s 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.

135 of 1311

20-10-5

S650 Service Manual

Dealer Copy -- Not for Resale 136 of 1311

20-10-6

S650 Service Manual

CYLINDER (LIFT)

Figure 20-20-2

Testing Lower the lift arms. Stop the engine. Raise the seat bar. 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.

2

P-90617

W-2145-0290

Install a cap (Item 1) [Figure 20-20-2] on the hose and tighten.

Figure 20-20-1

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

P-90616

Test only one cylinder at a time. Disconnect the hose (Item 1) [Figure 20-20-1] which goes to the base end of the cylinder.

137 of 1311

20-20-1

S650 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) Removal And Installation

WARNING

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) NOTE: Remove only one cylinder at a time.

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

Figure 20-20-4 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

2

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

2 P-90824

Cap and plug both fittings on the cylinder (Item 1) [Figure 20-20-4].

Figure 20-20-3 NOTE: Do not cap or plug the two hydraulic hoses (Item 2) [Figure 20-20-4]. Place the hoses (Item 2) [Figure 20-20-4] in a suitable container to collect the hydraulic fluid as the lift arms are raised. Recycle or dispose of used fluid in an environmentally safe manner.

1

WARNING P-90616

Mark and disconnect the two hydraulic hoses (Item 1) [Figure 20-20-3].

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. W-2072-0807

138 of 1311

20-20-2

S650 Service Manual

Dealer Copy -- Not for Resale

1

CYLINDER (LIFT) (CONT'D) Removal And Installation (Cont’d) Figure 20-20-5

1

2

P-90602A

Dealer Copy -- Not for Resale

Remove the retaining bolt and nut (Item 1) [Figure 2020-5] from the pin (Item 2) on the rod end of the cylinder. Installation: Tighten the retainer bolt and nut to 48 - 54 N•m (35 - 40 ft-lb) torque. Figure 20-20-6

1

P-90611

With a slide hammer, remove the pin (Item 1) [Figure 2020-6] from the rod end of the cylinder.

139 of 1311

20-20-3

S650 Service Manual

CYLINDER (LIFT) (CONT'D)

Figure 20-20-7

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 in the middle of the Bob-Tach as shown in (Item 1) [Figure 20-20-7]. 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

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-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.

140 of 1311

20-20-4

S650 Service Manual

Dealer Copy -- Not for Resale

•

Figure 20-20-11

CYLINDER (LIFT) (CONT'D) Removal And Installation (Cont’d) Open the rear door.

1

NOTE: When removing the left side lift cylinder the battery will need to be removed to gain access to the lower retaining bolt and nut. Remove the battery (if required). (See Removal And Installation on Page 60-20-1.) Figure 20-20-9

P-90827

1 With a slide hammer, remove the pin (Item 1) [Figure 2020-11] from the base end of the lift cylinder.

1

P-90834

Remove the retaining bolt and nut (Item 1) [Figure 2020-9] from the pin on the base end of the lift cylinder. 1

Installation: Tighten the retainer bolt and nut to 48 - 54 N•m (35 - 40 ft-lb) torque. Figure 20-20-10

P-90823

Using a chain hoist remove the lift cylinder (Item 1) [Figure 20-20-12] from the loader.

1

P-90825

Remove the grease fitting (Item 1) [Figure 20-20-10] from the base end of the lift cylinder. Installation: Tighten the grease fitting to 20 N•m (15 ftlb) torque.

141 of 1311

20-20-5

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-20-12

CYLINDER (LIFT) (CONT'D) Parts Identification Seal Hydraulic Tubeline Cylinder Case Tube Plug Clamp Nut Back-up Ring O-ring Piston Assembly Spacer O-ring Head Rod Seal Wiper Seal Rod Grease Fitting

4

3 4

5

6 7

Dealer Copy -- Not for Resale

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

8 2

9 10

1 8 12 13 14

8 7 15 16

NA1413S

142 of 1311

20-20-6

S650 Service Manual

CYLINDER (LIFT) (CONT'D)

Figure 20-20-15

Disassembly 2

Use the following tools to disassemble the cylinder: MEL1074 - O-ring Seal Hook Spanner Wrench

1

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 Figure 20-20-13 P-48038

1

NOTE: If the fiber surface (Item 3) [Figure 20-20-15] on the piston, becomes damaged, the complete piston must be replaced. Figure 20-20-16 1 P-48033

Use a spanner wrench to loosen the head (Item 1) [Figure 20-20-13] from the cylinder case. 3

Figure 20-20-14

2

4 3

2

P-48039

1 Remove the O-ring (Item 1). Remove the O-ring (Item 2) and the back-up ring (Item 3) [Figure 20-20-16] from the cylinder head. NOTE: The O-ring (Item 2) and back-up ring (Item 3) [Figure 20-20-16] are no longer available parts. The seal kit will contain a one piece seal that is used in place of the O-ring and back-up ring.

P-48036

Remove the nut (Item 1), piston (Item 2), spacer (Item 3) and head (Item 4) [Figure 20-20-14].

143 of 1311

20-20-7

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the back-up ring (Item 1) and O-ring (Item 2) [Figure 20-20-15] from the piston.

CYLINDER (LIFT) (CONT'D) Disassembly (Cont'd) Figure 20-20-17

1

P-48040

Dealer Copy -- Not for Resale

Remove the wiper seal (Item 1) [Figure 20-20-17] from the cylinder head. Figure 20-20-18

1

P-48042

Remove the rod seal (Item 1) [Figure 20-20-18] from the cylinder head.

144 of 1311

20-20-8

S650 Service Manual

CYLINDER (LIFT) (CONT'D)

Figure 20-20-20

Assembly Use the following tools to assemble the cylinder:

1 2

MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during installation.

Install the O-ring (Item 1) and seal (Item 2) [Figure 2020-20] on the cylinder piston.

Figure 20-20-19

Figure 20-20-21

1

P-48043

P7424

Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-20-19]. Allow the seal to stretch for 30 seconds before installing it on the piston.

P7427

Install the rod seal on the rod seal tool [Figure 20-20-21]. NOTE: During installation the spring side of the seal (Item 1) [Figure 20-20-21] must be installed toward the inside of the cylinder. Rotate the handles to collapse the rod seal [Figure 2020-21].

145 of 1311

20-20-9

S650 Service Manual

Dealer Copy -- Not for Resale

P-48038

Always install new O-rings and seals during assembly.

CYLINDER (LIFT) (CONT'D)

Figure 20-20-24

Assembly (Cont'd) Figure 20-20-22 1

2

P101716

Install the O-ring (Item 1) and the seal (Item 2) [Figure 20-20-24] on the cylinder head.

P7425

Figure 20-20-25 Figure 20-20-23 1

2

3 4

2

1

P-48036

P-48041

P-48042

Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2023].

NOTE: Clean and dry the rod threads. Install a NEW NUT with preapplied Loctite® included in the seal kit or if a new nut is no available use Loctite® #242 on threads. Install the head (Item 1), spacer (Item 2) piston (Item 3), and nut (Item 4) [Figure 20-20-25]. Tighten the nut (Item 4) [Figure 20-20-25] to 1491 N•m (1100 ft-lb) torque.

146 of 1311

20-20-10

S650 Service Manual

Dealer Copy -- Not for Resale

Install the rod seal in the head [Figure 20-20-22].

CYLINDER (LIFT) (CONT'D) Assembly (Cont'd) Figure 20-20-26

1

P-48035

Dealer Copy -- Not for Resale

Put the base end of the hydraulic cylinder in a vise. Using a spanner wrench, tighten the head (Item 1) [Figure 20-20-26] to 373 N•m (275 ft-lb) torque.

147 of 1311

20-20-11

S650 Service Manual

Dealer Copy -- Not for Resale 148 of 1311

20-20-12

S650 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.

2

1

Figure 20-21-1

1

P85852

Install a cap (Item 1) [Figure 20-21-2] in the hydraulic hose and tighten.

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.

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.

Repeat procedure to test the other cylinder.

W-2145-0290

Disconnect the hose (Item 1) [Figure 20-21-1] which goes to the base end of the cylinder.

149 of 1311

20-21-1

S650 Service Manual

Dealer Copy -- Not for Resale

Engage the parking brake. Lower the seat bar. Start the engine and press the PTOL button.

P-85553

CYLINDER (TILT) (CONT'D)

Figure 20-21-5

Removal And Installation Figure 20-21-3 3

2

1

1 P-85562

Disconnect the two hydraulic hoses (Items 1 and 2) [Figure 20-21-5] from the cylinder.

P-85554

Cap the hoses and plug the fittings on the cylinder. Figure 20-21-6

Dealer Copy -- Not for Resale

Remove the attachment from the Bob-Tach. Roll the BobTach forward Stop the engine. Raise the seat bar. Remove the retainer bolt and nut (Item 1) [Figure 20-213] from the rod end pivot pin.

1 Installation: Tighten the retainer nut to 48 - 54 N•m (35 40 ft-lb) torque. Figure 20-21-4 1

P-85648

Remove the base end pivot bolt and washer (Item 3) [Figure 20-21-5]. Remove the retainer nut and washer (Item 1) [Figure 2021-6] from the base end pivot pin.

P-85649

Installation: Tighten the retainer nut to 257,6 N•m (190 ft-lb) torque.

Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

150 of 1311

20-21-2

S650 Service Manual

CYLINDER (TILT) (CONT'D) Removal And Installation (Cont'd) Figure 20-21-7

P-85564

Dealer Copy -- Not for Resale

Slide the cylinder from the base pin and remove the cylinder from the loader [Figure 20-21-7].

151 of 1311

20-21-3

S650 Service Manual

CYLINDER (TILT) (CONT'D)

Figure 20-21-10

Base End Pivot Pin Removal And Installation Figure 20-21-8

P-85567

1 Inspect pivot pin and replace as needed [Figure 20-2110].

P-85565

Dealer Copy -- Not for Resale

Figure 20-21-9

1

P-85566

Remove the tilt cylinder from the cylinder base pin (Item 1) [Figure 20-21-8]. (See Removal And Installation on Page 20-21-2.) Use a 22,2 mm (7/8 in) shaft (Item 1) [Figure 20-21-9] and a hammer to remove the cylinder base pin from the lift arms.

152 of 1311

20-21-4

S650 Service Manual

CYLINDER (TILT) (CONT'D) Parts Identification (Earlier Models) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Tubeline Case Plug O-ring Grease Fitting Clamp Nut Seal Piston Head Wiper Rod Bushing

5

6

2

4 3

Dealer Copy -- Not for Resale

7 8 1 9

4 3 8 4 10 8 11 12

13

5

NA2481S

153 of 1311

20-21-5

S650 Service Manual

CYLINDER (TILT) (CONT'D) Parts Identification (Later Models) Tubeline Case Plug O-ring Grease Fitting Clamp Nut Seal Piston Collar Head Wiper Rod Bushing

5

6

2

4 3

7

Dealer Copy -- Not for Resale

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

8 1

9 4 3

10

8 4 11 8 12

13

14

5

NA8189S

154 of 1311

20-21-6

S650 Service Manual

CYLINDER (TILT) (CONT'D)

Figure 20-21-13

Disassembly

EARLIER MODELS

3

Use the following tools to disassemble the cylinder:

2

MEL1074 - O-ring Seal Hook MEL1075 - Adjustable Gland Nut Wrench

1

Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Put the base end of the cylinder in a vise. Figure 20-21-11 P-48071

Remove the nut (Item 1), piston (Item 2) and head (Item 3) [Figure 20-21-13]. 1

Figure 20-21-14 2

4

LATER MODELS

P-85651B

1 Remove the bushing (Item 1) [Figure 20-21-11] with a driver tool and hammer.

3

An identifying mark (Item 2) [Figure 20-21-11] on the rod end indicates a later model cylinder.

P109554

Figure 20-21-12 Remove the nut (Item 1), piston (Item 2), collar (Item 3) and head (Item 4) [Figure 20-21-14]. 1

P106021

Use an Adjustable Gland Nut Wrench to loosen the head (Item 1) [Figure 20-21-12] from the cylinder case.

155 of 1311

20-21-7

S650 Service Manual

Dealer Copy -- Not for Resale

2

CYLINDER (TILT) (CONT'D)

Figure 20-21-17

Disassembly (Cont'd) 1 Figure 20-21-15 Earlier Models 2

1

P109556

Remove the O-ring (Item 1) and the seal (Item 2) [Figure 20-21-17] from the cylinder head. P-48073B

Figure 20-21-18

Later Models 1 1

P-48040 P109555

Remove the seal (Item 1) [Figure 20-21-15] and [Figure 20-21-16] from the piston.

Remove the wiper seal (Item 1) [Figure 20-21-18] from the cylinder head. Figure 20-21-19

1

P-48042

Remove the rod seal (Item 1) [Figure 20-21-19] from the cylinder head.

156 of 1311

20-21-8

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-21-16

CYLINDER (TILT) (CONT'D)

Figure 20-21-21 Earlier Models

Assembly Use the following tools to assemble the cylinder:

1

MEL1396-1 - Universal Seal Expander MEL1033 - Rod Seal Installation Tool MEL1396-2 - Piston Ring Compressor MEL1075 - Adjustable Gland Nut Wrench Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts.

P-48073B

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

Figure 20-21-22 Later Models

Figure 20-21-20

P109555

Install the seal (Item 1) [Figure 20-21-21] and [Figure 20-21-22] on the cylinder piston.

P7424

Figure 20-21-23 Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-21-20]. Allow the seal to stretch for 30 seconds before installing it on the piston.

N-22358

Use a ring compressor to compress the seal to the correct size. Leave the piston in the compressor for approximately three minutes [Figure 20-21-23].

157 of 1311

20-21-9

S650 Service Manual

Dealer Copy -- Not for Resale

1

CYLINDER (TILT) (CONT'D)

Figure 20-21-26

Assembly (Cont'd) Figure 20-21-24

2

1 1

P-48041

Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2126].

P7427

Install the rod seal on the rod seal tool [Figure 20-21-24].

Figure 20-21-27

NOTE: During installation the spring side of the seal (Item 1) [Figure 20-21-24] must be installed toward the inside of the cylinder.

1

Dealer Copy -- Not for Resale

P-48043

P-48042

2

Rotate the handles to collapse the rod seal [Figure 2021-24]. Figure 20-21-25

P109556

Install the O-ring (Item 1) and seal (Item 2) [Figure 2021-27] on the cylinder head.

P7425

Install the rod seal in the head [Figure 20-21-25].

158 of 1311

20-21-10

S650 Service Manual

NOTE: Clean and dry the rod threads. Install a NEW NUT with preapplied Loctite® included in the seal kit or if a new nut is not available use Loctite® #242 on threads.

CYLINDER (TILT) (CONT'D) Assembly (Cont'd) Figure 20-21-28

Tighten the nut (Item 4) [Figure 20-21-29] to 1491 N•m (1100 ft-lb) torque.

Earlier Models

1

Put the base end of the hydraulic cylinder in a vise.

2

Figure 20-21-30

3

1

P-48071

NOTE: Clean and dry the rod threads. Install a NEW NUT with preapplied Loctite® included in the seal kit or if a new nut is not available use Loctite® #242 on threads. Tighten the nut (Item 3) [Figure 20-21-28] to 1152 N•m (850 ft-lb) torque.

P106021

Using an Adjustable Gland Nut Wrench, lightly lubricate with grease and tighten the head (Item 1) [Figure 20-2130] to 373 N•m (275 ft-lb) torque. Figure 20-21-31

Figure 20-21-29 3

1

Later Models

1

4 2

P-85651B P109554

NOTE: Lube chamfer on shaft with oil or grease before installing the collar.

Install the bushing (Item 1) [Figure 20-21-31] using a driver tool and hammer.

Install the head (Item 1), collar (Item 2), piston (Item 3) and nut (Item 4) [Figure 20-21-29].

159 of 1311

20-21-11

S650 Service Manual

Dealer Copy -- Not for Resale

Install the head (Item 1), piston (Item 2) and nut (Item 3) [Figure 20-21-28].

Dealer Copy -- Not for Resale 160 of 1311

20-21-12

S650 Service Manual

Figure 20-22-2

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.

P-85570

W-2072-0807

Disconnect the hose (Item 1) [Figure 20-22-2] from the Power Bob-Tach 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 20-22-1

P-85568

Install a plug in the hose (Item 1) [Figure 20-22-3] 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).

P-85570

Tilt the Bob-Tach forward, so it is parallel to the floor [Figure 20-22-1].

If there is any leakage from the base end cylinder port (Item 2) [Figure 20-22-3], remove the cylinder for repair.

Push and hold BOB-TACH “WEDGES UP” switch until levers are in the unlocked position (Wedges fully raised).

161 of 1311

20-22-1

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-22-3

CYLINDER (BOB-TACH) (CONT'D) Removal And Installation Figure 20-22-4

1

P-85570

Dealer Copy -- Not for Resale

Disconnect the hoses from the rod and base end cylinder fitting (Item 1) [Figure 20-22-4]. Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 24 ft-lb) torque. Install plugs in the hoses and cap on fittings. Figure 20-22-5

1

1

P-85569

Remove the bolts and washers (Item 1) [Figure 20-22-5]. Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ftlb) torque. Remove the cylinder from the lever pivots.

162 of 1311

20-22-2

S650 Service Manual

CYLINDER (BOB-TACH) (CONT'D) Parts Identification 1. Tube 2. Nut 3. Piston 4. O-ring 5. Seal 6. Spacer 7. Back-up Ring 8. Head 9. Wiper 10. Rod 1

2

Dealer Copy -- Not for Resale

3 4 5 6

5 4 8 5 9 4 7 10

PE3954S

163 of 1311

20-22-3

S650 Service Manual

CYLINDER (BOB-TACH) (CONT'D)

Figure 20-22-8

Disassembly

3

2

1

Figure 20-22-6

P16295

Piston: Remove the O-ring (Item 1), and seal (Item 2) from the piston (Item 3) [Figure 20-22-8].

P-85647

Figure 20-22-9 MEL1074 - O-ring Seal Hook Spanner Wrench

4

Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder.

2 1

Put the base end of the cylinder in a vise. Use a spanner wrench to loosen the head [Figure 20-226].

3

5

Figure 20-22-7 4

3

N-20611

2 1

Remove the wiper seal (Item 1), and rod seal (Item 2), the back-up ring (Item 3), the O-ring (Item 4), and the Oring (Item 5) [Figure 20-22-9] from the head. NOTE: The O-ring (Item 5) and back-up ring (Item 3) [Figure 20-22-9] are no longer available parts. The seal kit will contain a one piece seal that is used in place of the O-ring and back-up ring.

P16294

Remove the head and rod assembly from the cylinder [Figure 20-22-7]. Put the rod end in a vise. Remove the nut (Item 1), piston (Item 2), spacer (Item 3), and head (Item 4) [Figure 20-22-7] from the rod.

164 of 1311

20-22-4

S650 Service Manual

Dealer Copy -- Not for Resale

Use the following tools to disassemble the cylinder:

CYLINDER (BOB-TACH) (CONT'D)

Figure 20-22-11

Assembly

1

3

2

Use the following tools to assembly the cylinder: MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Wash the cylinder parts in solvent and air dry them.

4

Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during installation.

Piston: Install the O-ring (Item 1) and seal (Item 2) on the piston (Item 3) [Figure 20-22-11].

Figure 20-22-10

NOTE: The piston center hole (Item 4) [Figure 20-2211] has a bevel on one end. The bevel goes toward the rod. Figure 20-22-12

P7424

Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-22-10]. Allow the seal to stretch for 30 seconds before installing it on the piston.

N-20612

Install the rod seal on the rod seal tool [Figure 20-22-12]. NOTE: During installation the spring side of the seal must be toward the inside of the cylinder.

165 of 1311

20-22-5

S650 Service Manual

Dealer Copy -- Not for Resale

P16295

Always install new O-rings and seals during assembly.

CYLINDER (BOB-TACH) (CONT'D)

Figure 20-22-15

Assembly (Cont'd)

2 1

Figure 20-22-13

P106031

Install the back-up ring (Item 1) [Figure 20-22-15]. N-20613

Rotate the handles to collapse the rod seal [Figure 2022-13]. Figure 20-22-14

NOTE: Clean and dry the rod threads. Install a NEW NUT with preapplied Loctite® included in the seal kit or if a new nut is not available use Loctite® #242 on threads. Figure 20-22-16

1

2

3

4

P7425

Install the rod seal in the head [Figure 20-22-14].

P16294

Install the wiper seal with the wiper toward the outside of the head.

Install the head (Item 1), and spacer (Item 2) [Figure 2022-16]. Install the piston (Item 3) [Figure 20-22-16]. Grease the piston where the nut contacts the piston. do not get grease on the threads. Install the new nut (Item 4) [Figure 20-22-16]. Tighten the nut to 190 N•m (140 ft-lb) torque.

166 of 1311

20-22-6

S650 Service Manual

Dealer Copy -- Not for Resale

Install the O-ring (Item 2) [Figure 20-22-15] into the groove on the head.

CYLINDER (BOB-TACH) (CONT'D) Assembly (Cont'd) Figure 20-22-17

P-85647

Dealer Copy -- Not for Resale

Put the base end of the hydraulic cylinder in a vise. Tighten the head using a spanner wrench [Figure 20-2217] to 183 N•m (135 ft-lb) torque.

167 of 1311

20-22-7

S650 Service Manual

Dealer Copy -- Not for Resale 168 of 1311

20-22-8

S650 Service Manual

MAIN RELIEF VALVE (EARLIER MODELS) 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.

169 of 1311

20-30-1

S650 Service Manual

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D)

Figure 20-30-1

Testing 1

2

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. 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

Figure 20-30-2

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

2

The tools listed will be needed to do the following procedure:

1 TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) FLOW METER MEL10006 - Hydraulic Test Kit NA3267

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.

Start the engine and run at low idle. •

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

Press the AUXILIARY HYDRAULICS Button (Item 1) [Figure 20-30-2] once to engage the auxiliary hydraulics.

NOTE: The light (Item 2) [Figure 20-30-2] will be on.

170 of 1311

20-30-2

S650 Service Manual

Dealer Copy -- Not for Resale

P-85571

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D)

Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full rpm.

Testing (Cont’d) Refer to (See Hydraulic System on Page SPEC-10-4.) for both flow and pressure specifications of the hydraulic system.

Figure 20-30-3 Right Steering Lever Control

Test the free flow specification. With the engine at high idle and hydraulic fluid at 60°C (140°F) turn the restrictor control on the tester until the flow through the tester drops to zero. Test the relief pressure. If the relief pressure is not correct, stop the engine and adjust the main relief valve.

1

P-85572

Dealer Copy -- Not for Resale

Figure 20-30-4 Joystick Option Only

1

Right Steering Lever Control

P-26697

•

Push the front switch (Item 1) [Figure 20-30-3] and [Figure 20-30-4] to give the front quick couplers a constant flow of fluid.

•

To release from continuous operation, press the front switch (Item 1) [Figure 20-30-3] and [Figure 20-304] a second time.

171 of 1311

20-30-3

S650 Service Manual

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D) Adjusting NOTE: This procedure is for standard loaders, loaders equipped with ACS option and loaders equipped with SJC option. The main relief valve is located in the same place on all of the loaders. Figure 20-30-5

1

Dealer Copy -- Not for Resale

2

P-85573

If the pressure is not correct, adjust the main relief valve. 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. NOTE: If the correct pressure can not be reached, replace the main relief valve. Test the pressure setting of the new relief valve.

172 of 1311

20-30-4

S650 Service Manual

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D)

Figure 20-30-7

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.

1

I-2003-0888 P-37689

Raise the operator cab. (See Raising on Page 10-30-2.) Remove the O-rings and back-up rings (Item 1) [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 and tighten [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 pressure again. (See Testing on Page 20-30-2.) 1

P-85573

The main relief valve (Item 1) [Figure 20-30-6] is located at the lower front of the control valve below the lift and tilt spool connections. Loosen and remove the main relief valve (Item 1) [Figure 20-30-6].

173 of 1311

20-30-5

S650 Service Manual

Dealer Copy -- Not for Resale

Clean the area around the control valve.

Dealer Copy -- Not for Resale 174 of 1311

20-30-6

S650 Service Manual

MAIN RELIEF VALVE (LATER MODELS) Description The main relief valve and the optional auxiliary relief valve (if equipped) limit 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.) Figure 20-31-1

2

Dealer Copy -- Not for Resale

1 P107749A

The relief valves are adjustable and located on the hydraulic control valve. The main relief valve (Item 1) [Figure 20-31-1] is located below the spool linkages, facing the front of the machine. The optional auxiliary relief valve (Item 2) (if equipped) [Figure 20-31-2] is located on the top of the control valve facing the left side of the machine.

175 of 1311

20-31-1

S650 Service Manual

MAIN RELIEF VALVES (LATER MODELS) (CONT’D)

Figure 20-31-2

Testing 3

1

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.

2

W-2006-1209

The tools listed will be needed to do the following procedure:

Install the gauge (Item 1) and coupler (Item 2) to the test hose (Item 3) [Figure 20-31-2]. Raise the operator cab. (See Raising on Page 10-30-2.) Figure 20-31-3

Dealer Copy -- Not for Resale

MEL1355-3 - Pressure gauge 34474 KPa (345 bar) (5000 psi) MEL1723 - Coupler Hydraulic hose, approximately 1,5 m (5.0 ft), purchased locally. Must be rated for pressures above 34474 kPa (345 bar) (5000 psi).

P107936

NOTE: This procedure is for loaders equipped with ACS or SJC controls. The main relief valve is located in the same place on all of the loaders. 2

WARNING

1

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

P107935

Connect the test coupler (Item 1) to the control valve coupler (Item 2) [Figure 20-31-3]. Route the test gauge so it can be used in the operator cab when lowered. Make sure the hose will not interfere with any moving parts. Lower the operator cab. (See Lowering on Page 10-303.) NOTE: Do not have any attachment connected to the loader auxiliary quick couplers while testing.

176 of 1311

20-31-2

S650 Service Manual

MAIN RELIEF VALVES (LATER MODELS) (CONT’D)

Figure 20-31-4

Testing (Cont’d) Enter the loader and engage the parking brake. Start the engine. Increase the engine speed to full rpm and make sure the hydraulic fluid is at 60°C (140°F).

2 1

Testing Main Relief Pressure Without Auxiliary Relief Valve The main relief valve setting is 23,8 - 24,5 MPA (238 245 bar) (3450 - 3550 psi).

NA3172

Power loader lift arms down on the stops and monitor the test gauge for the relief pressure setting.

Testing Main Relief Pressure If Equipped With Auxiliary Relief Valve

Press the auxiliary hydraulics button (Item 1) [Figure 2031-4] to activate the auxiliary hydraulics. NOTE: The auxiliary indicator (Item 2) [Figure 20-314] will illuminate when activated. Figure 20-31-5 Right Steering Lever Control

If equipped with the optional auxiliary relief valve, the main relief setting is 25,5 - 26,2 MPA (255 - 262 bar) (3700 - 3800 psi). Power loader lift arms down on the stops and monitor the test gauge for the relief pressure setting. 1

If the relief pressure is not correct, stop the engine and adjust the relief valve. (See Main Relief Valve Adjustment on Page 20-31-4.). Testing Auxiliary Relief Pressure The auxiliary relief valve setting is 23787 - 24476 kPa (238 - 245 bar) (3450 - 3550 psi).

P107006B

Move the front auxiliary hydraulic switch (Item 1) [Figure 20-31-5] to the left or right and monitor the test gauge for the relief pressure setting. If the relief pressure is not correct, stop the engine and adjust the relief valve. (See Auxiliary Relief Valve Adjustment on Page 20-31-5.). Stop the machine and exit the loader.

177 of 1311

20-31-3

S650 Service Manual

Dealer Copy -- Not for Resale

If the relief pressure is not correct, stop the engine and adjust the relief valve. (See Main Relief Valve Adjustment on Page 20-31-4.).

MAIN RELIEF VALVES (LATER MODELS) (CONT’D)

Main Relief Valve Removal And Installation

Main Relief Valve Adjustment

IMPORTANT

Figure 20-31-6

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

2 Raise the operator cab. (See Raising on Page 10-30-2.) Clean the area around the control valve. 1

NOTE: This procedure is for loaders equipped with ACS or SJC controls. The main relief valve is located in the same place on all of the loaders.

P107744

Loosen the locknut (Item 1) [Figure 20-31-6].

Dealer Copy -- Not for Resale

Figure 20-31-7

Turn the adjustment screw (Item 2) [Figure 20-31-6] in or out until the pressure is correct. Turning the screw in will increase pressure. NOTE: If the correct pressure can not be reached, replace the main relief valve. Test the pressure setting of the new relief valve.

1

P107743

Remove the main relief valve (Item 1) [Figure 20-31-7].

178 of 1311

20-31-4

S650 Service Manual

MAIN RELIEF VALVES (LATER MODELS) (CONT’D)

Auxiliary Relief Valve Adjustment

Main Relief Valve Removal And Installation (Cont’d)

NOTE: This procedure is for loaders equipped with ACS or SJC controls. The auxiliary relief valve is located in the same place on all of the loaders.

Figure 20-31-8

Figure 20-31-9

2

1 2 1

P107745A

Remove the O-ring (Item 1) and back-up rings (Item 2) [Figure 20-31-8] from the relief valve. Clean the relief valve in clean solvent. Use air pressure to dry the valve.

Loosen the locknut (Item 1) [Figure 20-31-9].

Install a new O-ring (Item 1) and back-up ring (Item 2) [Figure 20-31-8]. Install the main relief valve and tighten.

Turn the adjustment screw (Item 2) [Figure 20-31-9] in or out until the pressure is correct. Turning the screw in will increase pressure.

Installation: Tighten the relief valve to 51 - 62 N•m (38 45 ft-lb) torque.

NOTE: If the correct pressure can not be reached, replace the auxiliary relief valve. Test the pressure setting of the new relief valve.

Test the relief valve. (See Testing on Page 20-31-2.)

179 of 1311

20-31-5

S650 Service Manual

Dealer Copy -- Not for Resale

P107747

MAIN RELIEF VALVES (LATER MODELS) (CONT’D)

Figure 20-31-11

Auxiliary Relief Valve Removal And Installation

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

I-2003-0888

P107627

Clean the area around the control valve.

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-31-11] from the auxiliary relief valve.

NOTE: This procedure is for loaders equipped with ACS or SJC controls. The auxiliary relief valve is located in the same place on all of the loaders.

Clean the relief valve in clean solvent. Use air pressure to dry the valve. Install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-31-11]. Install the relief valve and tighten.

Figure 20-31-10

Installation: Tighten the relief valve to 51 - 62 N•m (38 45 ft-lb) torque. Test the relief valve. (See Testing on Page 20-31-2.) 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.) 1

P107746

Remove the auxiliary relief valve (Item 1) [Figure 20-3110].

180 of 1311

20-31-6

S650 Service Manual

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising on Page 10-30-2.)

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) Description Figure 20-40-1

P-90327

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.

181 of 1311

20-40-1

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT’D)

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

Removal And Installation

Remove the control panel. (See Removal And Installation on Page 50-100-2.) Remove the control linkage. (See Linkage Removal And Installation on Page 50-90-2.)

DANGER

NOTE: Mark all tubelines, hoses, and electrical connections for correct installation. NOTE: Cap and plug all hydraulic connection points when tubelines or hoses are removed. Clean area around control valve.

•

•

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.

Open rear door. Figure 20-40-2

3

1

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

2

P-90187

Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and the place the fuel inlet assembly (Item 3) [Figure 20-40-2] off to the side.

IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888

Raise the lift arms and install an approved lift arm support device. (See LIFT ARM SUPPORT DEVICE on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

182 of 1311

20-40-2

S650 Service Manual

Dealer Copy -- Not for Resale

P-90328

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT’D)

Figure 20-40-5

Removal And Installation (Cont’d) Figure 20-40-3

2 1

1

P-90270

Disconnect the hose (Item 1) [Figure 20-40-5] that routes from the control valve to the brake valve. P-90267

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 20-40-3].

Disconnect the hose (Item 2) [Figure 20-40-5] that routes from the control valve to the fan motor. Figure 20-40-6

1

Figure 20-40-4 3 1

P-90271

2

Disconnect the hose (Item 1) [Figure 20-40-6] that routes from the top of the control valve to the hydraulic filter.

1 P-90269

Disconnect the wire harness connectors (Item 1) [Figure 20-40-4] from the control valve. Disconnect the hose (Item 2) [Figure 20-40-4] that routes from the control valve to the drain manifold. Disconnect the hose (Item 3) [Figure 20-40-4] that routes from the control valve to the inlet fitting of the hydraulic pump.

183 of 1311

20-40-3

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT’D)

Figure 20-40-9

Removal And Installation (Cont’d) Figure 20-40-7 1

1

2

2 1

1 P-90274

Disconnect 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.

P-90272

Disconnect the two tubelines (Item 2) [Figure 20-40-7] that route from the control valve to the front auxiliary hydraulics.

Dealer Copy -- Not for Resale

Figure 20-40-10

Remove the tubeline clamp (Item 1) [Figure 20-40-7].

1

Figure 20-40-8 2

P-90275

Disconnect the hose (Item 1) [Figure 20-40-10] that routes from the control valve to the junction block at the rear of the machine.

1

P-90273

Disconnect the lift arm bypass drain hose (Item 2) [Figure 20-40-10] from the control valve.

Remove the tubeline clamp (Item 1) [Figure 20-40-8].

184 of 1311

20-40-4

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (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].

Disconnect the hose (Item 1) [Figure 20-40-11] that routes from the bottom of the control valve to the outlet fitting of the hydraulic pump.

Figure 20-40-14

Dealer Copy -- Not for Resale

P-90276

2

Figure 20-40-12

1

1 P-90279

Remove the two control valve mount bolts (Item 1) [Figure 20-40-14]. P-90278

Remove the two frame bolts (Item 2) [Figure 20-40-14]. Support the control valve and remove the two bolts (Item 1) [Figure 20-40-12].

Installation: Torque the two frame bolts (Item 2) [Figure 20-40-14] to 406 - 447 N•m (300 - 330 ft-lb).

Remove the control valve from the loader.

Remove the control valve bracket from the loader.

185 of 1311

20-40-5

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Identification Chart Figure 20-40-15 C2

J4 J2

C3

B3

E3

E3

F2

G1

G2

D5 A3

B2

D3 A2

F4

D4

E2 C4

D1 D2

A1 H3 F1

E1

B1

H2 MR

H1

J1

J3 C1 P-90307

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 (275,8 bar) (4000 psi) Lift (Base End) Port Relief / Anti-Cavitation Valve – 27579 kPa (275,8 bar) (4000 psi) Tilt (Base End) Port Relief / Anti-Cavitation Valve – 27579 kPa (275,8 bar) (4000 psi) Tilt (Rod End) Port Relief / Anti-Cavitation Valve (Auxiliary) 27579 kPa (275,8 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 MR

Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm Bypass Orifice Drain (Case) Main Relief Valve – 24132 kPa (241,3 bar) (3500 psi)

D2

D3

D4

D5

186 of 1311

20-40-6

BICS™ Solenoid

S650 Service Manual

Dealer Copy -- Not for Resale

F3

Figure 20-40-18

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Lift Load Check Valve Removal And Installation

1

Figure 20-40-16 5 2

3 4

1

P-90309

Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-18]. P-90308

Inspect the orifice (Item 5) [Figure 20-40-18] to make sure it is not plugged.

Figure 20-40-17

1

P-90310

Remove the lift load check valve (Item 1) [Figure 20-4017] and fitting from the top of the control valve. Installation: Lubricate the O-ring and threads and tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

187 of 1311

20-40-7

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the charge tubeline (Item 1) [Figure 20-40-16] from the BICS™ valve fitting on the top of the lift load check valve.

Inspect the spring (Item 3) and the free movement in the load check valve (Item 4) [Figure 20-40-18].

Figure 20-40-20

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Load Check Valve Removal And Installation (Tilt And Auxiliary)

1 Figure 20-40-19 2 3 4

2

1 P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-40-20].

At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-40-19]. At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-40-19].

Installation: Install a new O-ring (Item 4) [Figure 20-4020] on the plug and lightly lubricate with oil before installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: The tilt and auxiliary load check valves are interchangeable.

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

188 of 1311

20-40-8

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the orifice (Item 3) [Figure 20-40-20] in the poppet to be sure it is not plugged.

P-90311

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (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

P-90314

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-40-21].

Dealer Copy -- Not for Resale

Loosen the lift circuit port relief / anti-cavitation valve (Item 1) [Figure 20-40-23].

P-90314

Figure 20-40-24

Figure 20-40-22

1 2 3

1

4

P-90315

Replace the O-ring (Item 1) [Figure 20-40-24] before installation.

P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-40-22].

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Inspect the orifice (Item 3) [Figure 20-40-22] in the poppet to be 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 52 - 61 N•m (38 - 45 ft-lb) torque.

189 of 1311

20-40-9

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (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

P-90314

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-40-25] from the base end of the tilt section.

Dealer Copy -- Not for Resale

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-40-27] from the rod end of the tilt section.

P-90314

Figure 20-40-28

Figure 20-40-26

1

1 P-90319

Replace the O-ring (Item 1) [Figure 20-40-28] before installation.

P-90316

Replace the O-ring (Item 1) [Figure 20-40-26] before installation.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

190 of 1311

20-40-10

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-31

Port Relief Valve Removal And Installation

1

Figure 20-40-29

1

P-90318A

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-40-31]. P-90314

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

P-51640

Installation: Always use new O-rings (Item 1) [Figure 20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

P-90318

Installation: Always use new O-rings (Item 1) [Figure 20-40-30]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

191 of 1311

20-40-11

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-35

Plug Removal And Installation Figure 20-40-33

1 1 P-51461

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-40-35]. P-68016

At the top side of the control valve, remove the plug (Item 1) [Figure 20-40-33]. Figure 20-40-34

1

P-51462

Installation: Always use new O-rings (Item 1) [Figure 20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.

1 P-51460A

Installation: Always use new O-rings (Item 1) [Figure 20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.

192 of 1311

20-40-12

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-40-36

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Rubber Boot Removal And Installation Figure 20-40-37 1

1

1

P-51506

Dealer Copy -- Not for Resale

Remove the three screws (Item 1) [Figure 20-40-37] on the rubber boot retainer plate. Installation: Tighten the screws to 10,2 - 11,3 N•m (90 100 in-lb) torque. Figure 20-40-38

1

2

1

P-51701

Remove the rubber boots (Item 1) from the retainer plate (Item 2) [Figure 20-40-38].

193 of 1311

20-40-13

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-41

End Cap Block Removal And Installation Figure 20-40-39

1

1

2 1

1

P-51699A

1 Figure 20-40-42 P-51697

Remove the lift spool lock solenoid (Item 1) and the tilt spool lock solenoid (Item 2) [Figure 20-40-39] from the end cap / spool lock block. 3

Figure 20-40-40

2

1

P-51701

Remove the four end cap / spool lock block mount screws (Item 1) [Figure 20-40-41] and [Figure 20-40-42]. 1 Installation: Tighten the screws to 10,2 - 11,3 N•m (90 100 in-lb) torque. Remove the rubber boots and retainer plate (Item 2) [Figure 20-40-42] from the lift and tilt spools.

P-90320

Disconnect the tube line (Item 1) [Figure 20-40-40] from the end cap / spool lock block.

194 of 1311

Remove the end cap / spool lock block (Item 3) [Figure 20-40-42] from the control valve.

20-40-14

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-45

Lift Spool And Detent Removal And Installation The tool listed will be needed to do the following procedure:

1

MEL1278 - Detent Tool MEL1285 - Detent Spring Tool Remove the end cap / spool lock block from the control valve. Figure 20-40-43 P-90321

Remove the end cap (Item 1) [Figure 20-40-45]. Figure 20-40-46

P-51511A

1 2

Remove the O-ring (Item 1) [Figure 20-40-43]. Installation: Replace the O-ring, and lubricate the o-ring lightly with grease or oil before installation of the end cap / spool lock block. Figure 20-40-44

P-51514

Use a screwdriver to remove the snap ring (Item 1) [Figure 20-40-46]. Remove the washer (Item 2) [Figure 20-40-46].

2 1

P-51512

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-44] from the lift spool.

195 of 1311

20-40-15

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-48

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-47

1

1

P-51516

Put a rag around the detent assembly [Figure 20-40-48]. This will prevent the detent balls and spring from being lost when the detent sleeve is removed.

2 P-51515

Dealer Copy -- Not for Resale

Figure 20-40-49 Remove the screws (Item 1) [Figure 20-40-47] from the detent bonnet. Remove the detent bonnet (Item 2) [Figure 20-40-47]. Installation: Lubricate the screws and tighten to 10,2 11,3 N•m (90 - 100 in-lb) torque. 2

1

3

IMPORTANT The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly. I-2012-0284

196 of 1311

2

P-51517

Remove the detent sleeve (Item 1), detent balls (Item 2) and spring (Item 3) [Figure 20-40-49].

20-40-16

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-52

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-50

P-8988

Clamp the linkage end of the spool in a vise [Figure 2040-52].

1

NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly and seal (Item 1) [Figure 20-40-50] from the control valve.

Figure 20-40-53

Dealer Copy -- Not for Resale

P-51518

2

Figure 20-40-51 1 3

1 N-18915

Install the spring tool (Item 1) [Figure 20-40-53] over the centering spring (Item 3).

P-51519

Remove the lift spool seal (Item 1) [Figure 20-40-51] from the linkage end of the valve.

197 of 1311

NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-40-53] from the centering spring, as it is under spring pressure.

20-40-17

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-56 1

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-54

N-19009

Remove spring tool (Item 1) [Figure 20-40-56] from the spring assembly.

2

Figure 20-40-57

N-18916

Put a rag around the detent assembly [Figure 20-40-54]. This will prevent the detent balls and spring from being lost when the detent adapter is removed.

2

1

3

Remove the detent adapter with an Allen wrench. 4

Remove the back-up washer (Item 1) and spool seal (Item 2) [Figure 20-40-54]. Figure 20-40-55 1

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-40-57].

N-19004

Remove the detent adapter (Item 1) [Figure 20-40-55] from the spring assembly.

198 of 1311

20-40-18

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-60

Lift Spool And Detent Removal And Installation (Cont'd) 2 Figure 20-40-58

1

N-18961

N-18918

Remove the stud from the end of the spool [Figure 2040-58].

NOTE: The lift spool will have an internal leak if there is damage to this O-ring. Always replace the O-ring and inspect the lift spool before the control valve is replaced. Figure 20-40-61

Figure 20-40-59

1

N-18920

N-18963

Removal of the plastic plug: Make a center point in the plug using a 1,6 mm (1/16 in) drill.

Install the plastic plug and O-ring in the spool [Figure 2040-61].

Drill a hole all the way through the plug using a 2,8 mm (7/64 in) tap drill. Turn a 6-32 tap (Item 1) [Figure 20-40-59] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap. Clean all the debris from inside the spool bore. NOTE: DO NOT USE Loctite® ON THE STUD THREADS.

199 of 1311

20-40-19

S650 Service Manual

Dealer Copy -- Not for Resale

Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-40-60].

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-64

Lift Spool And Detent Removal And Installation (Cont'd) 2 Figure 20-40-62 O-ring

1

3 2 N-18958

15,2 mm (0.60 in)

Apply grease on all the detent component surfaces before assembly [Figure 20-40-64]. B-14712

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 20-40-62].

Install the spring (Item 1) [Figure 20-40-64] and detent balls (Item 2) [Figure 20-40-64] into the adapter (Item 3) [Figure 20-40-64] and compress with the detent pliers (Item 1) [Figure 20-40-65]. Figure 20-40-65

Figure 20-40-63

1

1

N-18968 N-18967

Clamp the collar (Item 1) [Figure 20-40-63] in a vise.

Install the detent adapter (Item 1) [Figure 20-40-65] to the collar. 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.

200 of 1311

20-40-20

S650 Service Manual

Dealer Copy -- Not for Resale

Plastic Plug

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-68

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-66 1

1

N-19005

Install the spring assembly to the lift spool hand tight [Figure 20-40-68].

Install the spring tool (Item 1) [Figure 20-40-66] over the washer, spring, collar and detent adapter.

Inspect the alignment of the detent adapter and the washer. Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).

Figure 20-40-67

NOTE: The adapter must fit in the center of the washer (Item 1) [Figure 20-40-68]. Figure 20-40-69 2

1

N-18917

Install the spool seal (Item 1) and back-up washer (Item 2) [Figure 20-40-67]. CD-15051

Install the detent balls and spring [Figure 20-40-69].

201 of 1311

20-40-21

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spring tool.

N-19004

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-72

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-70

2 1

2 P-51515

Install the lift spool assembly in the spool bore [Figure 20-40-72].

Hold the detent balls in place with the detent pliers [Figure 20-40-70]. Figure 20-40-71

Install the mounting screws (Item 2) [Figure 20-40-72]. Installation: Lubricate the screws and tighten to 10 11,3 N•m (90 - 100 in-lb) torque. Figure 20-40-73

1

2 1 N-19008 P-51514

Install the detent sleeve (Item 1) [Figure 20-40-71] to the detent adapter.

202 of 1311

Install the washer (Item 1) and snap ring (Item 2) [Figure 20-40-73].

20-40-22

S650 Service Manual

Dealer Copy -- Not for Resale

Install the detent bonnet (Item 1) [Figure 20-40-72].

N-19007

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-76

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-74

1 1 2

P-51512

Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-40-76] on the lift spool.

Install the end cap (Item 1) [Figure 20-40-74]. Figure 20-40-75

1

1

P-51511A

Install the O-ring (Item 1) [Figure 20-40-77] on the control valve. P-51520

Install the spool seal (Item 1) [Figure 20-40-75] on the linkage end of the valve.

203 of 1311

20-40-23

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-40-77

P-90321

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-80

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-40-78 2 2 1 1 P-51697

3

The correct resistance for the coil is 16.02 - 19.58 ohm.

P-51701

Install the end cap / spool lock block (Item 1) and the mount bolt (Item 2) [Figure 20-40-78].

Installation: Install the lift spool (Item 1) and tilt spool (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 45 ft-lb) torque [Figure 20-40-80].

Install the lift and tilt spool rubber boots and mount plate (Item 3) and install the three mounting screws (Item 4) [Figure 20-40-78]. Installation: Tighten the screws to 10,2 - 11,3 N•m (90 100 in-lb) torque. Figure 20-40-79

1

P-90320

Connect the tubeline (Item 1) [Figure 20-40-79].

204 of 1311

20-40-24

S650 Service Manual

Dealer Copy -- Not for Resale

4

Use an ohmmeter to measure the lock solenoid coils resistance.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-83

Tilt Spool Removal And Installation Remove the lift and tilt end cap / spool lock block. (See End Cap Block Removal And Installation on Page 20-4014.)

2

Figure 20-40-81

1

P-90323

Installation: Replace the O-ring (Item 2) [Figure 20-4083] and lubricate the O-ring lightly with grease or oil before installation of the end cap / spool lock block. P-51521

Figure 20-40-84 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-81] from the tilt spool. Figure 20-40-82

1 2

P-51544

2

1

Remove the tilt spool, centering spring, back-up washer and spool seal [Figure 20-40-84].

P-90321

Assembly: Always use a new spool seal. Disconnect the two tubelines (Item 1) [Figure 20-40-82] from the spool centering block. Remove the three screws (Item 2) [Figure 20-40-82] from the spool centering block. Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

205 of 1311

20-40-25

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spool centering block (Item 1) [Figure 2040-83] from the control valve.

2

1

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-87

Tilt Spool Removal And Installation (Cont'd) 1

2 Figure 20-40-85

3

4 1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-40-87]. N-18942

Put the linkage end of the spool in the vise [Figure 2040-85].

2 1

Install the spool tool (Item 1) [Figure 20-40-85] over the centering spring. Figure 20-40-86

1 1

P-51545

N-18943

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-40-88]. Assembly: Always use a new spool seal. N-19014

Remove the bolt (Item 1) [Figure 20-40-86] holding the centering spring to the spool. Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque. Remove spring tool from the spring assembly.

206 of 1311

20-40-26

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-40-88

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-91

Auxiliary Spool Removal And Installation Figure 20-40-89

1

1 2

3

2

P-51547

1

2

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-91] from the auxiliary spool.

P-90321

Remove the two tubelines (Item 1) [Figure 20-40-89] from the spool centering block. Remove the three screws (Item 2) [Figure 20-40-89] from the spool centering block. Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

2

1

Remove the spool centering block (Item 3) [Figure 2040-89] from the control valve. Figure 20-40-90 P-51549A

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-40-92] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-40-92] must be replaced, replace the retainer on the opposite end also.

2 1

P-51546A

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-40-90] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-40-90] must be replaced, replace the retainer on the opposite end also.

207 of 1311

20-40-27

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-40-92

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-40-93

1

2

P-51550

Dealer Copy -- Not for Resale

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-93] from the auxiliary spool. Figure 20-40-94

1

P-51551

Remove the spool (Item 1) [Figure 20-40-94].

208 of 1311

20-40-28

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Auxiliary Solenoid Removal And Installation Figure 20-40-95

2 1

2

1

P-85528

Dealer Copy -- Not for Resale

Remove the screws (Item 1) [Figure 20-40-95] from both solenoids. Remove the solenoids (Item 2) [Figure 20-40-95] from the control valve. Installation: Tighten the nut to 2,44 - 2,98 N•m (21.6 26.4 in-lb) torque. Figure 20-40-96

1

P-85556

Remove the O-rings (Item 1) [Figure 20-40-96] from the solenoid stem. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 4.1 - 6.1 ohm.

209 of 1311

20-40-29

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-99

Solenoid Removal And Installation 1

Figure 20-40-97 1 2

P-85528

Remove the solenoid stem (Item 1) [Figure 20-40-99]. 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 20-40-97] from the solenoid stem.

Figure 20-40-100

Dealer Copy -- Not for Resale

P-90310

Installation: Tighten the nut to 6 N•m (53 in-lb) torque. Remove the solenoid coil (Item 2) [Figure 20-40-97].

3 2

Figure 20-40-98

1 1 1 N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-100] from the stem. Clean all parts in solvent and dry with compressed air. N-18693A

Remove the O-rings (Item 1) [Figure 20-40-98] from both ends of the solenoid coil. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 9.5 - 10.08 ohm.

Inspect all parts for wear and replace any showing excessive wear. NOTE: The screen (Item 3) [Figure 20-40-100] may be cleaned with solvent. If it is torn or worn, replace the solenoid valve. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-40-98] and [Figure 20-40-100] and new back-up rings (Item 2) [Figure 20-40-100] on the solenoid stem.

210 of 1311

20-40-30

S650 Service Manual

Figure 20-40-103

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Lock Valve Removal And Installation Figure 20-40-101

1 1 1 1 2 2

1

2 2

P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-103] from the lift lock valve, and replace with new.

Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-40-101] is for the lift circuit.

Figure 20-40-104

Dealer Copy -- Not for Resale

P-90310

Figure 20-40-102

1

1

P-51705

Locate the tilt circuit lock valve (Item 1) [Figure 20-40104]. P-90321

Remove the lift lock valve (Item 1) [Figure 20-40-102] from the back of the control valve. Installation: Lightly lubricate the lock valve O-rings and tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

211 of 1311

20-40-31

S650 Service Manual

Figure 20-40-107

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D) Lock Valve Removal And Installation (Cont’d) Figure 20-40-105

1 1 1

2 1 2 2 2

1

P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-107] from the tilt lock valve, and replace with new.

P-90325

Dealer Copy -- Not for Resale

Remove the lift spool lock solenoid (Item 1) [Figure 2040-105]. Remove the tilt spool lock solenoid (Item 2) [Figure 2040-105]. Installation: Lubricate the O-rings and tighten the spool lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque. Figure 20-40-106

1

P-90324

Remove the tilt lock valve (Item 1) [Figure 20-40-106] from the front of the control valve. Installation: Lightly lubricate the lock valve O-rings and tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

212 of 1311

20-40-32

S650 Service Manual

Main Relief Valve Removal And Installation

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-110

Lift Arm Bypass Orifice Removal And Installation Figure 20-40-108

1

1

P-51707

Remove the main relief valve (Item 1) [Figure 20-40110].

Remove the fitting (Item 1) [Figure 20-40-108] from the valve.

Figure 20-40-111

Dealer Copy -- Not for Resale

P-90308

Figure 20-40-109

1 1 P-51463

Remove the O-rings from the main relief valve (Item 1) [Figure 20-40-111].

P-51437

Inspect the lift arm bypass orifice (Item 1) [Figure 20-40109].

Installation: Always use new O-rings. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve casting.

213 of 1311

20-40-33

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)

Figure 20-40-114

Check Valve Removal And Installation Figure 20-40-112

1

1

P-68869

Installation: Lubricate the O-ring (Item 1) [Figure 20-40114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb) torque.

P-90308

Dealer Copy -- Not for Resale

Figure 20-40-115

Remove the tubeline (Item 1) [Figure 20-40-112]. Figure 20-40-113

1 1

P-90326

Inspect the screen (Item 1) [Figure 20-40-115].

P-90310

Remove the check valve fitting (Item 1) [Figure 20-40113] from the hydraulic control valve.

214 of 1311

20-40-34

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) Description Figure 20-41-1

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 is designed with two relief valve ports. The main relief valve is used on the 800, 700, and 600 series loaders. The auxiliary relief valve is standard on the 800 series and may be present on the 700 and 600 series. The relief valves are adjustable and located on the hydraulic control valve. The main relief valve port is adjacent to the spool linkages. The auxiliary relief valve port is located on top of the control valve between the case drain and load check valves.

215 of 1311

20-41-1

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (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

NOTE: Cap and plug all hydraulic connection points when tubelines or hoses are removed. Clean area around control valve. Open rear door. Figure 20-41-2 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 1

D-1009-0409

2

WARNING

P-90187

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.

Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and place the fuel inlet assembly (Item 3) [Figure 20-41-2] of to the side.

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

Raise the lift arms and install an approved lift arm support device. (See Installing 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.)

216 of 1311

20-41-2

S650 Service Manual

Dealer Copy -- Not for Resale

•

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D) Removal And Installation (Cont’d) Figure 20-41-3

1

P-90267

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 20-41-3]. Figure 20-41-4 3 1

2

1 P-90269

Disconnect the wire harness connectors (Item 1) [Figure 20-41-4] from the control valve. Disconnect the hose (Item 2) [Figure 20-41-4] that routes from the control valve to the drain manifold. Disconnect the hose (Item 3) [Figure 20-41-4] that routes from the control valve to the inlet fitting of the hydraulic pump.

217 of 1311

20-41-3

S650 Service Manual

Figure 20-41-7

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D) Removal And Installation (Cont’d) Figure 20-41-5

2

2 1

2 1

P-90272

Remove the tubeline clamp (Item 1) [Figure 20-41-7].

Disconnect the hose (Item 1) [Figure 20-41-5] that routes from the control valve to the brake valve.

Disconnect the two tubelines (Item 2) [Figure 20-41-7] that route from the control valve to the front auxiliary hydraulics.

Dealer Copy -- Not for Resale

P-90270

Figure 20-41-8

Disconnect the hose (Item 2) [Figure 20-41-5] that routes from the control valve to the fan motor. Figure 20-41-6

1 1

P-90273

Remove the tubeline clamp (Item 1) [Figure 20-41-8]. P-90271

Disconnect the hose (Item 1) [Figure 20-41-6] that routes from the top of the control valve to the hydraulic filter.

218 of 1311

20-41-4

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D)

Figure 20-41-11

Removal And Installation (Cont’d) Figure 20-41-9

1

1

1

P-90276

1

Disconnect the hose (Item 1) [Figure 20-41-11] that routes from the bottom of the control valve to the outlet fitting of the hydraulic pump.

Disconnect the three tubelines (Item 1) [Figure 20-41-9] that route from the control valve to the junction block at the rear of the loader.

Figure 20-41-12

Dealer Copy -- Not for Resale

P-90274

Figure 20-41-10

1 1

2 P-90278

Support the control valve and remove the two bolts (Item 1) [Figure 20-41-12]. P-90275

Remove the control valve from the loader. Disconnect the hose (Item 1) [Figure 20-41-10] that routes from the control valve to the junction block at the rear of the machine. Disconnect the lift arm bypass drain hose (Item 2) [Figure 20-41-10] from the control valve.

219 of 1311

20-41-5

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D) Mount Bracket Removal And Installation Figure 20-41-13

1

P-90280

Dealer Copy -- Not for Resale

Support the mount bracket (Item 1) [Figure 20-41-13]. Figure 20-41-14 2

1

P-90279

Remove the two control valve mount bolts (Item 1) [Figure 20-41-14]. Remove the two frame bolts (Item 2) [Figure 20-41-14]. Installation: Torque the two frame bolts (Item 2) [Figure 20-41-14] to 406 - 447 N•m (300 - 330 ft-lb). Remove the control valve bracket from the loader.

220 of 1311

20-41-6

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D) Identification Chart Figure 20-41-15 AR 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 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 (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

MR

Main Relief Valve – Without Auxiliary Relief Valve 24132 kPa (241 bar) (3500 psi) Main Relief Valve - With Auxiliary Relief Valve 25511-26200 kPa (255-262 bar) (3700-3800 psi)

D2

D3

D4

D5 D6

221 of 1311

MR AR

20-41-7

BICS™ Solenoid

Drain (Case)

Auxiliary Relief Valve - If Equipped 23787 - 24476 kPa (238-245 bar) (3450-3550 psi)

S650 Service Manual

Dealer Copy -- Not for Resale

A1 B1

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-17

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 20-41-16 Remove the lift load check valve (Item 1) [Figure 20-4117] and fitting from the top of the control valve.

Figure 20-41-18 1 1 5 P107872

2

Remove the charge tubeline (Item 1) [Figure 20-41-16] 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 20-41-18]. Inspect the spring (Item 3) and the free movement in the load check valve (Item 4) [Figure 20-41-18]. Inspect the orifice to make sure it is not plugged (Item 5) [Figure 20-41-18].

222 of 1311

20-41-8

S650 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) (LATER MODELS) (CONT'D)

Figure 20-41-20

Load Check Valve Removal And Installation (Tilt And Auxiliary) Figure 20-41-19

1 2

1

4

3 2

P107624

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-41-20].

At the front side of the control valve locate and remove the tilt section load check valve (Item 1) [Figure 20-4119].

Installation: Install a new O-ring (Item 4) [Figure 20-4120] 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 20-41-19]. NOTE: The tilt and auxiliary load check valves are interchangeable.

223 of 1311

20-41-9

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the orifice (Item 3) [Figure 20-41-20] in the poppet to make sure it is not plugged.

P107874

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D)

Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)

Anti-Cavitation Valve Removal And Installation (Lift, Rod End)

Figure 20-41-23

Figure 20-41-21

1 1

P107628

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-41-21].

Remove the lift circuit port relief / anti-cavitation valve and the port relief / anti-cavitation seat (Item 1) [Figure 20-41-23]. Figure 20-41-24

Figure 20-41-22

1 2 2 1 4

P107952

3 P107624

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-41-22]. Inspect the orifice (Item 3) [Figure 20-41-22] in the poppet to make sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4122] on the plug and lightly lubricate with oil before installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

224 of 1311

Remove the O-ring (Item 1) [Figure 20-41-24] from the port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2) [Figure 20-41-24] 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.

20-41-10

S650 Service Manual

Dealer Copy -- Not for Resale

P107628

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (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 20-41-27

Figure 20-41-25

1 1

P107628

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-41-25] 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 20-41-27] from the rod end of the tilt section. Figure 20-41-28

Figure 20-41-26

2 1

1

P107952 P107629

Remove the O-ring (Item 1) [Figure 20-41-26] 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 20-41-28] from the port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2) [Figure 20-41-28] 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.

225 of 1311

20-41-11

S650 Service Manual

Dealer Copy -- Not for Resale

P107628

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-31

Port Relief Valve Removal And Installation Figure 20-41-29 1

1

P107628

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-41-31]. P107628

Remove the auxiliary port relief valve. Figure 20-41-32

Dealer Copy -- Not for Resale

Remove the port relief plug (Item 1) [Figure 20-41-29] from the auxiliary circuit of the control valve. Figure 20-41-30

1 1

P107629

2 Remove the O-ring (Item 1) [Figure 20-41-32] from the optional auxiliary port relief valve.

P107630

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-30] 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.

226 of 1311

20-41-12

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT’D)

Figure 20-41-35

Port Relief Valve Removal And Installation (Cont’d) Figure 20-41-33 1

1

P107628

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-41-35]. P107628

Remove the auxiliary port relief valve. Figure 20-41-36

Dealer Copy -- Not for Resale

Remove the port relief plug (Item 1) [Figure 20-41-33] from the auxiliary circuit of the control valve. Figure 20-41-34

1 1

2 P107629

Remove the O-ring (Item 1) [Figure 20-41-36] from the optional auxiliary port relief valve.

P107630

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-34] 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.

227 of 1311

20-41-13

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-39

Plug Removal And Installation Figure 20-41-37

1 1

P107632

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-41-39]. P107631

At the top side of the control valve, remove the plug (Item 1) [Figure 20-41-37]. Figure 20-41-38

1

1 P107633

Remove the O-ring (Item 1) [Figure 20-41-40] from the plug. P107633

Installation: Tighten to 81,3 N•m (60 ft-lb) torque. Remove the O-ring (Item 1) [Figure 20-41-38] from the plug. Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

228 of 1311

20-41-14

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-41-40

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

End Cap Block Removal And Installation Figure 20-41-43

Rubber Boot Removal And Installation Figure 20-41-41 1

1 2 1

1

P107772

Remove the three screws (Item 1) [Figure 20-41-41] on the rubber boot retainer plate.

Remove the lift spool lock solenoid (Item 1) and the tilt spool lock solenoid (Item 2) [Figure 20-41-43] from the end cap block.

Dealer Copy -- Not for Resale

P-51506

Figure 20-41-44

Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque. Figure 20-41-42

1

1

2

P107666

Disconnect the tubeline (Item 1) [Figure 20-41-44] from the end cap block. P107664

Remove the rubber boots (Item 1) from the retainer plate (Item 2) [Figure 20-41-42].

229 of 1311

20-41-15

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (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 20-41-45

MEL1278 - Detent Tool MEL1285 - Detent Spring Tool Remove the end cap block from the control valve. Figure 20-41-46

2 1

1

Remove the end cap block mount screw (Item 1) [Figure 20-41-45]. P107776

Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque. Remove the end cap block (Item 2) [Figure 20-41-45] from the control valve.

Remove the O-ring (Item 1) [Figure 20-41-46]. Installation: Replace the O-ring, and lubricate the O-ring lightly with grease or oil before installation of the end cap block. Figure 20-41-47

2

1

P107775

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-41-47] from the lift spool.

230 of 1311

20-41-16

S650 Service Manual

Dealer Copy -- Not for Resale

P107773

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-50

Lift Spool And Detent Removal And Installation (Cont’d) Figure 20-41-48

2 1

P107846

P107779

Remove the four screws (Item 1) [Figure 20-41-48] 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 20-41-50] from the spool centering block. If removed, the sleeve detent must be inserted with the original orientation.

1

Figure 20-41-51

Figure 20-41-49 1

2 2

P107845A

1 P107778

Remove the spool centering block (Item 1) [Figure 2041-49]. Remove the O-ring (Item 2) [Figure 20-41-49].

231 of 1311

NOTE: If removed, use the following for correct installation: for a radius lift pattern machine, align the radius side (Item 1) [Figure 20-41-51] 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 20-41-51] so it faces the opening when seated. Install retaining ring over detent sleeve.

20-41-17

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-54

Lift Spool And Detent Removal And Installation (Cont’d) Figure 20-41-52

P107739

2

Clamp the linkage end of the spool in a vise [Figure 2041-54].

1

Remove the lift spool assembly (Item 1) and O-ring (Item 2) [Figure 20-41-52] from the control valve.

IMPORTANT

Figure 20-41-53

The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly. I-2012-0284

Figure 20-41-55 2 1

1 P107757A

Remove the lift spool seal (Item 1) [Figure 20-41-53] from the linkage end of the valve.

P107674A

Install the spring tool (Item 1) [Figure 20-41-55] over the centering spring. NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-41-55] from the centering spring, as it is under spring pressure.

232 of 1311

20-41-18

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Protect spool before clamping in vise.

P107790

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-58 1

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-41-56

3

4

2 1

P107676

Remove spring tool (Item 1) from the spring assembly (Item 2) [Figure 20-41-58].

2

Remove the spring assembly / spring tool (Item 1) from the spool (Item 2) [Figure 20-41-56]. 3

2

1

4

NOTE: The detent adapter has two detent balls (Item 3) held under pressure from a detent spring (Item 4) [Figure 20-41-58]. Use care when removing the detent adapter from the spring assembly so the detent balls are retained. Figure 20-41-57

P107677

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-41-59].

1

P107675

Remove the detent adapter (Item 1) [Figure 20-41-57] from the spring assembly.

233 of 1311

20-41-19

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-41-59

P107674

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-62

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-41-60

1

N-18967

Clamp the collar (Item 1) [Figure 20-41-62] in a vise. Figure 20-41-63

Remove the stud from the end of the spool [Figure 2041-60].

3 2

Figure 20-41-61

1

P107677

Apply grease on all the detent component surfaces before assembly [Figure 20-41-63].

15,2 mm (0.60 inch) 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 20-41-61].

234 of 1311

Install the spring (Item 1) [Figure 20-41-63] and detent balls (Item 2) [Figure 20-41-63] into the adapter (Item 3) [Figure 20-41-63] and compress with the detent pliers (Item 1) [Figure 20-41-64].

20-41-20

S650 Service Manual

Dealer Copy -- Not for Resale

N-18918

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-66

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-41-64

P107674

1 Install the spring assembly to the lift spool hand tight [Figure 20-41-66].

Install the detent adapter (Item 1) [Figure 20-41-64] to the collar. 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.

Check the alignment of the detent adapter and the washer. Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb). NOTE: The adapter must fit in the center of the washer. Figure 20-41-67

Figure 20-41-65

2

1

1

3 P107790 P107675

Install the spring tool (Item 1) [Figure 20-41-65] over the washer, spring, collar, and detent adapter.

Lubricate and install a new O-ring (Item 1) [Figure 20-4167]. Lubricate and install a new O-ring (Item 2) [Figure 20-4167]. Install the lift spool assembly (Item 3) [Figure 20-41-67] in the spool bore.

235 of 1311

20-41-21

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spring tool.

N-18968A

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-70

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-41-68

1

2

1

P107775

Install a spacer (Item 2) and an O-ring (Item 1) [Figure 20-41-70] on the lift spool.

2

Install the spool centering block (Item 1) [Figure 20-4168]. Install the four mounting screws (Item 2) [Figure 20-4168].

1

Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque. Figure 20-41-69

P107776

1 Install an O-ring (Item 1) [Figure 20-41-71] on the control valve.

P107679A

Install a new spool seal (Item 1) [Figure 20-41-69] on the linkage end of the valve.

236 of 1311

20-41-22

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-41-71

P107779

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-74

Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-41-72

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 20-41-72].

Installation: Install the lift spool (Item 1) and tilt spool (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 45 ft-lb) torque [Figure 20-41-74].

Install the lift and tilt spool rubber boots and mount plate (Item 3) and install the three mounting screws (Item 4) [Figure 20-41-72]. Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque. Figure 20-41-73

1

P107666

Connect the tubeline (Item 1) [Figure 20-41-73].

237 of 1311

20-41-23

S650 Service Manual

Dealer Copy -- Not for Resale

The correct resistance for the coil is 16.02 - 19.58 ohm.

P107664A

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-77

Tilt Spool Removal And Installation Remove the lift and tilt end cap block. (See End Cap Block Removal And Installation on Page 20-41-15.)

2

Figure 20-41-75 1

P107778

Installation: Replace the O-ring (Item 2) [Figure 20-4177] 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 20-41-75] from the tilt spool.

Figure 20-41-78

Installation: Install the spacer (Item 1) and an O-ring (Item 2) [Figure 20-41-75].

2

Figure 20-41-76

1 P107780

Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure 20-41-78]. 1 Installation: Replace the O-ring (Item 2) [Figure 20-4178] 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 20-41-76] from the spool centering block. Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque.

238 of 1311

20-41-24

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spool centering block (Item 1) [Figure 2041-77] from the control valve.

1

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-81

Tilt Spool Removal And Installation (Cont'd) Figure 20-41-79 1

1

P107647

Remove the bolt (Item 1) [Figure 20-41-81] holding the centering spring to the spool. P107781

Remove the tilt spool seal (Item 1) [Figure 20-41-79].

Remove the spring tool from the spring assembly.

Assembly: Always use a new spool seal.

Figure 20-41-82

Figure 20-41-80

2

1

3 1

4

N-18944B P107646

Put the linkage end of the spool in the vise [Figure 2041-80].

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-41-82].

NOTE: Protect spool before clamping in vise. Install the spring tool (Item 1) [Figure 20-41-80] over the centering spring.

239 of 1311

20-41-25

S650 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) (LATER MODELS) (CONT'D)

Figure 20-41-84

Auxiliary Spool Removal And Installation Figure 20-41-83 1 3

2

4 1 2 4 P107783

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-41-84] from the auxiliary spool.

3 P107782

Remove the spacer (Item 3) and O-ring (Item 4) [Figure 20-41-83] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-41-83] must be replaced, replace the retainer on the opposite end also.

NOTE: If the centering spring retainer (Item 2) [Figure 20-41-84] must be replaced, replace the retainer on the opposite end also. Installation: Lubricate and install an O-ring (Item 4) [Figure 20-41-84]. Figure 20-41-85

Installation: Lubricate and install an O-ring (Item 4) [Figure 20-41-83].

1

P107784

Remove the auxiliary spool (Item 1) [Figure 20-41-85].

240 of 1311

20-41-26

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-41-83] from the auxiliary spool.

Remove the spacer (Item 3) and O-ring (Item 4) [Figure 20-41-84] from the auxiliary spool.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-87

Auxiliary Solenoid Removal And Installation 1

Figure 20-41-86

2 1

2

2 P107798

1

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-87] from the solenoid stem. P107876

Remove the solenoids (Item 2) [Figure 20-41-86] 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 20-41-87].

Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9 in-lb) torque.

241 of 1311

20-41-27

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the screws (Item 1) [Figure 20-41-86] from both solenoids.

Use an ohmmeter to measure the solenoid coil resistance.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-90

Solenoid Removal And Installation Figure 20-41-88

1

1 2

P107876

Remove the solenoid stem (Item 1) [Figure 20-41-90]. 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 20-41-88] from the solenoid stem.

Figure 20-41-91

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 20-41-88].

3 2

Figure 20-41-89

1 1 1 N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-91] from the stem. Clean all parts in solvent and dry with compressed air. N-18693A

Remove the O-rings (Item 1) [Figure 20-41-89] 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 20-41-91] 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.

242 of 1311

20-41-28

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-94

Lock Valve Removal And Installation Figure 20-41-92

2

1

1

P107937

The inside diameter of the BICS™ valve (Item 1) [Figure 20-41-94] 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 20-4192].

1

3 2

Figure 20-41-93

1 P107767

Remove the O-ring (Item 1) [Figure 20-41-95]. Remove and inspect the spring (Item 2) and BICS™ valve (Item 3) [Figure 20-41-95].

P107786

Remove the lift lock valve (Item 1) [Figure 20-41-93] 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.

243 of 1311

20-41-29

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-41-95

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Figure 20-41-98

Lock Valve Removal And Installation (Cont’d) Figure 20-41-96

1 2 1 P107937

The inside diameter of the BICS™ valve (Item 1) [Figure 20-41-98] is threaded for easier removal and installation. P107788

Remove the lift spool lock solenoid (Item 1) [Figure 2041-96]. 1

Remove the tilt spool lock solenoid (Item 2) [Figure 2041-96].

3 2

Installation: Lubricate the O-rings and tighten the spool lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque. Figure 20-41-97

P107767

Remove the O-ring (Item 1) [Figure 20-41-99]. Remove and inspect the spring (Item 2) and BICS™ valve (Item 3) [Figure 20-41-99]. 1

P107789

Remove the tilt lock valve (Item 1) [Figure 20-41-97] 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.

244 of 1311

20-41-30

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-41-99

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Main Relief Valve Removal And Installation Figure 20-41-102

Lift Arm Bypass Orifice Removal And Installation Figure 20-41-100

1

P107787

1

Remove the main relief valve (Item 1) [Figure 20-41102].

Remove the fitting (Item 1) [Figure 20-41-100] from the valve.

Figure 20-41-103

Dealer Copy -- Not for Resale

P107693

Figure 20-41-101

1 1 P-51463

Remove the O-rings (Item 1) [Figure 20-41-103] from the main relief valve.

P-51437

Inspect the lift arm bypass orifice (Item 1) [Figure 20-41101].

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve casting.

245 of 1311

20-41-31

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)

Check Valve Removal And Installation Figure 20-41-106

Auxiliary Relief Valve Removal And Installation NOTE: The auxiliary relief valve (Item 1) [Figure 2041-104] is an optional item and may not be installed. Figure 20-41-104

1 1

P107693

Remove the tubeline (Item 1) [Figure 20-41-106].

Dealer Copy -- Not for Resale

Figure 20-41-107 P107870

Remove the auxiliary relief valve (Item 1) [Figure 20-41104]. Figure 20-41-105

1

2 P107786

Remove the check valve fitting (Item 1) [Figure 20-41107] from the hydraulic control valve. 1 P107627

Remove the O-rings (Item1) and back-up ring (Item 2) [Figure 20-41-105] from the auxiliary relief valve. Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

246 of 1311

20-41-32

S650 Service Manual

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D) Check Valve Removal And Installation (Cont’d) Figure 20-41-108

3

1 2 P107625

Dealer Copy -- Not for Resale

Inspect the spring (Item 2) and poppet (Item 3) [Figure 20-41-108]. Remove the O-ring (Item 1) [Figure 20-41-108]. Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ftlb) torque.

247 of 1311

20-41-33

S650 Service Manual

Dealer Copy -- Not for Resale 248 of 1311

20-41-34

S650 Service Manual

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS)

Removal And Installation

Description

DANGER

Figure 20-42-1 1

P-90328

•

•

NOTE: The 90° fitting (Item 1) [Figure 20-42-1] has been replaced with a tee fitting on late model machines.

D-1009-0409

WARNING

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 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.

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

249 of 1311

20-42-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-90337

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) (EARLIER MODELS) (CONT’D)

Figure 20-42-3

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.)

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.) Remove the control panel. (See Removal And Installation on Page 50-100-2.)

NOTE: Cap and plug all hydraulic connection points when tubelines or hoses are removed. Clean area around control valve.

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 20-42-3].

Open rear door. Figure 20-42-2

3

1

2

P-90187

Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and place the fuel inlet assembly (Item 3) [Figure 20-42-2] off to the side.

250 of 1311

20-42-2

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Mark all tubelines, hoses, and electrical connections for correct installation.

P-90267

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

NOTE: The hose (Item 1) has been relocated to the tee fitting on top of the load check valve (Item 3) [Figure 20-42-5] on late model machines.

Removal And Installation (Cont'd)

Figure 20-42-6

Figure 20-42-4 3

2

1

2 1

1

P-107219

Disconnect the wire harness connectors (Item 1) [Figure 20-42-4] from the control valve. Disconnect the hose (Item 2) [Figure 20-42-4] that routes from the control valve to the drain manifold. Disconnect the hose (Item 3) [Figure 20-42-4] that routes from the control valve to the inlet fitting of the hydraulic pump.

Disconnect the hose (Item 1) [Figure 20-42-6] that routes from the control valve to the brake valve. Disconnect the hose (Item 2) [Figure 20-42-6] that routes from the control valve to the fan motor. Figure 20-42-7

Figure 20-42-5 1 1 2

P-90271

Disconnect the hose (Item 1) [Figure 20-42-7] that routes from the top of the control valve to the hydraulic filter.

3 P-90270

Disconnect the hose (Item 1) [Figure 20-42-5] that routes from the control valve to the brake valve. Disconnect the hose (Item 2) [Figure 20-42-5] that routes from the control valve to the fan motor.

251 of 1311

20-42-3

S650 Service Manual

Dealer Copy -- Not for Resale

P-90269

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

Figure 20-42-10

Removal And Installation (Cont'd) Figure 20-42-8 1

1

2

2 1

1 P-90274

Disconnect the three tubelines (Item 1) [Figure 20-4210] that route from the control valve to the junction block at the rear of the loader.

P-90272

Disconnect the two tubelines (Item 2) [Figure 20-42-8] that route from the control valve to the front auxiliary hydraulics.

Dealer Copy -- Not for Resale

Figure 20-42-11

Remove the tubeline clamp (Item 1) [Figure 20-42-8].

1

Figure 20-42-9 2

P-90275

Disconnect the hose (Item 1) [Figure 20-42-11] that routes from the control valve to the junction block at the rear of the machine.

1

P-90273

Disconnect the lift arm bypass drain hose (Item 2) [Figure 20-42-11] from the control valve.

Remove the tubeline clamp (Item 1) [Figure 20-42-9].

252 of 1311

20-42-4

S650 Service Manual

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

Actuator Removal And Installation (In Loader)

Removal And Installation (Cont'd)

WARNING

Figure 20-42-12

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

1

Stop the engine. Raise the seat bar. Mark the actuator wiring harness connectors for proper installation.

Disconnect the hose (Item 1) [Figure 20-42-12] that routes from the bottom of the control valve to the outlet fitting of the hydraulic pump.

Figure 20-42-14

Dealer Copy -- Not for Resale

P-90276

Figure 20-42-13

1 1

P-90330

Unplug the actuator connectors (Item 1) [Figure 20-4214] from the loader harness. P-90278

Support the control valve and remove the two bolts and nuts (Item 1) [Figure 20-42-13]. Remove the control valve from the loader.

253 of 1311

20-42-5

S650 Service Manual

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

Figure 20-42-17

Actuator Removal And Installation (In Loader) (Cont’d) Figure 20-42-15

2

1

1

P-54568

Inspect the O-ring (Item 1) [Figure 20-42-17] on the face of the actuator, and replace as needed.

Dealer Copy -- Not for Resale

Inspect the linkage pin (Item 2) [Figure 20-42-17] and replace as needed.

P-54587

Remove the two screws (Item 1) [Figure 20-42-15] from the actuator retainer. Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 100 in-lb) torque. Figure 20-42-16

2 1

P-54566

Pull the actuator (Item 1) [Figure 20-42-16] away from the control valve. Use a punch to remove the actuator pin (Item 2) [Figure 20-42-16] 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.)

254 of 1311

20-42-6

S650 Service Manual

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

Figure 20-42-20

Actuator Removal And Installation (Out Of Loader) Remove the control valve from the loader. Figure 20-42-18

1 1

P-54339

Using a punch and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-42-20] from the actuator and the tilt spool.

1

Remove the two mount bolts (Item 1) [Figure 20-42-18] from the tilt actuator.

Dealer Copy -- Not for Resale

Remove the actuator and linkage pin from the valve.

P-54337

Figure 20-42-21

Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque. Figure 20-42-19 1

2

P-54340

Inspect the O-ring (Item 1) [Figure 20-42-21] on the face of the actuator, and replace as needed.

1

Inspect the linkage pin (Item 2) [Figure 20-42-21] and replace as needed.

P-54338

Slide the actuator mount bracket (Item 1) [Figure 20-4219] away from the control valve. Pull the actuator away from the control valve [Figure 2042-19].

255 of 1311

20-42-7

S650 Service Manual

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

Figure 20-42-24

Actuator Removal And Installation (Out of Loader) (Cont’d) Figure 20-42-22

1

1

P-54343

Using a punch and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-42-24] from the actuator and the tilt spool.

1 P-54341

Remove the two mount bolts (Item 1) [Figure 20-42-22] from the lift actuator.

Dealer Copy -- Not for Resale

Remove the actuator and linkage pin from the valve. Figure 20-42-25

Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque. Figure 20-42-23 1

2

P-54340

Inspect the O-ring (Item 1) [Figure 20-42-25] on the face of the actuator, and replace as needed.

1

Inspect the linkage pin (Item 2) [Figure 20-42-25] and replace as needed.

P-54342

Slide the actuator mount bracket (Item 1) [Figure 20-4223] away from the control valve. Pull the actuator away from the control valve [Figure 2042-23].

256 of 1311

20-42-8

S650 Service Manual

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Actuator Removal And Installation (Out Of Loader) (Cont’d) Figure 20-42-26 4

3

2

1 3

Dealer Copy -- Not for Resale

P-90329

NOTE: The two longer bolts (Item 1) are used to mount the lift actuator and end cap (Item 2) [Figure 20-42-26] to the control valve. The two shorter mount bolts (Item 3) are used to mount the tilt actuator to the end cap (Item 4) [Figure 20-42-26]. Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-42-26]

257 of 1311

20-42-9

S650 Service Manual

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Identification Chart Figure 20-42-27 C2

J4 J2

C3

B3

E3

E3

F2

G1

G2

D5 A3

B2

D3 A2

F4

D4

E2 C4

D1 D2

A1 H3 F1

E1

B1

H2 MR

H1

J1

J3 C1 P-90307

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 (275,8 bar) (4000 psi) Lift (Base End) Port Relief / Anti-Cavitation Valve – 27579 kPa (275,8 bar) (4000 psi) Tilt (Base End) Port Relief / Anti-Cavitation Valve – 27579 kPa (275,8 bar) (4000 psi) Tilt (Rod End) Port Relief / Anti-Cavitation Valve (Auxiliary) 27579 kPa (275,8 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 MR

Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm Bypass Orifice Drain (Case) Main Relief Valve – 24132 kPa (241,3 bar) (3500 psi)

D2

D3

D4

D5

258 of 1311

20-42-10

BICS™ Solenoid

S650 Service Manual

Dealer Copy -- Not for Resale

F3

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

Lift Load Check Valve Removal And Installation Figure 20-42-30

Mount Bracket Removal And Installation Figure 20-42-28

1 1 P-90308

Support the mounting bracket (Item 1) [Figure 20-42-28].

Remove the charge tubeline (Item 1) [Figure 20-42-30] from the BICS™ valve fitting on the top of the lift load check valve.

Dealer Copy -- Not for Resale

P-90280

Figure 20-42-31

Figure 20-42-29

2 1

1

P-90310 P-90279

Remove the two control valve mount bolts (Item 1) [Figure 20-42-29].

Remove the lift load check valve (Item 1) [Figure 20-4231] and fitting from the top of the control valve. Installation: Lubricate the O-ring and threads and tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

Remove the two frame bolts (Item 2) [Figure 20-42-29]. Installation: Torque the two frame bolts (Item 2) [Figure 20-42-29] to 406 - 447 N•m (300 - 330 ft-lb). Remove the control valve bracket from the loader.

259 of 1311

20-42-11

S650 Service Manual

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

Load Check Valve Removal And Installation (Tilt And Auxiliary)

Lift Load Check Valve Removal And Installation (Cont’d)

Figure 20-42-33

Figure 20-42-32 2 1 1 4 5 2

P-90311

3

Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-42-32].

At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-42-33]. NOTE: The tilt and auxiliary load check valves are interchangeable.

IMPORTANT

Figure 20-42-34

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

2 3

Inspect the spring (Item 3) and the free movement in the load check valve (Item 4) [Figure 20-42-32].

4

Inspect the orifice to make sure it is not plugged (Item 5) [Figure 20-42-32]. P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-34]. Inspect the orifice (Item 3) [Figure 20-42-34] in the poppet to be sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4234] on the plug and lightly lubricate with oil before installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb) torque.

260 of 1311

20-42-12

S650 Service Manual

Dealer Copy -- Not for Resale

At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-42-33].

P-90309

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

Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)

Anti-Cavitation Valve Removal And Installation (Lift, Rod End)

Figure 20-42-37

Figure 20-42-35

1 1

P-90314

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-42-35].

Dealer Copy -- Not for Resale

Loosen the lift circuit port relief / anti-cavitation valve (Item 1) [Figure 20-42-37].

P-90314

Figure 20-42-38

Figure 20-42-36

1 2 3

1

4

P-90315

Replace the O-ring (Item 1) [Figure 20-42-38] before installation.

P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-36].

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Inspect the orifice (Item 3) [Figure 20-42-36] in the poppet to be sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4236] on the plug and lightly lubricate with oil before installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb) torque.

261 of 1311

20-42-13

S650 Service Manual

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (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 20-42-41

Figure 20-42-39

1 1

P-90314

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-42-39] from the base end of the tilt section.

Dealer Copy -- Not for Resale

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-42-41] from the rod end of the tilt section.

P-90314

Figure 20-42-42

Figure 20-42-40

1

1 P-90319

Replace the O-ring (Item 1) [Figure 20-42-42] before installation.

P-90316

Replace the O-ring (Item 1) [Figure 20-42-40] before installation.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

262 of 1311

20-42-14

S650 Service Manual

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

Figure 20-42-45

Port Relief Valve Removal And Installation

1

Figure 20-42-43

1

P-90318A

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-42-45]. P-90314

Remove the auxiliary port relief valve. Figure 20-42-46

Dealer Copy -- Not for Resale

Remove the port relief plug (Item 1) [Figure 20-42-43] from the auxiliary circuit of the control valve. Figure 20-42-44

1

1

P-51640

Installation: Always use new O-rings (Item 1) [Figure 20-42-46]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

P-90318

Installation: Always use new O-rings (Item 1) [Figure 20-42-44]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

263 of 1311

20-42-15

S650 Service Manual

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

Figure 20-42-49

Plug Removal And Installation Figure 20-42-47

1

1 P-51461

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-42-49]. P-68016

At the top side of the control valve, remove the plug (Item 1) [Figure 20-42-47]. Figure 20-42-48

1

P-51462

Installation: Always use new O-rings (Item 1) [Figure 20-42-50]. Tighten to 81,3 N•m (60 ft-lb) torque.

1 P-51460A

Installation: Always use new O-rings (Item 1) [Figure 20-42-48]. Tighten to 81,3 N•m (60 ft-lb) torque.

264 of 1311

20-42-16

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-42-50

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (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 20-42-5.)

MEL1285 - Spring Tool

Figure 20-42-51

Figure 20-42-53

Remove the end cap block from the control valve.

1

1

P-90338

P-68042

Disconnect the tube line (Item 1) [Figure 20-42-51] from the end cap block. Remove the two end cap block mount screws (Item 2) [Figure 20-42-51]. Installation: Tighten the screws to 10,2 - 11,3 N•m (90 100 in-lb) torque.

Remove the O-ring (Item 1) [Figure 20-42-53]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap block. Figure 20-42-54

Figure 20-42-52

2

1 P-68047

1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-54] from the lift spool.

P-90339

Remove the end cap block (Item 1) [Figure 20-42-52] from the control valve.

265 of 1311

20-42-17

S650 Service Manual

Dealer Copy -- Not for Resale

2

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

Figure 20-42-57

Lift Spool Removal And Installation (Cont'd) Figure 20-42-55

1 1

P-68045

1

Remove the lift spool assembly and seal (Item 1) [Figure 20-42-57] from the control valve. P-68043

Remove the two screws (Item 1) [Figure 20-42-55] from the lift spool end cap. Installation: Lubricate the screws and tighten to 10,2 11,3 N•m (90 - 100 in-lb) torque. Figure 20-42-56

1

P-68046

1

Remove the lift spool seal (Item 1) [Figure 20-42-58] from the linkage end of the valve.

P-68044

Remove the lift spool end cap (Item 1) [Figure 20-42-56] from the control valve.

266 of 1311

20-42-18

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-42-58

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

Figure 20-42-61

Lift Spool Removal And Installation (Cont’d) 1 Figure 20-42-59

N-190146

Remove the bolt (Item 1) [Figure 20-42-61] holding the centering spring to the spool. P-51772

NOTE: Protect spool before clamping in vise.

Remove spring tool from the spring assembly. Figure 20-42-62

Figure 20-42-60 3 2 4

1

1

P-51776 P-51773

Install the spring tool (Item 1) [Figure 20-42-60] over the centering spring.

267 of 1311

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-62].

20-42-19

S650 Service Manual

Dealer Copy -- Not for Resale

Clamp the linkage end of the spool in a vise [Figure 2042-59].

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

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

NOTE: The lift spool will have an internal leak if there is damage to this O-ring. Always replace the O-ring. Always replace the O-ring and inspect the lift spool before the control valve is replaced.

Lift Spool Removal And Installation (Cont’d) Figure 20-42-63

Figure 20-42-65

1

N-18920

Make a center point in the plug using a 1,6 mm (1/16 in) drill.

Install the plastic plug and O-ring in the spool [Figure 2042-65].

Drill a hole all the way through the plug using a 2,8 mm (7/64 in) tap drill.

Figure 20-42-66

Turn a 6-32 tap (Item 1) [Figure 20-42-63] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap.

1

2

Clean all the debris from inside the spool bore. NOTE: DO NOT USE Loctite® ON THE STUD THREADS. 1

Figure 20-42-64

P-68046

2 1

P-51775

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-42-66]. Assembly: Always use a new spool seal.

P-74183

Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-42-64].

268 of 1311

20-42-20

S650 Service Manual

Dealer Copy -- Not for Resale

P-74184

Removal of the plastic plug:

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

Figure 20-42-69

Lift Spool Removal And Installation (Cont’d) Figure 20-42-67

1 2

1 2 3

P-68047

3

Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-42-69] on the lift spool. P-68044

Install the lift spool assembly (Item 1) [Figure 20-42-67] in the spool bore. 1 Install the end cap (Item 2) [Figure 20-42-67]. Install the mounting screws (Item 3) [Figure 20-42-67]. Installation: Lubricate the screws and tighten to 10,2 11,3 N•m (90 - 100 in-lb) torque. Figure 20-42-68

P-68042

Install the O-ring (Item 1) [Figure 20-42-70] on the control valve. 1 Installation: Replace the O-ring, lubricate lightly with oil or grease before installation of the end cap block.

P-68048

Install the spool seal (Item 1) [Figure 20-42-68] on the linkage end of the valve.

269 of 1311

20-42-21

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-42-70

Tilt Spool Removal And Installation

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Lift Spool Removal And Installation (Cont’d)

Remove the end cap block. (See End Cap Block Removal And Installation on Page 20-42-17.)

Figure 20-42-71

Figure 20-42-72 1

3

2

2 1 P-68040

Install the end cap block (Item 1) and the two mount bolts (Item 2) [Figure 20-42-71].

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-72] from the lift spool.

Installation: Tighten the screws to 10,2 - 11,3 N•m (90 100 in-lb) torque.

Figure 20-42-73

Connect the tubeline (Item 3) [Figure 20-42-71] to the end cap block.

1

Install the lift and tilt actuators to the control valve.

2 1 2 P-90321

Disconnect the two tubelines (Item 1) [Figure 20-42-73]. Remove the three screws (Item 2) [Figure 20-42-73] from the spool centering block. Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

270 of 1311

20-42-22

S650 Service Manual

Dealer Copy -- Not for Resale

P-68049

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

Figure 20-42-76

Tilt Spool Removal And Installation (Cont’d) Figure 20-42-74

1

2

N-18942

1 Put the linkage end of the spool in the vise [Figure 2042-76]. P-90342

Dealer Copy -- Not for Resale

Remove the spool centering block (Item 1) [Figure 2042-74] from the control valve.

Install the spring tool (Item 1) [Figure 20-42-76] over the centering spring. Figure 20-42-77

Installation: Replace the O-ring (Item 2) [Figure 20-4274] and lubricate lightly with oil / grease before installation of the end cap block.

1

Figure 20-42-75

1 N-19014

Remove the bolt (Item 1) [Figure 20-42-77] holding the centering spring to the spool. Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

P-68052

Remove the tilt spool, centering spring, back-up washer and spool seal (Item 1) [Figure 20-42-75].

Remove spring tool from the spring assembly.

Assembly: Always use a new spool seal.

271 of 1311

20-42-23

S650 Service Manual

Auxiliary Spool Removal And Installation

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

Figure 20-42-80

Tilt Spool Removal And Installation (Cont’d) Figure 20-42-78

1 2

1

3 2 4 1 2 P-90321

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-78].

Remove the three screws (Item 2) [Figure 20-42-80] from the spool centering block.

Figure 20-42-79

Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 100 in-lb) torque. 2 Remove the spool centering block from the control valve.

1

Figure 20-42-81

1

P-51545

2

N-18943

Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-42-79].

1 P-68053

Assembly: Always use a new spool seal.

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-81] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-42-81] must be replaced, replace the retainer on the opposite end also.

272 of 1311

20-42-24

S650 Service Manual

Dealer Copy -- Not for Resale

Disconnect the two tubelines (Item 1) [Figure 20-42-80] from the spool centering block.

N-18944A

Figure 20-42-84

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-42-82

1 2 2 P-68077

1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-84] from the auxiliary spool. P-68054

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-82] from the auxiliary spool. Figure 20-42-83

1 2

1

P-68078

Remove the auxiliary spool (Item 1) [Figure 20-42-85]. P-68076

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-83] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-42-83] must be replaced, replace the retainer on the opposite end also.

273 of 1311

20-42-25

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-42-85

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Auxiliary Solenoid Removal And Installation Figure 20-42-86

2 1

1

2

P-90337

Dealer Copy -- Not for Resale

Remove the screws (Item 1) [Figure 20-42-86] from both solenoids. Remove the solenoids (Item 2) [Figure 20-42-86]. Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6 - 26.4 in-lb) torque. Figure 20-42-87

1

P-85556

Remove the O-rings (Item 1) [Figure 20-42-87] from the solenoid stem. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 4.1 - 6.1 ohm.

274 of 1311

20-42-26

S650 Service Manual

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

Figure 20-42-90

Solenoid Removal And Installation Figure 20-42-88

1 1

2

P-90346

Remove the solenoid stem (Item 1) [Figure 20-42-90]. 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 20-42-88] from the solenoid stem.

Figure 20-42-91

Dealer Copy -- Not for Resale

P-90337

Installation: Tighten the nut to 6 N•m (53 in-lb) torque. Remove the solenoid coil (Item 2) [Figure 20-42-88].

3 2

Figure 20-42-89

1 1 1 N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-91] from the stem. Clean all parts in solvent and dry with compressed air. N-18693A

Remove the O-rings (Item 1) [Figure 20-42-89] from both ends of the solenoid coil. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 9.5 - 10.08 ohm.

Inspect all parts for wear and replace any showing excessive wear. NOTE: The screen (Item 3) [Figure 20-42-91] may be cleaned with solvent. If it is torn or worn the solenoid stem needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-42-89] and [Figure 20-42-91] and new back-up rings (Item 2) [Figure 20-42-91] on the solenoid stem.

275 of 1311

20-42-27

S650 Service Manual

Figure 20-42-94

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D) Lock Valve Removal And Installation Figure 20-42-92

1

1 2

P-51792

Remove the tilt lock valve (Item 1) [Figure 20-42-94] from the back of the control valve. P-90310

Dealer Copy -- Not for Resale

Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-42-92] is for the lift circuit.

Installation: Lightly lubricate the lock valve O-rings and tighten to 27 - 33 N•m (20 - 24 ft-lb) torque. Figure 20-42-95

Figure 20-42-93

1 1 1 1 1 2 2 2 P-51564 P-90321

Remove the lift lock valve (Item 1) [Figure 20-42-93] from the back of the control valve.

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-95] from the valve, and replace with new.

Installation: Lightly lubricate the lock valve O-rings and tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

276 of 1311

20-42-28

S650 Service Manual

Main Relief Valve Removal And Installation

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

Figure 20-42-98

Lift Arm Bypass Orifice Removal And Installation Figure 20-42-96

1

1

P-51794

Remove the main relief valve (Item 1) [Figure 20-42-98].

Remove the fitting (Item 1) [Figure 20-42-96] from the valve.

Figure 20-42-99

Dealer Copy -- Not for Resale

P-90308

Figure 20-42-97

1 1

P-90344

Remove the O-rings from the main relief valve (Item 1) [Figure 20-42-99].

P-51437

Inspect the lift arm bypass orifice (Item 1) [Figure 20-4297].

Installation: Always use new O-rings. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve casting.

277 of 1311

20-42-29

S650 Service Manual

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

Figure 20-42-102

Check Valve Removal And Installation Figure 20-42-100

1

1

P-68869

Installation: Lubricate the O-ring (Item 1) [Figure 20-42102] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb) torque.

P-90308

Dealer Copy -- Not for Resale

Figure 20-42-103

Remove the tubeline (Item 1) [Figure 20-42-100]. Figure 20-42-101

1 1

P-90326

Inspect the screen (Item 1) [Figure 20-42-103].

P-90310

Remove the check valve fitting (Item 1) [Figure 20-42101] from the hydraulic control valve.

278 of 1311

20-42-30

S650 Service Manual

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)

Removal And Installation

Description

DANGER

Figure 20-43-1

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.

WARNING

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.

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.

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.

W-2059-0598

The hydraulic control valve is designed with two relief valve ports. The main relief valve is used on the 800, 700, and 600 series loaders. The auxiliary relief valve is standard on the 800 series and may be present on the 700 and 600 series.

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.

The relief valves are adjustable and located on the hydraulic control valve. The main relief valve port is adjacent to the actuator side. The auxiliary relief valve port is located on top of the control valve between the case drain and load check valves.

279 of 1311

20-43-1

I-2003-0888

S650 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) (LATER MODELS) (CONT’D)

Figure 20-43-3

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.)

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.) Remove the control panel. (See Removal And Installation on Page 50-100-2.)

Clean area around control valve.

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 20-43-3].

Open rear door.

Figure 20-43-4

NOTE: Cap and plug all hydraulic connection points when tubelines or hoses are removed.

Figure 20-43-2

3 1

3 1 2

1

2

P-90269 P-90187

Disconnect the wire harness connectors (Item 1) [Figure 20-43-4] from the control valve. Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and the place the fuel inlet assembly (Item 3) [Figure 20-43-2] off to the side.

Disconnect the hose (Item 2) [Figure 20-43-4] that routes from the control valve to the drain manifold. Disconnect the hose (Item 3) [Figure 20-43-4] that routes from the control valve to the inlet fitting of the hydraulic pump.

280 of 1311

20-43-2

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Mark all tubelines, hoses, and electrical connections for correct installation.

P-90267

Figure 20-43-7

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Removal And Installation (Cont'd) Figure 20-43-5

2

2 1

2

P-90272

Remove the tubeline clamp (Item 1) [Figure 20-43-7]. P107219

Disconnect the hose (Item 1) [Figure 20-43-5] that routes from the control valve to the brake valve.

Disconnect the two tubelines (Item 2) [Figure 20-43-7] that route from the control valve to the front auxiliary hydraulics.

Dealer Copy -- Not for Resale

1

Figure 20-43-8

Disconnect the hose (Item 2) [Figure 20-43-5] that routes from the control valve to the fan motor. Figure 20-43-6

1 1

P-90273

Remove the tubeline clamp (Item 1) [Figure 20-43-8]. P-90271

Disconnect the hose (Item 1) [Figure 20-43-6] that routes from the top of the control valve to the hydraulic filter.

281 of 1311

20-43-3

S650 Service Manual

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

Figure 20-43-11

Removal And Installation (Cont'd) Figure 20-43-9

1

1

1

P-90276

1

Disconnect the hose (Item 1) [Figure 20-43-11] that routes from the bottom of the control valve to the outlet fitting of the hydraulic pump.

Disconnect the three tubelines (Item 1) [Figure 20-43-9] that route from the control valve to the junction block at the rear of the loader.

Figure 20-43-12

Dealer Copy -- Not for Resale

P-90274

Figure 20-43-10

1 1

2 P-90278

Support the control valve and remove the two bolts and nuts (Item 1) [Figure 20-43-12]. P-90275

Remove the control valve from the loader. Disconnect the hose (Item 1) [Figure 20-43-10] that routes from the control valve to the junction block at the rear of the machine. Disconnect the lift arm bypass drain hose (Item 2) [Figure 20-43-10] from the control valve.

282 of 1311

20-43-4

S650 Service Manual

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

Figure 20-43-14

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 10-20-1.)

Remove the two screws (Item 1) [Figure 20-43-14] 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 20-43-15 Figure 20-43-13

2

1 1

P-54566 P-90330

Unplug the actuator connectors (Item 1) [Figure 20-4313] from the loader harness.

Pull the actuator (Item 1) [Figure 20-43-15] away from the control valve. Use a punch to remove the actuator pin (Item 2) [Figure 20-43-15] from the actuator and spool. Remove the actuator from the hydraulic control valve. NOTE: The calibration procedure must be followed when replacing a lift or tilt actuator. (See Lift And Tilt Calibration (SJC) on Page 60-160-4.)

283 of 1311

20-43-5

S650 Service Manual

Actuator Removal And Installation (Out Of Loader)

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

Remove the control valve from the loader.

Actuator Removal And Installation (In Loader) (Cont’d)

Figure 20-43-17

Figure 20-43-16

1

1

2

1

P107802

Remove the O-ring (Item 1) [Figure 20-43-16] on the face of the actuator. Inspect the linkage pin (Item 2) [Figure 20-43-16] and replace as needed.

Remove the two mount bolts (Item 1) [Figure 20-43-17] from the tilt actuator. Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque. Figure 20-43-18

NOTE: Repeat this procedure to remove the lift actuator.

1

P107803

Slide the actuator mount bracket (Item 1) [Figure 20-4318] away from the control valve. Pull the actuator away from the control valve [Figure 2043-18].

284 of 1311

20-43-6

S650 Service Manual

Dealer Copy -- Not for Resale

P-54568

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

Figure 20-43-21

Actuator Removal And Installation (Out of Loader) (Cont’d) 1 Figure 20-43-19

1 P107804

1

Remove the two mount bolts (Item 1) [Figure 20-43-21] from the lift actuator.

Using a punch and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-19] from the actuator and the tilt spool.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque.

P107808

Figure 20-43-22

Remove the actuator and linkage pin from the valve. Figure 20-43-20

1 1 P107805

2

Slide the actuator mount bracket (Item 1) [Figure 20-4322] away from the control valve. Pull the actuator away from the control valve [Figure 2043-22].

P-54340

Remove the O-ring (Item 1) [Figure 20-43-20] on the face of the actuator. Inspect the linkage pin (Item 2) [Figure 20-43-20] and replace as needed.

285 of 1311

20-43-7

S650 Service Manual

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

Figure 20-43-25 4

Actuator Removal And Installation (Out Of Loader) (Cont’d) Figure 20-43-23 2

1

3 P107807A

1

P107806

Using a punch and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-23] from the actuator and the tilt spool.

Installation: Tighten the mounting bolts to 10,2 - 11,3 N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-43-25].

Remove the actuator and linkage pin from the valve. Figure 20-43-24

1

2

P-54340

Remove the O-ring (Item 1) [Figure 20-43-24] on the face of the actuator. Inspect the linkage pin (Item 2) [Figure 20-43-24] and replace as needed.

286 of 1311

20-43-8

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: The two long bolts (Item 1) are used to mount the lift actuator (Item 2) [Figure 20-43-25] to the control valve. The two short bolts (Item 3) are used to mount the tilt actuator (Item 4) [Figure 20-43-25].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Identification Chart Figure 20-43-26 AR

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 – Without Auxiliary Relief Valve 24132 kPa (241 bar) (3500 psi)

MR

Main Relief Valve – With Auxiliary Relief Valve 25511-26200 kPa (255-262 bar) (3700-3800 psi)

AR

Auxiliary Relief Valve - If Equipped 2378724476 kPa (238-245 bar) (3450-3550 psi)

D2

D3

D4

D5

287 of 1311

20-43-9

BICS™ Solenoid

S650 Service Manual

Dealer Copy -- Not for Resale

MR

F1

E1

B1

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

Lift Load Check Valve Removal And Installation

Mount Bracket Removal And Installation

IMPORTANT

Figure 20-43-27

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 20-43-29

1

P-90280

1

Figure 20-43-28

P107848

2

Remove the charge tubeline (Item 1) [Figure 20-43-29] from the BICS™ valve fitting on the top of the lift load check valve. 1

P100202

Remove the two control valve mount bolts (Item 1) [Figure 20-43-28]. Remove the two frame bolts (Item 2) [Figure 20-43-28]. Installation: Torque the two frame bolts (Item 2) [Figure 20-43-28] to 300 - 330 ft lb (406 - 447 N•m). Remove the control valve bracket from the loader.

288 of 1311

20-43-10

S650 Service Manual

Dealer Copy -- Not for Resale

Support the mounting bracket (Item 1) [Figure 20-43-27].

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

Load Check Valve Removal And Installation (Tilt And Auxiliary)

Lift Load Check Valve Removal And Installation (Cont’d)

Figure 20-43-32

Figure 20-43-30 2 1 1

P107849

Remove the lift load check valve (Item 1) [Figure 20-4330] 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 20-4332]. At the front side of the control valve locate and remove the auxiliary section load check valve (Item 2) [Figure 20-43-32]. NOTE: The tilt and auxiliary load check valves are interchangeable.

Figure 20-43-31

Figure 20-43-33 1 5 1 2 2 3

4

4

P107716

3 P107624

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-43-31]. Inspect the spring (Item 3) and the free movement in the load check valve (Item 4) [Figure 20-43-31]. Inspect the orifice to make sure it is not plugged (Item 5) [Figure 20-43-31].

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-33]. Inspect the orifice (Item 3) [Figure 20-43-33] in the poppet to make sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4333] and lubricate with oil before installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

289 of 1311

20-43-11

S650 Service Manual

Dealer Copy -- Not for Resale

P107850

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

Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)

Anti-Cavitation Valve Removal And Installation (Lift, Rod End)

Figure 20-43-36

Figure 20-43-34

1 1

P107628

At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-43-34].

Remove the lift circuit port relief / anti-cavitation valve and the port relief / anti-cavitation seat (Item 1) [Figure 20-43-36]. Figure 20-43-37

Figure 20-43-35

1 2 2 1 4

P107952

3 P107624

Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-35]. Inspect the orifice (Item 3) [Figure 20-43-35] in the poppet to make sure it is not plugged. Installation: Install a new O-ring (Item 4) [Figure 20-4335] on the plug and lightly lubricate with oil before installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

290 of 1311

Remove the O-ring (Item 1) [Figure 20-43-37] from the port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2) [Figure 20-43-24] 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.

20-43-12

S650 Service Manual

Dealer Copy -- Not for Resale

P107628

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (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 20-43-40

Figure 20-43-38

1 1

P107628

Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-43-38] 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 20-43-40] from the rod end of the tilt section. Figure 20-43-41

Figure 20-43-39

2 1

1

P107952 P107629

Remove the O-ring (Item 1) [Figure 20-43-39] 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 20-43-41] from the port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2) [Figure 20-43-41] 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.

291 of 1311

20-43-13

S650 Service Manual

Dealer Copy -- Not for Resale

P107628

Figure 20-43-44

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Port Relief Valve Removal And Installation Figure 20-43-42

1

1

P107628

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-43-44]. P107628

Remove the auxiliary port relief valve. Figure 20-43-45

Dealer Copy -- Not for Resale

Remove the port relief plug (Item 1) [Figure 20-43-42] from the auxiliary circuit of the control valve. Figure 20-43-43

1 1

2 P107629

Remove the O-ring (Item 1) [Figure 20-43-45] from the optional auxiliary port relief valve.

P107630

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-43-43] 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.

292 of 1311

20-43-14

S650 Service Manual

Figure 20-43-48

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Port Relief Valve Removal And Installation (Cont’d) Figure 20-43-46

1

1

P107628

The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-43-48]. P107628

Remove the auxiliary port relief valve. Figure 20-43-49

Dealer Copy -- Not for Resale

Remove the port relief plug (Item 1) [Figure 20-43-46] from the auxiliary circuit of the control valve. Figure 20-43-47

1 1

2

P107629

Remove the O-ring (Item 1) [Figure 20-43-49] from the optional auxiliary port relief valve.

P107630

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-43-47] 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.

293 of 1311

20-43-15

S650 Service Manual

Figure 20-43-52

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Plug Removal And Installation Figure 20-43-50

1 1

P107632

At the bottom side of the control valve remove the plug (Item 1) [Figure 20-43-52]. P107631

At the top side of the control valve, remove the plug (Item 1) [Figure 20-43-50]. Figure 20-43-51

1

1 P107633

Remove the O-ring (Item 1) [Figure 20-43-53] from the plug. P107633

Installation: Tighten to 81,3 N•m (60 ft-lb) torque. Remove the O-ring (Item 1) [Figure 20-43-51] from the plug. Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

294 of 1311

20-43-16

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-43-53

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (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 20-43-5.)

MEL1285 - Spring Tool

Figure 20-43-54

Figure 20-43-56

Remove the end cap block from the control valve.

1

2

P107851

P107853

Disconnect the tubeline (Item 1) [Figure 20-43-54] from the end cap block. Remove the two end cap block mount screws (Item 2) [Figure 20-43-54]. 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 20-43-56]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap block. Figure 20-43-57

Figure 20-43-55

2

1 P107753

1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-57] from the lift spool.

P107852

Remove the end cap block (Item 1) [Figure 20-43-55] from the control valve.

295 of 1311

20-43-17

S650 Service Manual

Dealer Copy -- Not for Resale

1

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

Figure 20-43-60

Lift Spool Removal And Installation (Cont'd) Figure 20-43-58

2 1 P107756

Remove the lift spool assembly (Item 1) and O-ring (Item 2) [Figure 20-43-60] from the control valve.

1 P107854

Remove the four screws (Item 1) [Figure 20-43-58] from the spool centering block. Installation: Lubricate the screws and tighten to 10,4 11,6 N•m (95 - 105 in-lb) torque. Figure 20-43-59

1

P107757

2 Remove the lift spool seal (Item 1) [Figure 20-43-61] from the actuator end of the valve. 1 P107855

Remove the spool centering block (Item 1) and O-ring (Item 2) [Figure 20-43-59] from the control valve. Installation: Replace the O-ring (Item 2) [Figure 20-4359] and lubricate lightly with oil before installation of the spool centering block.

296 of 1311

20-43-18

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-43-61

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

Figure 20-43-64

Lift Spool Disassembly And Assembly Figure 20-43-62

1

P107647

Remove the bolt (Item 1) [Figure 20-43-64] holding the centering spring to the spool. P107740

NOTE: Protect spool before clamping in vise.

Remove spring tool from the spring assembly. Figure 20-43-65

Figure 20-43-63 3 2 4

1

1

P-51776B P107646

Install the spring tool (Item 1) [Figure 20-43-63] over the centering spring.

297 of 1311

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-43-65].

20-43-19

S650 Service Manual

Dealer Copy -- Not for Resale

Clamp the actuator end of the spool in a vise [Figure 2043-62].

Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105 in-lb) torque.

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

Figure 20-43-68

Tilt Spool Removal And Installation Remove the end cap block. (See End Cap Block Removal And Installation on Page 20-43-17.) 2

Figure 20-43-66

1

P107769

Remove the tilt spool assembly (Item 1) and O-ring (Item 2) [Figure 20-43-68].

1

P107856

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-66] from the tilt spool. Figure 20-43-67 1

1 P107770

Remove the spool seal (Item 1) [Figure 20-43-69].

P107769

Remove the O-ring (Item 1) [Figure 20-43-67]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the spool centering block.

298 of 1311

20-43-20

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-43-69

2

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

Figure 20-43-72

Tilt Spool Disassembly And Assembly 2 Figure 20-43-70

1

3

4

1 N-18944B

Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-43-72]. P107646

Dealer Copy -- Not for Resale

Put the actuator end of the spool in the vise [Figure 2043-70]. NOTE: Protect spool before clamping in vise. Install the spring tool (Item 1) [Figure 20-43-70] over the centering spring. Figure 20-43-71

1

P107647

Remove the bolt (Item 1) [Figure 20-43-71] 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.

299 of 1311

20-43-21

S650 Service Manual

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

Figure 20-43-75

Auxiliary Spool Removal And Installation Figure 20-43-73

2 1

2

P107760

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-75] from the auxiliary spool.

1

Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-73] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-43-73] must be replaced, replace the retainer on the opposite end also.

NOTE: If the centering spring retainer (Item 2) [Figure 20-43-75] must be replaced, replace the retainer on the opposite end also. Figure 20-43-76

Figure 20-43-74

2

1

2

P107761

1

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-76] from the auxiliary spool.

P107759

Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-74] from the auxiliary spool.

300 of 1311

20-43-22

S650 Service Manual

Dealer Copy -- Not for Resale

P107758

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Auxiliary Spool Removal And Installation (Cont’d)

Auxiliary Solenoid Removal And Installation Figure 20-43-78

Figure 20-43-77

2

1 2

1

1 P107847

Remove the auxiliary spool (Item 1) [Figure 20-43-77].

Remove the screws (Item 1) [Figure 20-43-78] from both solenoids. Remove the solenoids (Item 2) [Figure 20-43-78]. Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 23.9 in-lb) torque. Figure 20-43-79

1

2

P107798

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-79] from the solenoid stem. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 5.1 ohm. Installation: Lubricate and install new O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-79].

301 of 1311

20-43-23

S650 Service Manual

Dealer Copy -- Not for Resale

P107762

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

Figure 20-43-82

Solenoid Removal And Installation 1

Figure 20-43-80 1

2

P107857

Remove the solenoid stem (Item 1) [Figure 20-43-82]. 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 20-43-80] from the solenoid stem.

Figure 20-43-83

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 20-43-80].

3 2

Figure 20-43-81

1 1 1 N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-83] from the stem. Clean all parts in solvent and dry with compressed air. N-18693A

Remove the O-rings (Item 1) [Figure 20-43-81] 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 20-43-83] 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.

302 of 1311

20-43-24

S650 Service Manual

Figure 20-43-86

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Lock Valve Removal And Installation Figure 20-43-84

1

1

2

P107937

The inside diameter of the BICS™ valve (Item 1) [Figure 20-43-86] 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 20-4384].

1

Figure 20-43-85

3 2

1

P107767

Remove the O-ring (Item 1) [Figure 20-43-87]. Remove and inspect the spring (Item 2) and BICS™ valve (Item 3) [Figure 20-43-87].

P107859

Remove the lift lock valve retaining cap (Item 1) [Figure 20-43-85] 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.

303 of 1311

20-43-25

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-43-87

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

Figure 20-43-89

Lock Valve Removal And Installation (Cont’d) Figure 20-43-88

1

1

P107937

The inside diameter of the BICS™ valve (Item 1) [Figure 20-43-89] is threaded for easier removal and installation. P107860

Remove the tilt lock valve retaining cap (Item 1) [Figure 20-43-88] 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 20-43-90]. Remove and inspect the spring (Item 2) and BICS™ valve (Item 3) [Figure 20-43-90].

304 of 1311

20-43-26

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-43-90

Main Relief Valve Removal And Installation

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

Figure 20-43-93

Lift Arm Bypass Orifice Removal And Installation Figure 20-43-91

1 1

P107862

Remove the main relief valve (Item 1) [Figure 20-43-93].

Remove the fitting (Item 1) [Figure 20-43-91] from the valve.

Figure 20-43-94

Dealer Copy -- Not for Resale

P107861

Figure 20-43-92

1

1

P107659

Remove the O-rings (Item 1) [Figure 20-43-94] from the main relief valve.

P-51437

Inspect the lift arm bypass orifice (Item 1) [Figure 20-4392].

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve casting.

305 of 1311

20-43-27

S650 Service Manual

Check Valve Removal And Installation

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

Figure 20-43-97

Auxiliary Relief Valve Removal And Installation Figure 20-43-95

1

1

P107848

Remove the tubeline (Item 1) [Figure 20-43-97].

Remove the auxiliary relief valve (Item 1) [Figure 20-4395].

Figure 20-43-98

Figure 20-43-96

2

1

P107864

1

Remove the check valve fitting (Item 1) [Figure 20-4398] from the hydraulic control valve.

P107627

Remove the O-rings (Item 1) [Figure 20-43-96] and back-up ring (Item 2) [Figure 20-43-96] from the auxiliary relief valve. Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

306 of 1311

20-43-28

S650 Service Manual

Dealer Copy -- Not for Resale

P107863

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D) Check Valve Removal And Installation (Cont’d) Figure 20-43-99

3

1 2 P107625

Dealer Copy -- Not for Resale

Inspect the spring (Item 2) and poppet (Item 3) [Figure 20-43-99]. Remove the O-ring (Item 1) [Figure 20-43-99]. Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ftlb) torque.

307 of 1311

20-43-29

S650 Service Manual

Dealer Copy -- Not for Resale 308 of 1311

20-43-30

S650 Service Manual

LIFT ARM BYPASS CONTROL VALVE

Testing

Description

Figure 20-50-1

The lift arm bypass control valve is located on the right side of the machine. The lift arm bypass control valve is manually operated by turning the lift arm bypass valve knob (Item 1) [Figure 20-50-1] 90 degrees 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.

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] clockwise 1/4 turn. Then pull up and hold the Lift Arm Bypass Control Knob until the lift arms slowly lower. The knob should return to its normal position.

309 of 1311

20-50-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-85290B

LIFT ARM BYPASS CONTROL VALVE (CONT’D)

Figure 20-50-2

Removal And Installation

1 3

DANGER

2

P-85670

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

Hold the lift arm bypass control knob (Item 1) [Figure 2050-2] and loosen the jam nut on the lift arm bypass valve shaft. Remove the lift arm bypass control knob (Item 1). Remove the jam nut (Item 2) from the valve shaft [Figure 20-50-2]. 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

Lower the lift arms. 1

Raise the operator cab. (See Raising on Page 10-30-2.)

P-85671

Disconnect and cap the hydraulic tubeline and hose (Item 1) [Figure 20-50-3]. Remove the two mounting bolts and nuts (Item 2) [Figure 20-50-3]. Installation: Tighten the mounting bolts to 21 - 23 N•m (180 - 200 in-lb) torque. Remove the lift arm bypass valve.

310 of 1311

20-50-2

S650 Service Manual

Dealer Copy -- Not for Resale

•

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

Reverse the removal procedure to install the lift arm bypass valve in the loader.

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.

311 of 1311

20-50-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the two bolts (Item 1) [Figure 20-50-4] to replace the bypass valve mounting bracket if necessary.

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 312 of 1311

20-50-4

S650 Service Manual

Description The hydraulic pump is attached to the end of the hydrostatic pumps and is located on the right side of the loader between the hydraulic control valve and the engine.

Start the engine and run at low idle rpm. Press the Auxiliary hydraulics button. Engage the front auxiliary with the trigger on the right handle or joystick. 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*.

The hydraulic pump is a combination of gear pumps that provide hydraulic flow to several hydraulic systems.

Warm the fluid to 60°C (140°F) by turning the restrictor control clockwise on the tester so it reads about 6895 kPa (68,9 bar) (1000 psi).

The hydraulic pump has a dedicated charge pump. This supplies flow to the hydraulic fan motor and charge pressure to the hydrostatic pump.

NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700 psi).

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. Pump Test At Quick Couplers The tools listed will be needed to do the following procedure: TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit Figure 20-60-1

Turn the restrictor control (Item 2) [Figure 20-60-1] on the tester counterclockwise to obtain free flow, the flow should be approximately 87,1 - 90,8 L/min (23 - 24 U.S. gpm). Start turning the restrictor clockwise, causing more restriction on the flow. The L/min (U.S. gpm) 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). Turn the restrictor (Item 2) [Figure 20-60-1] counterclockwise to free flow. Shut the auxiliary hydraulics off. If flow and pressure specifications are not obtained, go to Direct Pump Testing. (See Direct Pump Test (Standard Section) on Page 20-60-2.)

1

*Refer to (See Hydraulic System on Page SPEC-10-4.) for system relief pressure and full rpm.

2

P-90171

NOTE: When testing the hydraulic flow of a machine, hoses must be at least 19,05 mm (3/4 in) in diameter and connected directly to the hydraulic tester without using any type of “quick coupler” on the connection to the tester. Also make sure your hydraulic tester is capable of at least 189,3 L/min (50 U.S. gpm). Install a hydraulic tester (Item 1) [Figure 20-60-1] onto the front auxiliary quick couplers. This procedure will require one operator in the cab and one operator running the tester.

313 of 1311

20-60-1

S650 Service Manual

Dealer Copy -- Not for Resale

HYDRAULIC PUMP

Figure 20-60-2

HYDRAULIC PUMP (CONT'D) Direct Pump Test (Standard Section) The tools listed will be needed to do the following procedure:

2

MEL1563 or 7217666 - Remote Start Tool Kit TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit

1

WARNING

1

2

W-2017-0286

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

P-90178

P-90176

Disconnect the OUTLET hose (Item 1) [Figure 20-60-2] that comes from the gear pump, and connects to the control valve fitting (Item 2) [Figure 20-60-2] (Inset). Figure 20-60-3

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

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.

P-90580

W-2059-0598

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.)

2

Connect the INLET hose (Item 1) [Figure 20-60-3] from the tester to the OUTLET hose (Item 1) [Figure 20-60-2] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-60-3] from the tester to the control valve fitting (Item 2) [Figure 20-60-2] on the control valve.

NOTE: The control panel is shown removed for photo clarity.

314 of 1311

20-60-2

S650 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) 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 (68,9 bar) (1000 psi). DO NOT exceed system relief pressure. Open the restrictor control and record the free flow (L/min [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 handle or joystick for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (L/min [U.S. gpm]). The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump. *Refer to (See Hydraulic System on Page SPEC-10-4.) for system relief pressure and full rpm.

315 of 1311

20-60-3

S650 Service Manual

HYDRAULIC PUMP (CONT'D)

Figure 20-60-4 Earlier Models

Direct Pump Test (Charge Section) The tools listed will be needed to do the following procedure:

1

MEL1563 or 7217666 - Remote Start Tool Kit TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit

WARNING

W-2017-0286

P114639

Figure 20-60-5 Later Models 1

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

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.

P115656

Disconnect the inlet hose (Item 1) [Figure 20-60-4] or [Figure 20-60-5].

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.)

316 of 1311

20-60-4

S650 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)

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*.

Direct Pump Test (Charge Section) (Cont’d) Figure 20-60-6

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 (L/min [U.S. gpm]) at full rpm*. Turn the restrictor down to system operating pressure approximately 6895 kPa (68,9 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.

2

1

%=

HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 FREE FLOW (L/min [U.S. gpm])

P-90580

A low percentage may indicate a failed pump. *Refer to the Hydraulic Schematics for pump flow and rpm.

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284

317 of 1311

20-60-5

S650 Service Manual

Dealer Copy -- Not for Resale

Connect the INLET hose (Item 1) [Figure 20-60-6] from the tester to the OUTLET hose (Item 1) [Figure 20-60-4] or [Figure 20-60-5] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-60-6] from the tester to the inlet fitting on the fan (Item 1) [Figure 20-60-4] or [Figure 2060-5].

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 20-60-7

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 and cap the four hoses (Item 1) [Figure 2060-7] 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 20-60-8

2

D-1009-0409

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

Lift and block the rear of the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

P106593

Remove the bracket mounting bolt / nut (Item 1) [Figure 20-60-8]. Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28 ft-lb) torque.

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

318 of 1311

20-60-6

S650 Service Manual

Dealer Copy -- Not for Resale

P-90180

HYDRAULIC PUMP (CONT'D)

Figure 20-60-10

Removal And Installation (Cont’d) Figure 20-60-9

1 1 2

1 P-43940

3

P-43938A

Replace the O-ring (Item 1) [Figure 20-60-10] on the hydraulic pump.

Disconnect and cap the outlet hoses (Item 1) [Figure 2060-9] from the hydraulic pump.

Reverse the removal procedure to install the hydraulic pump.

Dealer Copy -- Not for Resale

P-90509

Remove the two mounting bolts (Item 2) [Figure 20-60-9] and [Figure 20-60-9] from the hydraulic pump. Installation: Clean the threads and apply Loctite® 242 to the mounting bolts and tighten to 75 - 85 N•m (55 - 60 ftlb) torque. Remove the hydraulic pump (Item 3) [Figure 20-60-9] from the loader.

319 of 1311

20-60-7

S650 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 20-60-11

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. With the loader parked on a level surface and lift arms down, check and fill the hydraulic reservoir as required. Check for hydraulic leaks.

Dealer Copy -- Not for Resale

1

P100685

Figure 20-60-12

1

2

P100352

Attach a push button starter switch (MEL1712) (Item1) [Figure 20-60-11] to the starter terminal S (Item 1) and the positive battery cable (Item 2) [Figure 20-60-12].

320 of 1311

20-60-8

S650 Service Manual

HYDRAULIC PUMP (CONT'D) Parts Identification Figure 20-60-13 Bolt Charge Pump End Section Section Seal Wear Plate Charge Pump Center Section Idler Gear Drive Gear Dowel Pin Spline Shaft Load Seal Preload Seal Center Section Auxiliary Pump Center Section Auxiliary Pump End Section Shaft Seal 7 8 9 10

4

Dealer Copy -- Not for Resale

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

3

1

8

6

5 8

11 14

3

11

2

3

4

7

10

3

12

4

4

8

6

13

15

P-66540

321 of 1311

20-60-9

S650 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 20-60-9.) for proper placement of components along with the information below.

Dealer Copy -- Not for Resale

NOTE: A seal kit is available through Bobcat Service Parts. Assembly: Tighten the eight pump housing bolts (Item 1) [Figure 20-60-13] to 50 N•m (37 ft-lb) torque. NOTE: Position the wear plate (Item 4) [Figure 20-6013] as shown with the bronze side toward the gears. NOTE: Inspect all gears, shafts and pump end sections. If any of these components have excessive wear or damage, the complete pump must be replaced.

322 of 1311

20-60-10

S650 Service Manual

HYDRAULIC PUMP (HIGH FLOW)

This procedure will require one operator in the cab and one operator running the tester.

Description

The hydraulic gear pump is a combination of gear pumps that provide hydraulic flow to several hydraulic systems. The hydraulic gear pump has a dedicated charge pump. This supplies flow to the hydraulic fan motor and charge pressure to the hydrostatic pump. The high flow hydraulic pump has an additional pump section that provides an additional amount of flow that is controlled by an external valve. The valve is switched from a button on the panel in the cab. A seal kit is available to service the hydraulic pump. If any of the main components of the pump are damaged, the entire pump must be replaced. Pump Test At Quick Couplers The tools listed will be needed to do the following procedure: TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit Figure 20-61-1

Start the engine and run at low idle rpm. Press the Auxiliary hydraulics button. Engage the front auxiliary with the trigger on the right handle or joystick. 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*. Warm the fluid to 60°C (140°F) by turning the restrictor control clockwise on the tester so it reads about 6895 kPa (68,9 bar) (1000 psi). NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700 psi). Turn the restrictor control (Item 2) [Figure 20-61-1] on the tester counterclockwise to obtain free flow, the flow should be approximately 87,1 - 90,8 L/min (23 - 24 U.S. gpm). Start turning the restrictor clockwise, causing more restriction on the flow. The L/min (U.S. gpm) 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). Turn the restrictor (Item 2) [Figure 20-61-1] counterclockwise to free flow. Shut the auxiliary hydraulics off. If flow and pressure specifications are not obtained, go to Direct Pump Testing. (See Direct Pump Test (Standard Section) on Page 20-61-2.)

1

*Refer to (See Hydraulic System on Page SPEC-10-4.) for system relief pressure and full rpm.

2

P-90171

NOTE: When testing the hydraulic flow of a machine, hoses must be at least 19,05 mm (3/4 in) in diameter and connected directly to the hydraulic tester without using any type of quick coupler on the connection to the tester. Install a hydraulic tester (Item 1) [Figure 20-61-1] onto the front auxiliary quick couplers.

323 of 1311

20-61-1

S650 Service Manual

Dealer Copy -- Not for Resale

The hydraulic gear pump is attached to the end of the hydrostatic pumps and is located on the right side of the loader between the hydraulic control valve and the engine.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

NOTE: The control panel is shown removed for photo clarity.

Direct Pump Test (Standard Section) Figure 20-61-2 The tools listed will be needed to do the following procedure: MEL1563 or 7217666 - Remote Start Tool Kit TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit 2

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.

1

2 P-90178

P-90176

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Disconnect the OUTLET hose (Item 1) that comes from the gear pump, and connects to the control valve fitting (Item 2) [Figure 20-61-2] (Inset). Figure 20-61-3

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

2

W-2059-0598

Raise the operator cab. (See Raising on Page 10-30-2.)

P-90580

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.)

324 of 1311

Connect the INLET hose (Item 1) [Figure 20-61-3] from the tester to the OUTLET hose (Item 1) [Figure 20-61-2] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-61-3] from the tester to the control valve fitting (Item 2) [Figure 20-61-2] on the control valve.

20-61-2

S650 Service Manual

Dealer Copy -- Not for Resale

W-2017-0286

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Direct Pump Test (Charge Section)

Direct Pump Test (Standard Section) (Cont'd)

The tools listed will be needed to do the following procedure:

Warm the fluid to 60°C (140°F) by turning the restrictor control on the tester to about 6895 kPa (68,9 bar) (1000 psi). DO NOT exceed system relief pressure. Open the restrictor control and record the free flow (L/min [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 handle or joystick for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (L/min [U.S. gpm]). The high pressure flow must be at least 80% of free flow. %=

MEL1563 or 7217666 - Remote Start Tool Kit TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter MEL10006 - Fitting Kit

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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump. *Refer to (See Hydraulic System on Page SPEC-10-4.) for system relief pressure and full rpm.

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

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.)

325 of 1311

20-61-3

S650 Service Manual

Dealer Copy -- Not for Resale

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*.

Figure 20-61-6

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge S ection) (Cont’d) Figure 20-61-4 Earlier Models

1

2

1

P-90580

P114639

Figure 20-61-5 Later Models 1

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*.

P115656

Disconnect the inlet hose (Item 1) [Figure 20-61-4] or [Figure 20-61-5].

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 (L/min [U.S. gpm]) at full rpm*. Turn the restrictor down to system operating pressure approximately 6895 kPa (68,9 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 (L/min [U.S. gpm]) X 100 FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump. *Refer to the Hydraulic Schematics for pump flow and rpm.

326 of 1311

20-61-4

S650 Service Manual

Dealer Copy -- Not for Resale

Connect the INLET hose (Item 1) [Figure 20-61-6] from the tester to the OUTLET hose (Item 1) [Figure 20-61-4] or [Figure 20-61-5] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-61-6] from the tester to the inlet fitting on the fan (Item 1) [Figure 20-61-4] or [Figure 2061-5].

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Figure 20-61-7

Direct Pump Test (High Flow Section)

1

WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

P-90186

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.

Install a jumper hose (Item 1) [Figure 20-61-7] onto the front auxiliary quick couplers. Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Dealer Copy -- Not for Resale

WARNING

W-2059-0598

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284

The tools listed will be needed to do the following procedure: MEL1563 or 7217666 - Remote Start Tool Kit MEL10003 or MEL1744 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) 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.)

327 of 1311

20-61-5

S650 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Start the engine and run at low idle rpm. Press the front auxiliary button. Press the High Flow button. Push the button (on the right control lever) for fluid flow to the quick coupler. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*.

Direct Pump Test (High Flow Section) (Cont'd) Figure 20-61-8

1

Warm the fluid to 60°C (140°F) by turning the restrictor control on the tester to about 6895 kPa (68,9 bar) (1000 psi). NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700 psi).

P-90183

Disconnect the high flow pump OUTLET hose (Item 1) from the high flow check valve INLET fitting (Item 2) [Figure 20-61-8].

If pressure readings are not obtained go to the High Flow Valve, relief valve adjustment procedure.(See High Flow Relief Valve Removal And Installation on Page 20-61-8.) Record the highest pressure (psi) and flow (L/min [U.S. gpm]). The high pressure flow must be at least 80% of free flow.

Figure 20-61-9

%=

HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics Legend for system relief pressure and full rpm.

2

1

P-90580

Connect the INLET hose (Item 1) [Figure 20-61-9] from the tester, to the high flow pump OUTLET hose (Item 1) [Figure 20-61-8]. Connect the OUTLET hose (Item 2) [Figure 20-61-9] from the tester, to the high flow check valve INLET fitting (Item 2) [Figure 20-61-8]. Lower the cab.

328 of 1311

20-61-6

S650 Service Manual

Dealer Copy -- Not for Resale

Open the restrictor control and record the free flow (L/min [U.S. gpm]) at full rpm. Increase the restriction and the flow should drop to 0 L/min (0 U.S. gpm) between 24132 kPa (241,3 bar) (3500 psi) and 25511 kPa (255,1 bar) (3700 psi).

2

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Figure 20-61-11

High Flow Relief Valve Adjustment If the pump is unable to reach 24132 kPa (241,3 bar) (3500 psi) stop the engine. The relief screw (Item 1) [Figure 20-61-12] will need to be turned 90° clockwise and retested with the procedure above. (90° turn equals approximately 1379 kPa (13,8 bar) (200 psi).) NOTE: If the relief screw has been turned in 1/4 turn and the pressure remains the same, go to the high flow relief valve removal and installation section. (See High Flow Relief Valve Removal And Installation on Page 20-61-8.) If relief valve has been tested and is okay, go to the high flow pump disassembly and assembly section. (See Disassembly And Assembly on Page 20-61-14.) Remove right rear wheel. (See Wheel Nuts on Page 10160-1.)

1

2

P-45443

Locate the high flow relief valve (Item 1) [Figure 20-6111] along the right side of the engine. Remove the plug (Item 2) [Figure 20-61-11] located on the bottom of the high flow relief valve.

Dealer Copy -- Not for Resale

Figure 20-61-10 Figure 20-61-12

1

1

P-90577

P-45445

Remove the mounting bolts (Item 1) [Figure 20-61-10] from the access cover and remove the cover from the loader.

NOTE: [Figure 20-61-12] shows adjusting the relief screw. If the pump reaches 25511 kPa (255,1 bar) (3700 psi) and there is flow stop the engine. The relief screw must be turned 90° counterclockwise and retested with the procedure above.

329 of 1311

20-61-7

S650 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Figure 20-61-14

High Flow Relief Valve Removal And Installation

1

WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

Remove right rear wheel. (See Wheel Nuts on Page 10160-1.) Figure 20-61-13

P-45444

Locate the high flow relief valve through rear door along the right side of the engine.

1 Installation: Tighten the relief valve to 41 - 47 N•m (30 35 ft-lb) torque. Figure 20-61-15

1

1

P-90577

3 Remove the mounting bolts (Item 1) [Figure 20-61-13] from the access cover and remove the cover from the loader.

2

P-45459

Inspect the relief valve and replace the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-61-15]. If the relief valve is bad, it must be replaced as a complete unit. Remove the plug (Item 3) and replace the O-ring [Figure 20-61-15].

330 of 1311

20-61-8

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the relief valve (Item 1) [Figure 20-61-14] from the pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Figure 20-61-18

Solenoid Removal And Installation

2

Figure 20-61-16

1

1 P-45461

NOTE: Mark the pump housing (Item 1) [Figure 20-6118] for proper installation of the solenoid valve cartridge.

At the right side access hole, disconnect the electrical connector (Item 1) [Figure 20-61-16] from the high flow pump solenoid.

Remove the valve cartridge (Item 2) [Figure 20-61-18]. Installation: Tighten the solenoid valve to 47 - 54 N•m (35 - 40 ft-lb).

Figure 20-61-17 Figure 20-61-19 1 2

2

1

P-45460 P-45462

Remove the solenoid nut (Item 1) [Figure 20-61-17]. Replace the O-ring (Item 1) [Figure 20-61-19]. Remove the solenoid (Item 2) [Figure 20-61-17]. Installation: Tighten the solenoid nut to 5 - 8 N•m (48 72 in-lb).

331 of 1311

Replace the O-ring and back-up ring (Item 2) [Figure 2061-19].

20-61-9

S650 Service Manual

Dealer Copy -- Not for Resale

P-43958

HYDRAULIC PUMP (HIGH FLOW) (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 20-61-20 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.

1

W-2059-0598

DANGER

1 1

Disconnect and cap the inlet hoses (Item 1) [Figure 2061-20] from the front of the hydraulic pump. Figure 20-61-21 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

1

IMPORTANT

P-90185

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

Disconnect and cap the hoses (Item 1) [Figure 20-61-21] from the back of the hydraulic pump. Remove the Power Bob-Tach block (if equipped). (See Removal And Installation on Page 20-120-1.)

Lift and block the rear of the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

332 of 1311

20-61-10

S650 Service Manual

Dealer Copy -- Not for Resale

P-90184

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Figure 20-61-24

Removal And Installation (Cont’d) Figure 20-61-22 1

1 2 1 P-43940

P-43938A

Replace the O-ring (Item 1) [Figure 20-61-24] on the hydraulic pump.

P-90509A

Remove the bracket mounting bolt / nut (Item 1) [Figure 20-61-22].

Reverse the removal procedure to install the hydraulic pump.

Dealer Copy -- Not for Resale

3

Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28 ft-lb) torque. Figure 20-61-23 1

2 1

3 P-90509A

Disconnect and cap the outlet hoses (Item 1) [Figure 2061-23] from the hydraulic pump. Remove the two mounting bolts (Item 2) [Figure 20-6122] and [Figure 20-61-23]from the hydraulic pump. Installation: Tighten the mounting bolts to 75 - 85 N•m (55 - 60 ft-lb) torque. Remove the hydraulic pump (Item 3) [Figure 20-61-23] from the loader.

333 of 1311

20-61-11

S650 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 (HIGH FLOW) (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 20-61-25

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. With the loader parked on a level surface and lift arms down, check and fill the hydraulic reservoir as required. Check for hydraulic leaks.

Dealer Copy -- Not for Resale

1

P100685

Figure 20-61-26

1

2

P100352

Attach a push button starter switch (MEL1712) (Item 1) [Figure 20-61-25] to the starter terminal S (Item 1) and the positive battery cable (Item 2) [Figure 20-61-26].

334 of 1311

20-61-12

S650 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Parts Identification Figure 20-61-27

21

5

4 3

6

22 24 1

10

2 3 23

7

4

9

8

10

17 4 3 10 3 9

8

7

1. Stem 2. Valve 3. Wear Plate 4. Seal Section 5. Rear Housing 6. Bolt 7. Preload Seal 8. Load Seal 9. Spline Connector 10. Pin 11. Gear Set 12. Gear Housing 13. Gear Housing 14. Gear Set 11 15. Gear Housing 16. Gear Set 17. Center Housing 12 18. Center Housing 19. Front Housing 20. Shaft Seal 21. High Flow Relief 22. Seal 23. Nut 24. Coil 14

Dealer Copy -- Not for Resale

22

4 10

18

13

4 3 10

4

7

8

4 15 16

19 20 10

MS1456S

335 of 1311

20-61-13

S650 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (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 20-61-13.) for proper placement of components along with the information below.

Dealer Copy -- Not for Resale

NOTE: A seal kit is available through Bobcat Service Parts. Assembly: Tighten the eight pump housing bolts (Item 6) [Figure 20-61-27] to 50 N•m (37 ft-lb) torque. NOTE: Position the wear plate (Item 3) [Figure 20-6127] inlets and traps as shown with the bronze side toward the gears on all wear plates. NOTE: Inspect all gears, shafts and pump end sections. If any of these components have excessive wear or damage is visible. The complete pump must be replaced. NOTE: The relief valve and the solenoid can be replaced along with the O-rings and back-up rings.

336 of 1311

20-61-14

S650 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS

Housing Removal And Installation

Description

DANGER

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. 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.

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

337 of 1311

20-70-1

S650 Service Manual

Dealer Copy -- Not for Resale

D-1009-0409

HYDRAULIC / HYDROSTATIC FILTER (CONT’D) Housing Removal And Installation (Cont’d)

Remove and plug the two hoses (Item 1) [Figure 20-702] from the bottom of the hydraulic / hydrostatic filter housing.

Figure 20-70-1

Figure 20-70-3 2

2

1 2 1

P-90010

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

P-90537

Remove the two bolts (Item 1) [Figure 20-70-3]. Remove the hydraulic / hydrostatic filter housing from the loader.

Raise the operator cab. (See Raising on Page 10-30-2.) Drain the fluid from the reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.) Disconnect the electrical connector (Item 1) [Figure 2070-1] from the hydraulic / hydrostatic filter sender. Disconnect and plug the three hoses (Item 2) [Figure 2070-1] from the hydraulic / hydrostatic filter housing. Figure 20-70-2

1

P-90011

338 of 1311

20-70-2

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Hex head filter shown but the procedure is the same for all filters.

1

HYDRAULIC FLUID RESERVOIR

Figure 20-80-2

Description The hydraulic fluid reservoir is a storage container for the loader’s hydraulic / hydrostatic fluid. The reservoir contains a vented fill cap with a fluid screen to prevent contaminants from entering the reservoir while adding fluid.

1

The hydraulic fluid reservoir is located behind the operator’s cab under the rear grille on the right side of the loader. Removal And Installation P-90579

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Remove the two bolts, (Item 1) [Figure 20-80-2] nuts, and bracket

Remove the rear grille. (See REAR GRILLE on Page 5060-1.) Drain the fluid from the reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

Remove the hydraulic fluid reservoir from the loader. Installation: Tighten the mount bolts and nuts to 21,7 24,4 N•m (16 - 18 ft-lb) torque.

Remove the Hydraulic / Hydrostatic Filter Housing. (See Housing Removal And Installation on Page 20-70-1.) Figure 20-80-1

1

P-90013

Remove the clamp and the hose (Item 1) [Figure 20-801].

339 of 1311

20-80-1

S650 Service Manual

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising on Page 10-30-2.)

HYDRAULIC FLUID RESERVOIR (CONT'D) Hydraulic Fluid Screen Remove the rear grille. (See REAR GRILLE on Page 5060-1.) Figure 20-80-3

1

Dealer Copy -- Not for Resale

P-90506

Remove the hydraulic fluid reservoir breather cap [Figure 20-80-3] from the reservoir. Remove the hydraulic fluid screen (Item 1) [Figure 2080-3] from the reservoir. Wash the screen in clean solvent and air dry, before replacing.

340 of 1311

20-80-2

S650 Service Manual

OIL COOLER

Removal And Installation

Description

Earlier Models

The oil cooler is used to cool the loaders hydraulic and hydrostatic oil. Oil passages are coiled into a heat exchanger. Air is forced, with the cooling fan, around the passages cooling the oil. The oil cooler is located underneath the rear grille between the A/C condenser (if so equipped) and the radiator.

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 rear grille from the loader. (See REAR GRILLE on Page 50-60-1.) Figure 20-90-1 1

3

P-85938

Slide the plastic sleeve (Item 1) away from the oil cooler (Item 2). Remove the clip (Item 3) [Figure 20-90-1] and pull hose out. Cap or plug all hoses and fittings.

341 of 1311

20-90-1

S650 Service Manual

Dealer Copy -- Not for Resale

2

OIL COOLER (CONT’D)

NOTE: When installing the cooler hoses, the fittings should make a clicking sound when pushed together.

Removal And Installation (Cont’d) Earlier Models (Cont’d)

Lift up the oil cooler and remove the cooler from the loader.

Figure 20-90-2 Later Models 2

The oil cooler and radiator are removed from the loader as a unit. (See Radiator / Oil Cooler Removal And Installation on Page 70-51-1.)

1

3

Dealer Copy -- Not for Resale

P-85936

Slide the plastic sleeve (Item 1) away from the oil cooler (Item 2). Remove the clip (Item 3) [Figure 20-90-2] and pull hose out. Cap or plug all hoses and fittings. Figure 20-90-3 4

4

2

5 3

2

1

P-85905

Undo the rubber straps (Item 1) [Figure 20-90-3] Remove the bolts (Item 2) and remove the condenser guards (Item 3) [Figure 20-90-3]. Remove the clips and pins (Item 4) [Figure 20-90-3]. Remove the bolt (Item 5) [Figure 20-90-3] from the prop rod.

342 of 1311

20-90-2

S650 Service Manual

BUCKET POSITION VALVE

Cover the fuel tank inlet.

Description

Figure 20-100-2

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.

3

The bucket position valve is mounted to the inside lower right rear side of the loader frame. 2

See Hydraulic Schematic for more circuit information. Solenoid Removal And Installation

DANGER 1

P-90197

Disconnect the cap the two tubelines (Item 2) [Figure 20100-2]. 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.

Remove the solenoid nut, coil, and stem (Item 3) from the bucket positioning valve [Figure 20-100-2]. Installation: Put oil on O-rings and back-up rings and tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb) torque.

D-1009-0409

Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb) torque. Overtightening may cause valve failure.

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

NOTE: The engine is shown removed for photo clarity.

Figure 20-100-1

Figure 20-100-3

3 1

1

2

2

P-90187

N-18191

Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and the place the fuel inlet assembly (Item 3) [Figure 20-100-1] off to the side.

343 of 1311

Inspect the solenoid stem and replace the O-rings (Item 1) and the back-up ring (Item 2) [Figure 20-100-3].

20-100-1

S650 Service Manual

Dealer Copy -- Not for Resale

Disconnect the wire harness connector (Item 1) [Figure 20-100-2] from the bucket position shut-off solenoid.

BUCKET POSITION VALVE (CONT'D)

Cover the fuel tank inlet.

Solenoid Testing

Figure 20-100-5

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. Removal And Installation

DANGER 1

P-90197

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.

NOTE: Mark all hoses and tubelines for correct installation. Disconnect the electric solenoid connector (Item 1) [Figure 20-100-5]. Figure 20-100-6

D-1009-0409

1

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.) Figure 20-100-4

2

3 4

1

3 P-90188

Disconnect and cap the tilt base inlet hose (Item 1), the tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3), and the lift base inlet hose (Item 4) [Figure 20-100-6] that route from the control valve. 2

P-90187

Remove the two bolts (Item 1), move the hose clamp (Item 2) to the middle of the hose, and the place the fuel inlet assembly (Item 3) [Figure 20-100-4] off to the side.

344 of 1311

20-100-2

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: The engine is shown removed for photo clarity.

BUCKET POSITION VALVE (CONT'D)

Figure 20-100-9

Removal And Installation (Cont'd) Figure 20-100-7

1

P-90190A

1

2 Remove the mounting screws (Item 1) [Figure 20-100-9]. P-90189A

Remove the bucket position valve from the loader.

Dealer Copy -- Not for Resale

Disconnect and cap the tilt cylinder hose (Item 1) and the tilt cylinder base end hose (Item 2) [Figure 20-100-7] from the valve block. Figure 20-100-8

2 2 1

1 P-90197A

Disconnect and cap the lift base outlet hose and tubeline (Item 1) and the lift rod outlet hose and tubeline (Item 2) [Figure 20-100-8] that route from the lift cylinders.

345 of 1311

20-100-3

S650 Service Manual

BUCKET POSITION VALVE (CONT'D)

Figure 20-100-12

Disassembly And Assembly Figure 20-100-10 3

1

2 1

3 2

P-90194

Remove the solenoid nut (Item 1), coil (Item 2), and the stem (Item 3) [Figure 20-100-10].

Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64 ft-lb) torque.

Assembly: Tighten the nut to a maximum of 8 N•m (6 ftlb) torque. Overtightening may cause valve failure.

Figure 20-100-13

Assembly: Put oil on O-rings and back-up rings and tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb) torque.

1

2

3

Figure 20-100-11

1

P-90193

Remove the plug (Item 1), spring (Item 2) and unloading spool (Item 3) [Figure 20-100-13]. Inspect all parts and replace as needed. Install a new Oring on the plug before installing.

P-90195

Remove the flow adjustment valve and O-ring (Item 1) [Figure 20-100-11].

Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64 ft-lb) torque.

Assembly: Tighten the flow adjustment valve to 36,6 48,8 N•m (27 - 36 ft-lb) torque. NOTE: Always install new O-rings before any parts are installed into the valve. Inspect the parts for wear or damage and replace as needed.

346 of 1311

20-100-4

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the tilt cylinder check valve (Item 1), spring (Item 2), and plug (Item 3) [Figure 20-100-12]. Inspect for wear, replace the O-ring.

P-90192

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, one set 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 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]. Coil wires do not have polarity. Correct resistance is 8.6 - 9.5 ohm. P9137

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]. Coil wires do not have polarity. Correct resistance for the solenoid coil with a molded connector is 8.1 - 9.9 ohm.

347 of 1311

20-110-1

S650 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D)

Figure 20-110-5

Removal And Installation

1

DANGER

1

P-93303

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 and cap the tubelines (Item 1) [Figure 20110-5]. Figure 20-110-6

D-1009-0409

1

Put jackstands under the rear corners of the loader. Raise the lift arms and install an approved lift arm support device. (See Installing 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.)

P100810

Figure 20-110-4 Disconnect the accessory wiring harness (Item 1) [Figure 20-110-6] from the main harness.

1

P-90583

Disconnect and cap the tubelines (Item 1) [Figure 20110-4].

348 of 1311

20-110-2

S650 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 20-110-7

Inspect cartridges, check valves, solenoid valves and sealing washers for contamination or damage. Wash all parts in clean solvent. Use air pressure to dry them. Install new O-rings and back-up rings.

2

Inspect diverter valve cavities for contamination. Wash valve in clean solvent. Use air pressure to dry.

1

Figure 20-110-8

P-90581

1 1 P-48751

Figure 20-110-9

1

P-48752

Clean the diverter valve to remove dirt before disassembly. Valve ports are labeled for correct assembly. Several plugs (Item 1) [Figure 20-110-8] and [Figure 20110-9] are located all over the diverter valve and can be removed for clean out purposes. Assembly: Put oil on O-rings and back-up rings. Tighten to 13,6 N•m (10 ft-lb) torque.

349 of 1311

20-110-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the two bolts (Item 1) and remove the valve (Item 2) [Figure 20-110-7].

REAR AUXILIARY DIVERTER VALVE (CONT'D)

Figure 20-110-12

Disassembly And Assembly (Cont'd)

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 P-48755

Figure 20-110-10

1

2

2

1

P-48755 P-48757

Figure 20-110-11 Remove the differential sensing valve (Item 1) [Figure 20-110-12] and [Figure 20-110-13] from diverter valve and inspect the O-rings and back-up rings (Item 2) [Figure 20-110-13] for damage. 2

2

2

Assembly: Put oil on O-ring and back-up rings. Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.

1

P-48756

Remove the shuttle valve (Item 1) [Figure 20-110-10] and [Figure 20-110-11] from diverter valve and inspect the O-rings and back-up rings (Item 2) [Figure 20-11011] for damage. Assembly: Put oil on the O-rings and back-up rings. Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

350 of 1311

20-110-4

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-110-13

REAR AUXILIARY DIVERTER VALVE (CONT'D)

Figure 20-110-16

Disassembly And Assembly (Cont'd) Figure 20-110-14

1

P-48759

1 Figure 20-110-17 P-48753

Figure 20-110-15

3

1 2 1

P-48760

NOTE: Before removing the solenoid coils mark the coils for proper alignment. Remove the nut (Item 1) [Figure 20-110-16] and [Figure 20-110-17] from the solenoid valve stem.

P-48754

Inspect the O-rings and back-up rings (Item 1) [Figure 20-110-15] for damage.

Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb) torque.

Assembly: Put oil on O-ring and back-up rings. Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.

Remove the spacer (Item 2) and solenoid valve coils (Item 3) [Figure 20-110-17].

351 of 1311

20-110-5

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the relief valve (Item 1) [Figure 20-110-14].

REAR AUXILIARY DIVERTER VALVE (CONT'D)

Figure 20-110-19

Disassembly And Assembly (Cont'd) Figure 20-110-18

1

1

P-48762

Figure 20-110-20 P-48761

Remove the nuts (Item 1) [Figure 20-110-18] from the solenoid valve stems. Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb) torque.

1

2

2 1

P-48763

Remove the solenoid valve stem (Item 1) [Figure 20110-19] and [Figure 20-110-20] and inspect the O-rings and back-up rings (Item 2) [Figure 20-110-20] for damage. Assembly: Put oil on O-rings and back-up rings. Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.

352 of 1311

20-110-6

S650 Service Manual

Dealer Copy -- Not for Resale

NOTE: Before removing the solenoid coils mark the coils for proper alignment.

REAR AUXILIARY DIVERTER VALVE (CONT'D)

Figure 20-110-23

Disassembly And Assembly (Cont'd) Figure 20-110-21 1 1

P-48765

Remove the plug (Item 1) [Figure 20-110-23]. P-48763A

Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque. Figure 20-110-22

1

Dealer Copy -- Not for Resale

Figure 20-110-24

2

1 P-48764

P-48766

Remove the solenoid valve stem (Item 1) [Figure 20110-21] and [Figure 20-110-22] and inspect the O-rings and back-up rings (Item 2) [Figure 20-110-22] for damage.

Remove and inspect the orifice (Item 1) [Figure 20-11024] for dirt and debris. Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb) torque.

Assembly: Put oil on O-rings and back-up rings. Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.

353 of 1311

20-110-7

S650 Service Manual

Figure 20-110-27

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-110-25

1 1

P-48758

Remove the plugs (Item 1) [Figure 20-110-27]. P-48765

Remove the plug (Item 1) [Figure 20-110-25]. Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque.

Inspect cartridges, check valves, solenoid valves and sealing washers for contamination or damage. Wash all parts in clean solvent. Use air pressure for drying them. Install new O-rings and back-up rings.

Figure 20-110-26 Inspect diverter valve cavities for contamination. Wash valve in clean solvent. Use air pressure to dry.

1

P-48786

Remove the orifice (Item 1) [Figure 20-110-26]. Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb) torque.

354 of 1311

20-110-8

S650 Service Manual

Dealer Copy -- Not for Resale

Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.

BOB-TACH (POWER) BLOCK

Removal And Installation

Description

WARNING

The Power Bob-Tach is an option that allows the operator to hydraulically control the Bob-Tach levers for mounting and dismounting the attachments. The Power Bob-Tach is operated by a switch on the right switch panel. The Power Bob-Tach block is mounted on the right side of the machine in front of the engine on the back side of the hydraulic pump.

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-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

355 of 1311

20-120-1

S650 Service Manual

Dealer Copy -- Not for Resale

DANGER

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-2 1

Removal And Installation (Cont'd) NOTE: Earlier models shown. The photos may appear different for later models but the procedure is the same.

2

4

Figure 20-120-1

3

3 1 3

P-90969

Mark the hydraulic hoses for proper installation.

Remove the hydraulic muffler (if equipped) (Item 2) [Figure 20-120-18] from block.

P-90968

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

Disconnect and cap the hoses (Item 3) [Figure 20-12018] from block.

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Remove the four mounting bolts (Item 4) [Figure 20-12018] from block.

Raise the operator cab. (See Raising on Page 10-30-2.)

Installation: Tighten the mounting bolts to 48 - 54 N•m (35 - 40 ft-lb) torque.

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

Remove the Power Bob-Tach block.

Disconnect and cap the two electrical solenoid connectors (Item 1) [Figure 20-120-1] from the loader electrical harness.

356 of 1311

20-120-2

S650 Service Manual

Dealer Copy -- Not for Resale

Disconnect and cap the outlet hose (Item 1) [Figure 20120-18] from block.

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-4

Disassembly And Assembly (Earlier Models) Figure 20-120-3

3

1 4

2 2 1 P-48120

Remove the spring guide (Item 1), spring (Item 2) and the spool (Item 3) [Figure 20-120-4].

Clean the block (Item 1) [Figure 20-120-3] to remove dirt before disassembly. Block ports are labeled for correct assembly.

Replace the O-ring (Item 4) [Figure 20-120-4] on the plug.

Dealer Copy -- Not for Resale

P-48115

Figure 20-120-5

Remove the plug (Item 2) [Figure 20-120-3]. Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ftlb) torque.

IMPORTANT

1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P-48116

I-2003-0888

NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced. Do not remove the plug (Item 1) [Figure 20-120-5]. Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ftlb) torque.

357 of 1311

20-120-3

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-8

Disassembly And Assembly (Earlier Models) (Cont'd) Figure 20-120-6

1 1 P-48122

Do not remove the plugs (Item 1) [Figure 20-120-8]. P-48382

Remove the check valve (Item 1) [Figure 20-120-6]. Installation: Oil the check valve and O-rings and tighten the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.

Dealer Copy -- Not for Resale

NOTE: Do not remove plugs. If the plugs are removed the internal pressure relieving spring setting will be altered. Figure 20-120-9

Figure 20-120-7

1 2 1 P-48384

3 Remove the plug (Item 1) [Figure 20-120-9], and replace the O-ring.

P-48119

Inspect the check valve (Item 1) and piston assembly (Item 2) [Figure 20-120-7].

Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ftlb) torque.

Replace the O-rings and back-up rings (Item 3) [Figure 20-120-7] on the check valve and piston assembly.

358 of 1311

20-120-4

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-12

Disassembly And Assembly (Earlier Models) (Cont'd) 2

Figure 20-120-10

1

2 1 P-48106A

Remove the first solenoid coil (Item 1) and the second solenoid coil (Item 2) [Figure 20-120-12].

Remove the orifice screw (Item 2) located behind the plug (Item 1) [Figure 20-120-10].

NOTE: Remember the solenoid coil orientation for ease of installation.

Dealer Copy -- Not for Resale

P-48664

Figure 20-120-13 Installation: Tighten the orifice screw to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque. Figure 20-120-11

1 1 2 P-48386

Remove the solenoid stem (Item 1) [Figure 20-120-13]. P-48127

Installation: Tighten the solenoid stem to 27,1 - 34 N•m (20 - 25 ft-lb) torque. NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced. Do not remove the plug (Item 1) [Figure 20-120-11]. Remove the solenoid nut (Item 2) [Figure 20-120-11]. Installation: Tighten the solenoid valve stem nut to 1,7 5,1 N•m (15 - 45 in-lb) torque.

359 of 1311

20-120-5

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-16

Disassembly And Assembly (Earlier Models) (Cont'd) Figure 20-120-14 1

P-48174

1 Remove the screened orifice plug (Item 1) [Figure 20120-16].

Remove the armature assembly (Item 1) [Figure 20-12014].

Installation: Tighten the screened orifice plug to 14,9 16,3 N•m (11 - 12 ft-lb) torque.

Dealer Copy -- Not for Resale

P-48175

Figure 20-120-17 Figure 20-120-15

3 2

2 1

1 P-48138 P-48173

Inspect the solenoid stem (Item 1), armature assembly (Item 2) and the spool (Item 3) for damage [Figure 20120-15].

Inspect the screened orifice plug (Item 1) [Figure 20120-17] for damage replace as needed. If the screened orifice plug is blocked replace with a new plug. Replace the O-ring (Item 2) [Figure 20-120-17].

NOTE: If the solenoid stem is damaged (Item 1) inspect the armature assembly (Item 2) for damage. The armature assembly (Item 2) and spool (Item 3) are non-serviceable parts. If they are damaged, order a new Power Bob-Tach block assembly from Bobcat parts [Figure 20-12015].

360 of 1311

20-120-6

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-19

Disassembly And Assembly (Later Models)

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

I-2003-0888 P100769

Figure 20-120-18 Clean the block (Item 1) to remove dirt before disassembly. Block ports are labeled for correct assembly.[Figure 20-120-19]. Remove the plug (Item 2) [Figure 20-120-19]. Installation: Tighten the plug to 67,8 N•m (50 ft-lb) torque. Figure 20-120-20

3

P100820

Do not remove these plugs (Item 1) [Figure 20-120-18]. 1 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.

2

4 P100770

Remove plug (Item 1), spring (Item 2) and spool (Item 3) [Figure 20-120-20] and inspect. Replace damaged parts as needed. Replace the O-ring (Item 4) [Figure 20-120-20] on the plug.

361 of 1311

20-120-7

S650 Service Manual

Dealer Copy -- Not for Resale

1

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-23

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-21

1

1 P100826

Remove the plug (Item 1) [Figure 20-120-23], and replace the O-ring.

Remove the plug (Item 1) [Figure 20-120-21], and replace the O-ring.

Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque.

Dealer Copy -- Not for Resale

P100823

Figure 20-120-24 Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque. Figure 20-120-22

1 3 2

P100821

1 Remove the orifice screw (Item 1) [Figure 20-120-24]. P107069

Installation: Tighten the orifice screw to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque. Remove the spool (Item 1), spring (Item 2) and the orifice (Item 3) [Figure 20-120-22]. Inspect the spring, spool and orifice replace as needed. Installation: Clean threads on the orifice and apply Loctite® 603. Tighten the orifice (Item 3) [Figure 20-12023].

362 of 1311

20-120-8

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-27

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-25

1

1

P100827

Remove the solenoid coil stem (Item 1) [Figure 20-12027].

NOTE: Mark the solenoid coil orientation for ease of installation.

Installation: Tighten the solenoid coil stem to 27,1 N•m (20 ft-lb) torque. Figure 20-120-28

Remove the solenoid coil nut (Item 1) [Figure 20-12025]. 2

2

Installation: Tighten the solenoid coil valve stem nut to 6,8 N•m (5 ft-lb) torque.

2

Figure 20-120-26

1

1

1

1

2 1

P100776

Replace the O-rings (Item 1) and the back-up rings (Item 2) [Figure 20-120-28].

P100773

Remove the first solenoid coil (Item 1) and the second solenoid coil (Item 2) [Figure 20-120-26].

363 of 1311

20-120-9

S650 Service Manual

Dealer Copy -- Not for Resale

P100774

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-31

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-29 1

1

P100840

P100828

Remove the plug (Item 1) [Figure 20-120-31], and replace the O-ring. Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque.

Figure 20-120-30

Figure 20-120-32

Dealer Copy -- Not for Resale

Remove the fitting (Item 1) [Figure 20-120-29].

1 1 P100829

Replace the O-ring (Item 1) [Figure 20-120-30].

364 of 1311

P100841

Remove the filter assembly (Item 1) [Figure 20-120-32], inspect and replace as needed.

20-120-10

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-35

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-33 1

1

P100845

Remove the plug (Item 1) [Figure 20-120-35], and replace the O-ring.

P100842

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque. Figure 20-120-36

Dealer Copy -- Not for Resale

Remove the plug (Item 1) [Figure 20-120-33], and replace the O-ring. Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque. Figure 20-120-34

1

2 1 P100839

Remove the plug (Item 1) [Figure 20-120-36], and replace the O-ring. P100843

Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque. Remove the shuttle seat (Item 1) and check ball (Item 2) [Figure 20-120-34]. Inspect the shuttle seat and check ball, replace as needed.

365 of 1311

20-120-11

S650 Service Manual

Figure 20-120-39

BOB-TACH (POWER) BLOCK (CONT'D) Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-37

2 1 2 1 P100838

Remove the spring (Item 1) and the check ball (Item 2) [Figure 20-120-39]. Inspect and replace as needed.

P100835

Figure 20-120-40

Figure 20-120-38

1

1 P100853

Using a small diameter tool remove the pilot piston (Item 1) [Figure 20-120-40].

P100837

Remove the plug (Item 1) [Figure 20-120-38], and replace the O-ring. Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque.

366 of 1311

20-120-12

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the spring (Item 1) and the check ball (Item 2) [Figure 20-120-37], inspect and replace as needed.

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-43

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-41 1

1 P100852

Remove the plug (Item 1) [Figure 20-120-43], and replace the O-ring.

P100847

Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque.

Figure 20-120-42

Figure 20-120-44

Dealer Copy -- Not for Resale

Remove pilot piston (Item 1) [Figure 20-120-41].

2

2 1

1

2

3 P100834

P100849

Inspect the pilot piston (Item 1), the back-up rings (Item 2) and the O-ring (Item 3) [Figure 20-120-42] for damage and replace as needed.

367 of 1311

Remove the annular orifice shaft (Item 1) and the annular orifice shaft guide (Item 2) [Figure 20-120-44], inspect and replace as needed.

20-120-13

S650 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D)

Figure 20-120-47

Disassembly And Assembly (Later Models) (Cont'd) Figure 20-120-45

1

1

P100854

Remove the O-ring (Item 1) [Figure 20-120-47] and replace.

P100850

Dealer Copy -- Not for Resale

Remove the plug (Item 1) [Figure 20-120-45], and replace the O-ring. Installation: Tighten the plug to 30 N•m (22 ft-lb) torque. Figure 20-120-46

1

P100851

Remove the plug (Item 1) [Figure 20-120-46], and replace the O-ring. Installation: Tighten the plug to 17,6 N•m (13 ft-lb) torque.

368 of 1311

20-120-14

S650 Service Manual

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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.

369 of 1311

20-121-1

S650 Service Manual

Figure 20-121-2

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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).

370 of 1311

20-121-2

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-121-3

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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 jam nut (Item 1) and turn the adjusting screw (Item 2) [Figure 20-121-4] clockwise to increase pressure or counterclockwise to decrease pressure. Test the relief valve setting after adjustment has been made.

371 of 1311

20-121-3

S650 Service Manual

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

W-2059-0598

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

DANGER

Remove the fan duct. (See Fan Duct Removal And Installation on Page 70-50-4.) or (See Fan Duct Removal And Installation on Page 70-51-4.) 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

IMPORTANT

P122161

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

372 of 1311

20-121-4

S650 Service Manual

Dealer Copy -- Not for Resale

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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.

373 of 1311

20-121-5

S650 Service Manual

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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.

374 of 1311

20-121-6

S650 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 A3NV25242 AND A3NW13834 & 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.

375 of 1311

20-121-7

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 20-121-14

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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 20-121-18]. 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 (Item 1) [Figure 20-12116] to 17,6 N•m (13 ft-lb) torque.

376 of 1311

20-121-8

S650 Service Manual

Figure 20-121-21

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & 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 20-121-23]. 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.

377 of 1311

20-121-9

S650 Service Manual

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & ABOVE) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-121-23

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.

378 of 1311

20-121-10

S650 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.

379 of 1311

20-130-1

S650 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].

380 of 1311

20-130-2

S650 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 20-130-14] for damage and replace as needed.

381 of 1311

20-130-3

S650 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.

382 of 1311

20-130-4

S650 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.

383 of 1311

20-130-5

S650 Service Manual

Dealer Copy -- Not for Resale 384 of 1311

20-130-6

S650 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.

385 of 1311

20-140-1

S650 Service Manual

AUTOMATIC RIDE CONTROL (CONT'D) Removal And Installation

WARNING

Open the rear door. Remove the rear grille and engine cover. (See REAR GRILLE 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

386 of 1311

20-140-2

S650 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].

387 of 1311

Disconnect the three connectors (Item 1) [Figure 20140-5] from the manifold.

20-140-3

S650 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.

388 of 1311

20-140-4

S650 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:

WARNING

W-2103-0508

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

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

389 of 1311

20-140-5

S650 Service Manual

Dealer Copy -- Not for Resale

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.

AUTOMATIC RIDE CONTROL (CONT'D)

Figure 20-140-11

Checking The Pressure In The Accumulator (Cont’d) Figure 20-140-9 2

1

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.

Remove the cap (Item 1) [Figure 20-140-9] from the accumulator.

Figure 20-140-12

Figure 20-140-10 1

1

2

P128489

P128322

Loosen the Allen screw (Item 1) [Figure 20-140-10] approximately 1/4 turn.

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). 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]. 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.

390 of 1311

20-140-6

S650 Service Manual

Dealer Copy -- Not for Resale

P128321

AUTOMATIC RIDE CONTROL (CONT'D)

Figure 20-140-14

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 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.

P128322

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.

2

P128488

W-3015-0816

Install the tool / gauge (Item 1) [Figure 20-140-15] onto the accumulator.

Figure 20-140-13

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.

391 of 1311

20-140-7

S650 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.

392 of 1311

20-140-8

S650 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 30-20-2 30-20-4 30-20-5

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-11 HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-30-1 30-30-1 30-30-2 30-30-3 30-30-4 30-30-6

HYDROSTATIC MOTOR CARRIER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-31-1 30-31-1 30-31-2 30-31-3 30-31-4 30-31-7

CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-40-1 30-40-1 30-40-1 30-40-3 30-40-4

393 of 1311

30-01

S650 Service Manual

Dealer Copy -- Not for Resale

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 - A3NW12724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11

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 Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-60-1 30-60-1 30-60-1 30-60-1 30-60-4 30-60-5

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2 Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4 TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-71-1 30-71-1 30-71-2 30-71-4

DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

394 of 1311

30-02

S650 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.

395 of 1311

30-10-1

S650 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.

396 of 1311

30-10-2

S650 Service Manual

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE

HYDROSTATIC DRIVE MOTOR Description The hydrostatic motors are driven by high pressure from the hydrostatic pumps. 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.

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 drive chains.

397 of 1311

30-20-1

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D)

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

Removal And Installation Remove the motor cover. Mark the hoses for correct installation.

DANGER

Figure 30-20-1

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

P-90510

Disconnect the case drain hose (Item 1) [Figure 30-201]. Disconnect the high pressure hoses (Item 2) [Figure 3020-1].

WARNING

Figure 30-20-2

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 1 2 1

1

W-2059-0598

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

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

P-90495

Remove the ten mounting bolts (Item 1) [Figure 30-202]. Installation: Tighten the mounting bolts to 149 N•m (110 ft-lb) torque. NOTE: The two bolts (Item 2) [Figure 30-20-2] mount the cam ring to the motor, and do not have to be removed, to remove the motor from the loader. Remove the motor / cam ring section from the loader.

398 of 1311

30-20-2

S650 Service Manual

Dealer Copy -- Not for Resale

•

HYDROSTATIC DRIVE MOTOR (CONT’D) Removal And Installation (Cont’d) Figure 30-20-3

1

P5405

Dealer Copy -- Not for Resale

Remove the piston / roller section (Item 1) [Figure 30-203] from the loader, if it was not removed with the motor / cam ring. Figure 30-20-4

11 13

12

1

10

2

3

9 8

4 7

5 6 N-22535

Remove and replace O-ring (Item 13) [Figure 30-20-4] with new O-ring Installation: Install the O-ring (Item 1) by pressing the Oring into the groove starting at the 12 o’clock position then 6, 2, 10, 3 9, 4, 8, 5, 7, 1 and 11 [Figure 30-20-4] until the O-ring is fully seated in the groove. NOTE: Do not roll, kink or stretch O-ring in to groove and verify the O-ring is completely flush with no protrusions. To remove the motor carrier. (See Removal And Installation on Page 30-30-2.)

399 of 1311

30-20-3

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D) Parts Identification

Distributor Spring Seal O-ring Plug Washer Spool Rear Housing Stop Pin Bolt Shim Poppet Cam Roller Piston Block

3 2

1

3

4 4 2

7

4 6 2

5

8 5

4

3 3

9

14 4

15

10 10

4 4

12 11 2 4

4

5

13 16

B-17125

400 of 1311

30-20-4

S650 Service Manual

Dealer Copy -- Not for Resale

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

HYDROSTATIC DRIVE MOTOR (CONT’D)

Figure 30-20-6

Disassembly And Assembly

IMPORTANT

2

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 P5765

Figure 30-20-5

Inspect the cylinder block surface and the roller / piston assemblies for scratches or wear. NOTE: Put all the roller / piston assembly back in their original position. Assembly: Install the roller (Item 1) in the piston (Item 2) [Figure 30-20-6]. Assembly: Dip the roller / piston assembly into oil and install into the bore in the cylinder.

N-17861

Remove the piston / roller section (Item 1) [Figure 30-205] from the motor.

Repeat for each roller / piston assembly.

Assembly: Install the motor on the loader and tighten the mount bolts to 149 N•m (110 ft-lb) torque. NOTE: Before operating the hydrostatic motor, make sure it is full of fluid. There are several methods to fill the motor with fluid; (1) with the case drain hose disconnected, fill the motor with fluid through the case drain port; (2) with the case drain hose disconnected, BICS™ brake locked, engine running, stroke the steering lever until fluid comes out of the case drain port.

401 of 1311

30-20-5

S650 Service Manual

Dealer Copy -- Not for Resale

Apply low air pressure to each port in the cylinder block to remove the roller (Item 1) and piston / ring assembly (Item 2) [Figure 30-20-6].

1

Figure 30-20-9

HYDROSTATIC DRIVE MOTOR (CONT’D) Disassembly And Assembly (Cont'd)

1 2

Figure 30-20-7

1

1

N-17864

Remove the stop pin (Item 1) from the rear motor housing (Item 2) [Figure 30-20-9].

Remove the two cam ring mounting bolts (Item 1) [Figure 30-20-7].

Assembly: Install the stop pin and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.

Dealer Copy -- Not for Resale

N-17860

Figure 30-20-10 Assembly: Install the two cam ring mounting bolts and tighten to 67,8 N•m (50 ft-lb) torque. 3

Figure 30-20-8 1

1

4 2 N-17868

NOTE: The distributor removal, is best accomplished by lifting the housing (Item 2) [Figure 30-2010] 50,8 - 76,2 mm (2 - 3 in) above a wooden surface, and dropping the housing.

N-17863

Remove the cam ring (Item 1) [Figure 30-20-8] from the motor housing.

Assembly: Install the stop pin (Item 1) [Figure 30-20-9] and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.

Inspect the cam ring for surface scratches or wear. Assembly: Install the cam ring (Item 1) [Figure 30-20-8] and align the mounting bolt holes.

Assembly: Install the distributor (Item 2) [Figure 30-2010] into the housing. Assembly: Align the distributor hole (Item 3) [Figure 3020-10] with the stop pin. When aligned correctly, the distributor can be depressed slightly. Assembly: Install and lightly smear grease on the O-ring (Item 4) [Figure 30-20-10].

402 of 1311

30-20-6

S650 Service Manual

Figure 30-20-13

HYDROSTATIC DRIVE MOTOR (CONT’D) Disassembly And Assembly (Cont'd) Figure 30-20-11

5 2

1

2

4

3

1 N-17872

Remove and replace the two seals and back-up O-rings (Item 1) [Figure 30-20-11] on the distributor.

Assembly: Remove and replace the O-ring (Item 5) [Figure 30-20-13].

Inspect the distributor and springs (Item 2) [Figure 3020-11] for damage or surface scratches.

Assembly: Tighten the plug to 12 - 15 N•m (9 - 11 ft-lb) torque.

Assembly: Put grease on the springs to hold them in place.

Figure 30-20-14

Assembly: Install the springs into the distributor. 5

Figure 30-20-12

2

3

4

2

1

1 N-17871

Remove, inspect and install the plug (Item 1), springs (Item 2), spool (Item 3) and washer (Item 4) [Figure 3020-14].

N-17866

Remove the two seals (Item 1) [Figure 30-20-12] from the housing and replace with new seals. Remove the two O-rings and replace with new O-rings. The O-rings are located under the seals.

Assembly: Remove and replace the O-ring (Item 5) [Figure 30-20-14]. Assembly: Tighten the plug to 25 - 30 N•m (18 - 22 ft-lb) torque.

Assembly: Lightly smear grease over the seals.

403 of 1311

30-20-7

S650 Service Manual

Dealer Copy -- Not for Resale

Remove, inspect and install the plug (Item 1), spring (Item 2), shim (Item 3) and poppet (Item 4) [Figure 3020-13].

N-17869

Dealer Copy -- Not for Resale 404 of 1311

30-20-8

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724)

WARNING

Description

This hydrostatic motor contains a spring applied pressure release braking system to stop the loader. This braking system is located on the end of the hydrostatic motor. The hydrostatic motor contains 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. There are two hydrostatic motors mounted to motor carriers. The motor carriers are mounted to the transmission chaincase which houses the drive chains.

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

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

Removal And Installation

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

DANGER

Raise the operator cab. (See Raising on Page 10-30-2.) Drain the hydraulic reservoir. (See Removal And Installation on Page 20-90-1.)

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. D-1009-0409

405 of 1311

30-21-1

S650 Service Manual

Dealer Copy -- Not for Resale

The hydrostatic motors are driven by high pressure from the hydrostatic pumps.

Disconnect the hydraulic hose (Item 3) [Figure 30-21-2] that goes to the make-up port on the two-speed / brake block.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D) Removal And Installation (Cont'd)

Figure 30-21-3

Figure 30-21-1

1

1

P-90257

Remove the motor cover mount bolts (Item 1) [Figure 3021-1].

Disconnect the hydraulic hose (Item 1) [Figure 30-21-3] that goes to the drain manifold. Figure 30-21-4

Remove the motor cover from the loader. Mark the hoses for correct installation. 1 Figure 30-21-2

1

3 1

P-90257

2

Remove the eight flange bolts (Item 1) [Figure 30-21-4] from the high pressure hoses on the motor. P-90258

Disconnect the hydraulic hose (Item 1) [Figure 30-21-2] that goes to the two-speed port on the two-speed / brake block. Disconnect the hydraulic hose (Item 2) [Figure 30-21-2] that goes to the brake port on the two-speed / brake block.

406 of 1311

30-21-2

S650 Service Manual

Dealer Copy -- Not for Resale

P-90256

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-7

11

Removal And Installation (Cont'd) 13

12

1

10

Figure 30-21-5

2

3

9 2

8

3

4 7

5 6 N-22535

1

Remove and replace O-ring (Item 13) [Figure 30-21-7].

P100901

Installation: Install both flanges and tighten the bolts to half of the required torque in the sequence shown in [Figure 30-21-5]. Re-tighten all bolts to 48 - 54 N•m (35 40 ft-lb) torque in the same sequence.

Installation: Install the O-ring (Item 1) by pressing the Oring into the groove starting at the 12 o’clock position then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-21-7] until the O-ring is fully seated in the groove. NOTE: Do not roll, kink or stretch O-ring in to groove and verify the O-ring is completely flush with no protrusions.

Figure 30-21-6

1

P-90496

Remove the ten (12 mm) mount bolts (Item 1) [Figure 30-21-6] from the motor. NOTE: The two smaller diameter bolts (8 mm), hold the cam ring to the motor and do not have to be remove for motor removal. Remove the motor from the loader.

407 of 1311

30-21-3

S650 Service Manual

Dealer Copy -- Not for Resale

4

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D) Parts Identification Ref. Description Roller Piston Ring Clamp Block Cam Quad Ring Distributor Spring Seal/O-ring Poppet Shim O-ring Plug Pin Housing Washer Quad Ring Bushing Shaft 4 Dowel Bolt Shim Brake Disc Snap Ring Seal Clamp Piston Spring Gasket Cover

10 10 10 10 10 10 8

7 1

9

6

2 3 6 3 24

4 22

3

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. 23. 24. 25. 26. 27. 28. 29. 30. 31.

23

16 21 1314 12

9 17

20 19

18

9 14 16 11 12 9 13

25 9

13

17

31

12 14

22

30

22

29

15

13 28 27 26

13

MS1467S

408 of 1311

30-21-4

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

NOTE: Remove and / or tighten the bolts one turn at a time to maintain equal preload on the end cap and the brake spring.

Disassembly

Figure 30-21-10

Figure 30-21-8

1

2

N-22492

1

N-22489

NOTE: Install a mark on the motor, brake, and motor carrier housings for correct assembly [Figure 30-21-8]. NOTE: Always protect any sealing surfaces. Any scratches or marks will cause premature failure. Place the cam sealing surface (Item 1) [Figure 30-21-8] on a protective material.

Remove the cover plate gasket (Item 1) [Figure 30-2110]. Remove the brake spring (Item 2) [Figure 30-21-10] from the brake housing. NOTE: Mark the top side of the brake spring for proper installation. Figure 30-21-11

Drain the fluid from the motor casing. Figure 30-21-9 1 2

1 N-22493

Remove the piston from the brake housing (Item 1) [Figure 30-21-11].

N-22490

Remove the twelve mounting bolts (Item 1) [Figure 3021-9] from the brake cover plate.

NOTE: The use of air pressure through the brake line connection (Item 2) [Figure 30-21-11] will aid in piston removal. Inspect the brake piston for damage and replace the seal.

409 of 1311

30-21-5

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the cover plate from the brake housing.

Figure 30-21-14

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D) Disassembly (Cont'd)

1

Figure 30-21-12 2

1

P-69985

Remove the brake discs (Item 1) [Figure 30-21-14] from the brake shaft. Mark the position of the brake discs and the shims. P-69973

Remove the five mounting bolts (Item 1) [Figure 30-2112] from the brake housing.

1

Remove the brake housing (Item 2) [Figure 30-21-12] from the rear housing.

2

Figure 30-21-13

2

P-69978

Remove the two-speed spool (Item 1) [Figure 30-21-15] from the housing assembly. Remove and discard the O-rings (Item 2) [Figure 30-2115] on the housing.

1 P-73062

Protect the sealing surface. Remove the snap ring (Item 1) [Figure 30-21-13] to remove the seal from the brake housing.

410 of 1311

30-21-6

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-21-15

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque. NOTE: Current motor housings are provided with break off plugs (Item 2) [Figure 30-21-17] on the side of the flushing spool housing. Earlier motors were equipped with threaded plugs.

Disassembly (Cont'd) Figure 30-21-16

Figure 30-21-18 1

1

2

4 3 N-22501

NOTE: If the two speed spool (Item 1) [Figure 30-2116] is damaged the entire rear housing assembly has to be replaced.

Remove the flushing spool assembly (Item 1) [Figure 3021-18] from the housing. Figure 30-21-19

1

NOTE: S/N A3NT14900, A3NU12252 and above loaders incorporate an inner make-up spool inside the two speed spool (Item 1) [Figure 3021-16]. The make-up spool is disassembled, both the make-up spool and the two speed spool will be damaged.

2

3

4

Figure 30-21-17 1 N-22504

Remove the spring (Item 1), washer (Item 2) and rear spring (Item 3) from the spool (Item 4) [Figure 30-21-19]. 2 Inspect all parts and replace as needed.

P-69979

Remove the flushing spool plug (Item 1) [Figure 30-2117] from the housing.

411 of 1311

30-21-7

S650 Service Manual

Dealer Copy -- Not for Resale

P-73057

Inspect the spool (Item 1), the spring (Item 2), washer (Item 3) and the snap ring (Item 4) and replace as needed [Figure 30-21-16].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-22

Disassembly (Cont'd) Figure 30-21-20

1 3

2

1 N-22507

Inspect the poppet (Item 1), shim (Item 2) and spring (Item 3) for wear and replace as needed [Figure 30-2122]. P-69981

Figure 30-21-23

Installation: Tighten the plug to 22 N•m (18 ft-lb) torque.

1

Dealer Copy -- Not for Resale

Remove the plug (Item 1) [Figure 30-21-20] from the housing. 1

Figure 30-21-21

1

P-73058

Remove the two (8 mm) cam ring mount bolts (Item 1) [Figure 30-21-23]. Turn the housing, cam ring, and rotating group assembly over and place on a stand. Remove the cam ring from the housing.

P-69982

Remove the poppet assembly (Item 1) [Figure 30-21-21] from the housing.

412 of 1311

30-21-8

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-26

Disassembly (Cont'd) Figure 30-21-24

1

N-22511

Protect the sealing surfaces. Remove the roller / piston assembly (Item 1) [Figure 30-21-26] from the cylinder block.

Protect the sealing surfaces. Inspect the cam ring inside surface for wear and scratches [Figure 30-21-24]. Figure 30-21-25

Inspect all roller and piston assemblies for wear and replace as needed. NOTE: Put all roller / piston assembles back in the original bore. Figure 30-21-27

1

2

1 N-22509 P-73059

Remove the cylinder block (Item 1) [Figure 30-21-25] from the housing. Remove the O-ring (Item 2) [Figure 30-21-25] from the housing.

Remove the shaft from the distributor [Figure 30-21-27]. NOTE: The end of the shaft with the snap ring (Item 1) [Figure 30-21-27] must be toward the brake housing during assembly. Remove the distributor from the housing.

413 of 1311

30-21-9

S650 Service Manual

Dealer Copy -- Not for Resale

N-22510

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-30

1

Disassembly (Cont'd) Figure 30-21-28 1

N-22523

Remove the bushing (Item 1) [Figure 30-21-30] from the distributor, if worn or scratched.

NOTE: The distributor removal is best accomplished by lifting the housing (Item 1) [Figure 30-2128] 2 - 3 inches above a wooden surface, and dropping the housing [Figure 30-21-28]. Figure 30-21-29 2

1

1

N-22519

2 Remove the six seals (Item 1), and six back-up O-rings (Item 2) from the distributor [Figure 30-21-31].

N-22521

Protect the sealing surfaces. Remove the locating pin (Item 1) [Figure 30-21-29] from the distributor. Remove the springs (Item 2) [Figure 30-21-29] from the distributor. Inspect the springs, distributor surface and bushing for damage or wear and replace as needed.

414 of 1311

30-21-10

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-21-31

P-69984

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-34 1

Assembly NOTE: Always use new O-rings and seals during motor and brake assembly. Figure 30-21-32

N-22525

Install a new bushing (Item 1) [Figure 30-21-34] in the distributor if the old bushing was removed. 1

N-22511

During installation of pistons in the bore, position the piston ring gap 180° from one piston to the next. One piston installed with the gap to the right, the next piston installed with the gap to the left. Dip each of the roller / piston assemblies (Item 1) [Figure 30-21-32] in oil and replace back its original bore.

NOTE: When installing seals, apply a light coating of oil to the seal and the mating surfaces of the distributor. Install the O-rings and seals, allow 30 minutes for the seals to set on the distributor before installing the distributor in the housing. Figure 30-21-35

Figure 30-21-33

1

1

P-73060

Using a small amount of grease, install the springs into the distributor valve (Item 1) [Figure 30-21-35].

N-22518

Apply a small amount of grease to the locating pin (Item 1) [Figure 30-21-33] and install the locating pin in the housing

415 of 1311

30-21-11

S650 Service Manual

Dealer Copy -- Not for Resale

Install new O-rings and seals on the distributor [Figure 30-21-35].

Figure 30-21-38

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

1

Assembly (Cont'd) Figure 30-21-36

1

N-22509

N-22515

Install the distributor (Item 1) [Figure 30-21-36] in the housing. Protect the sealing surface of the distributor.

Install the cam ring to the rear housing. Apply liquid adhesive (Loctite® 243) to the two cam ring mounting bolts. Install the bolts finger tight. Figure 30-21-39

Figure 30-21-37 1 1

1

P-69983 P-73061

The pin in the distributor must align with the hole in the housing (Item 1) [Figure 30-21-37]. Use a hand press to push the distributor in place. When installed correctly, the distributor will spring back slightly when pushed by hand into the housing.

Turn the motor so that it sets on the cam ring, and cylinder block [Figure 30-21-39]. NOTE: Be careful when turning or moving the motor so the cylinder block stays in the motor housing and the sealing surfaces are protected. Tighten the two cam ring mounting bolts (Item 1) [Figure 30-21-39] to 35 - 39 N•m (26 - 29 ft-lb) torque.

416 of 1311

30-21-12

S650 Service Manual

Dealer Copy -- Not for Resale

Install the cylinder block assembly (Item 1) [Figure 3021-38].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-42 1

Assembly (Cont'd) 2

Figure 30-21-40 1 2

P-69986

P-69978

Install new o-rings (Item 1) [Figure 30-21-40] on the housing assembly and apply grease to the o-rings.

Apply liquid adhesive (Loctite® 243) to the five mounting bolts. Install the bolts (Item 2) [Figure 30-21-42] and tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque. Figure 30-21-43

Install the two speed spool (Item 2) [Figure 30-21-40]. Install the shaft into the distributor [Figure 30-21-40]. 1

Figure 30-21-41

P-73064

If needed, install the shims first, then install the brake disc pack starting with an outer disc (Item 1) [Figure 3021-43] and alternating with an inner disc, throughout the pack.

N-18347

Clamp the disc pack in a vise and measure the height [Figure 30-21-41]. The height must be 31,1 mm (1.22 in).

End the disc pack with an outer disc

The normal thickness of the individual brake disc is 1 mm (0.039 in). If any individual disc's thickness is 0,95 mm (0.037 in) or less, replace the complete disc pack.

417 of 1311

30-21-13

S650 Service Manual

Dealer Copy -- Not for Resale

Install the brake housing (Item 1) [Figure 30-21-42] on the motor housing.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D)

Figure 30-21-46

Assembly (Cont'd) Figure 30-21-44

1

1 3

2

N-22493

Install the piston (Item 1) [Figure 30-21-46] in the brake housing.

Install the brake seal (Item 1) [Figure 30-21-44]. NOTE: Install the seal with the metal case end towards the brake pack.

2 1

Install the snap ring (Item 2) [Figure 30-21-44] to secure the seal in the brake housing. Install a new O-ring (Item 3) [Figure 30-21-44] in the seal. Figure 30-21-45 N-22492

Install the brake spring (Item 1) [Figure 30-21-47]. Install the end plate gasket (Item 2) [Figure 30-21-47].

1

N-22498

Lightly coat the piston with oil and install a new piston seal (Item 1) [Figure 30-21-45].

418 of 1311

30-21-14

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-21-47

P-73055

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 A3NW12724) (CONT’D) Assembly (Cont'd) Figure 30-21-48

1

N-22490

Dealer Copy -- Not for Resale

Install the brake end cover (Item 1) [Figure 30-21-48]. Install the twelve end cover mount bolts and tighten evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.

419 of 1311

30-21-15

S650 Service Manual

Dealer Copy -- Not for Resale 420 of 1311

30-21-16

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE)

Removal And Installation

DANGER

Description The hydrostatic motors are driven by high pressure from the hydrostatic pumps. This hydrostatic motor contains a spring applied pressure release braking system. This braking system is located on the end of the hydrostatic motor.

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.

There are two hydrostatic motors mounted to motor carriers. The motor carriers are mounted to the transmission chaincase which houses the drive chains.

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

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

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing 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.)

421 of 1311

30-22-1

S650 Service Manual

Dealer Copy -- Not for Resale

The hydrostatic motor contains 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.

Figure 30-22-3

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D) Removal And Installation (Cont'd)

2

Figure 30-22-1 1 2

2

1

P107950

Disconnect the hydraulic hose (Item 1) [Figure 30-22-3] that goes to the drain manifold. Remove the eight flange bolts (Item 1) [Figure 30-22-3] from the high pressure hoses on the motor.

P106586

Dealer Copy -- Not for Resale

Remove the four bolts (Item 1) and cover (Item 2) [Figure 30-22-1]. Mark the hoses for correct installation. Figure 30-22-2

2

1

P107951

Disconnect the hydraulic hose (Item 1) [Figure 30-22-2] that goes to the two-speed port on the two-speed / brake block. Disconnect the hydraulic hose (Item 2) [Figure 30-22-2] that goes to the brake port on the two-speed / brake block.

422 of 1311

30-22-2

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-6

11

Removal And Installation (Cont'd) 13

12

1

10

Figure 30-22-4

2

3

9 2

8

3

4 7

5 6 N-22535

1

Remove and replace O-ring (Item 13) [Figure 30-22-6] with new O-ring P100901

Installation: Install both flanges and tighten the bolts to half of the required torque in the sequence shown in [Figure 30-22-4]. Re-tighten all bolts to 48 - 54 N•m (35 40 ft-lb) torque in the same sequence. Figure 30-22-5

Installation: Install the O-ring (Item 1) by pressing the Oring into the groove starting at the 12 o’clock position then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-22-6] until the O-ring is fully seated in the groove. NOTE: Do not roll, kink or stretch O-ring in to groove and verify the O-ring is completely flush with no protrusions.

1

P-90496

Remove the 10 (12 mm) mount bolts (Item 1) [Figure 3022-5] from the motor. NOTE: The two smaller diameter bolts (8 mm), hold the cam ring to the motor and do not have to be remove for motor removal. Remove the motor from the loader.

423 of 1311

30-22-3

S650 Service Manual

Dealer Copy -- Not for Resale

4

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D) Parts Identification Roller Piston Ring Clamp Ring Block Cam Quad Ring Distributor Spring Seal/O-ring Poppet Spool Spring O-ring Plug Pin Housing Washer Quad Ring Bushing Shaft 4 Dowel Bolt Shim Brake Disc Snap Ring Seal Clamp Piston Spring Gasket Cover

11 11 11 11 11 11 9

8

10

7

1 2 3 6 5

26

4 24

5

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. 23. 24. 25. 26. 27. 28. 29. 30. 31 32. 33.

25

18 23

13

1516 14 19

22 21

20

14 16 18 12 13 14 15

27 14

15

19

33

13 16

24

32

24

31

17

15 30 29 28

15

MS1467S

424 of 1311

30-22-4

S650 Service Manual

NOTE: Remove and / or tighten the bolts one turn at a time to maintain equal preload on the end cap and the brake spring.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D) Disassembly

Figure 30-22-9

Figure 30-22-7

1

2

N-22492

1

N-22489

NOTE: Install a mark on the motor, brake, and motor carrier housings for correct assembly [Figure 30-22-7]. NOTE: Always protect any sealing surfaces. Any scratches or marks will cause premature failure. Place the cam sealing surface (Item 1) [Figure 30-22-7] on a protective material.

Remove the cover plate gasket (Item 1) [Figure 30-22-9]. Remove the brake spring (Item 2) [Figure 30-22-9] from the brake housing. NOTE: Mark the top side of the brake spring for proper installation. Figure 30-22-10

Drain the fluid from the motor casing. Figure 30-22-8 1 2

1 N-22493

Remove the piston from the brake housing (Item 1) [Figure 30-22-10].

N-22490

Remove the twelve mounting bolts (Item 1) [Figure 3022-8] from the brake cover plate.

NOTE: The use of air pressure through the brake line connection (Item 2) [Figure 30-22-10] will aid in piston removal. Inspect the brake piston for damage and replace the seal.

425 of 1311

30-22-5

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the cover plate from the brake housing.

Figure 30-22-13

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D) Disassembly (Cont'd)

1

Figure 30-22-11 2

1

P-69985

Remove the brake discs (Item 1) [Figure 30-22-13] from the brake shaft. Mark the position of the brake discs and the shims. P-69973

Remove the five mounting bolts (Item 1) [Figure 30-2211] from the brake housing.

1

Remove the brake housing (Item 2) [Figure 30-22-11] from the rear housing.

2

Figure 30-22-12

2

P-69978

Remove the two-speed spool (Item 1) [Figure 30-22-14] from the housing assembly. Remove and discard the O-rings (Item 2) [Figure 30-2214] on the housing.

1 P-73062

Protect the sealing surface. Remove the snap ring (Item 1) [Figure 30-22-12] to remove the seal from the brake housing.

426 of 1311

30-22-6

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-22-14

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque. Figure 30-22-17

Disassembly (Cont'd) Figure 30-22-15 1 1

2

P-73057

4 3

Inspect the spool (Item 1), the spring (Item 2), washer (Item 3) and the snap ring (Item 4) and replace as needed [Figure 30-22-15].

Figure 30-22-18

1 2

NOTE: If the two speed spool (Item 1) [Figure 30-2215] is damaged the entire housing assembly has to be replaced.

3

4

NOTE: There is an inner make-up spool inside the two speed spool (Item 4) [Figure 30-22-15]. The make-up spool is not serviceable. If the two speed spool is disassembled, both the make-up spool and the two speed spool will be damaged. N-22504

Figure 30-22-16 1

Remove the spring (Item 1), washer (Item 2) and rear spring (Item 3) from the spool (Item 4) [Figure 30-22-18]. Inspect all parts and replace as needed.

P-69979

Remove the flushing spool plug (Item 1) [Figure 30-2216] from the housing.

427 of 1311

30-22-7

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the flushing spool assembly (Item 1) [Figure 3022-17] from the housing.

N-22501

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-21

Disassembly (Cont'd) Figure 30-22-19

1 3

2

1 N-22507

Inspect the poppet (Item 1), shim (Item 2) and spring (Item 3) for wear and replace as needed [Figure 30-2221]. P-69981

Figure 30-22-22

Installation: Tighten the plug to 22 N•m (18 ft-lb) torque.

1

Dealer Copy -- Not for Resale

Remove the plug (Item 1) [Figure 30-22-19] from the housing. 1

Figure 30-22-20

1

P-73058

Remove the two (8 mm) cam ring mount bolts (Item 1) [Figure 30-22-22]. Turn the housing, cam ring, and rotating group assembly over and place on a stand. Remove the cam ring from the housing.

P-69982

Remove the poppet assembly (Item 1) [Figure 30-22-20] from the housing.

428 of 1311

30-22-8

S650 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-25

Disassembly (Cont'd) Figure 30-22-23

1

N-22511

Protect the sealing surfaces. Remove the roller / piston assembly (Item 1) [Figure 30-22-25] from the cylinder block.

Protect the sealing surfaces. Inspect the cam ring inside surface for wear and scratches [Figure 30-22-23]. Figure 30-22-24

Inspect all roller and piston assemblies for wear and replace as needed. NOTE: Put all roller / piston assembles back in the original bore. Figure 30-22-26

1

2

1 N-22509 P-73059

Remove the cylinder block (Item 1) [Figure 30-22-24] from the housing. Remove the O-ring (Item 2) [Figure 30-22-24] from the housing.

Remove the shaft from the distributor [Figure 30-22-26]. NOTE: The end of the shaft with the snap ring (Item 1) [Figure 30-22-26] must be toward the brake housing during assembly. Remove the distributor from the housing.

429 of 1311

30-22-9

S650 Service Manual

Dealer Copy -- Not for Resale

N-22510

Figure 30-22-29

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

1

Disassembly (Cont'd) Figure 30-22-27 1

N-22523

Remove the bushing (Item 1) [Figure 30-22-29] from the distributor, if worn or scratched.

NOTE: The distributor removal is best accomplished by lifting the housing (Item 1) [Figure 30-2227] 50,8 - 76,2 mm (2 - 3 in) above a wooden surface, and dropping the housing [Figure 3022-27]. Figure 30-22-28

1 1

N-22519

2 Remove the six seals (Item 1), and six back-up O-rings (Item 2) from the distributor [Figure 30-22-30].

N-22521

Protect the sealing surfaces. Remove the locating pin (Item 1) [Figure 30-22-28] from the distributor. Remove the springs (Item 1) [Figure 30-22-28] from the distributor. Inspect the springs, distributor surface and bushing for damage or wear and replace as needed.

430 of 1311

30-22-10

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-22-30

P-69984

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-33 1

Assembly NOTE: Always use new O-rings and seals during motor and brake assembly. Figure 30-22-31

N-22525

Install a new bushing (Item 1) [Figure 30-22-33] in the distributor if the old bushing was removed. 1

N-22511

During installation of pistons in the bore, position the piston ring gap 180° from one piston to the next. One piston installed with the gap to the right, the next piston installed with the gap to the left. Dip each of the roller / piston assemblies (Item 1) [Figure 30-22-31] in oil and replace back its original bore.

NOTE: When installing seals, apply a light coating of oil to the seal and the mating surfaces of the distributor. Install the O-rings and seals, allow 30 minutes for the seals to set on the distributor before installing the distributor in the housing. Figure 30-22-34

Figure 30-22-32

1

1

P-73060

Using a small amount of grease, install the springs into the distributor valve (Item 1) [Figure 30-22-34].

N-22518

Apply a small amount of grease to the locating pin (Item 1) [Figure 30-22-32] and install the locating pin in the housing.

431 of 1311

30-22-11

S650 Service Manual

Dealer Copy -- Not for Resale

Install new O-rings and seals on the distributor [Figure 30-22-34].

Figure 30-22-37

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

1

Assembly (Cont'd) Figure 30-22-35

1

N-22509

N-22515

Install the distributor (Item 1) [Figure 30-22-35] in the housing. Protect the sealing surface of the distributor.

Install the cam ring to the rear housing. Apply liquid adhesive (Loctite® 243) to the two cam ring mounting bolts. Install the bolts finger tight. Figure 30-22-38

Figure 30-22-36 1 1

1

P-69983 P-73061

The pin in the distributor must align with the hole in the housing (Item 1) [Figure 30-22-36]. Use a hand press to push the distributor in place. When installed correctly, the distributor will spring back slightly when pushed by hand into the housing.

Turn the motor so that it sets on the cam ring, and cylinder block [Figure 30-22-38]. NOTE: Be careful when turning or moving the motor so the cylinder block stays in the motor housing and the sealing surfaces are protected. Tighten the two cam ring mounting bolts (Item 1) [Figure 30-22-38] to 35 - 39 N•m (26 - 29 ft-lb) torque.

432 of 1311

30-22-12

S650 Service Manual

Dealer Copy -- Not for Resale

Install the cylinder block assembly (Item 1) [Figure 3022-37].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-41 1

Assembly (Cont'd) Figure 30-22-39 1

2 2

P-69986

P-69978

Install new O-rings (Item 1) [Figure 30-22-39] on the housing assembly and apply grease to the O-rings.

Apply liquid adhesive (Loctite® 243) to the five mounting bolts. Install the bolts (Item 2) [Figure 30-22-41] and tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque. Figure 30-22-42

Install the two speed spool (Item 2) [Figure 30-22-39]. Install the shaft into the distributor [Figure 30-22-39]. 1

Figure 30-22-40

P-73064

If needed, install the shims first, then install the brake disc pack starting with an outer disc (Item 1) [Figure 3022-42] and alternating with an inner disc, throughout the pack.

N-18347

Clamp the disc pack in a vise and measure the height [Figure 30-22-40]. The height must be 31,1 mm (1.22 in).

End the disc pack with an outer disc

The normal thickness of the individual brake disc is 1 mm (0.039 in). If any individual discs thickness is 0,95 mm (0.037 in) or less, replace the complete disc pack.

433 of 1311

30-22-13

S650 Service Manual

Dealer Copy -- Not for Resale

Install the brake housing (Item 1) [Figure 30-22-41] on the motor housing.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D)

Figure 30-22-45

Assembly (Cont'd) Figure 30-22-43

1

1 3

2

N-22493

Install the piston (Item 1) [Figure 30-22-45] in the brake housing.

Install the brake seal (Item 1) [Figure 30-22-43]. NOTE: Install the seal with the metal case end towards the brake pack.

2 1

Install the snap ring (Item 2) [Figure 30-22-43] to secure the seal in the brake housing. Install a new O-ring (Item 3) [Figure 30-22-43] in the seal. Figure 30-22-44 N-22492

Install the brake spring (Item 1) [Figure 30-22-46]. Install the end plate gasket (Item 2) [Figure 30-22-46].

1

N-22498

Lightly coat the piston with oil and install a new piston seal (Item 1) [Figure 30-22-44].

434 of 1311

30-22-14

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-22-46

P-73055

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) (CONT'D) Assembly (Cont'd) Figure 30-22-47

1

N-22490

Dealer Copy -- Not for Resale

Install the brake end cover (Item 1) [Figure 30-22-47]. Install the twelve end cover mount bolts and tighten evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.

435 of 1311

30-22-15

S650 Service Manual

Dealer Copy -- Not for Resale 436 of 1311

30-22-16

S650 Service Manual

HYDROSTATIC MOTOR CARRIER Description The hydrostatic motor carrier is the mating connection from the hydrostatic drive motor to the transmission chain 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.

Dealer Copy -- Not for Resale

The hydrostatic motor carriers are made to fit on both the right and left hand side of the loader.

437 of 1311

30-30-1

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (CONT’D)

Remove the control pedal linkages. (See Linkage Removal And Installation on Page 50-90-2.)

Removal And Installation Figure 30-30-1

DANGER 1 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. D-1009-0409

P5467A

Remove the six mounting bolts (Item 1) [Figure 30-30-1] from the carrier. Installation: Tighten the mounting bolts to 461 - 488 N•m (340 - 360 ft-lb) torque. Slide the motor carrier toward the rear and remove the rear drive chain.

WARNING

Figure 30-30-2

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.

2

W-2059-0598

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

1

Raise the lift arm and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.) P5489A

Remove the fluid from the chain case. (See Removing And Replacing Fluid on Page 10-130-2.) Remove the center chain case cover. (See Center Cover Removal And Installation on Page 40-30-2.) Remove the front axle sprocket. (See Axle, Sprocket And Bearings Removal And Installation on Page 40-20-4.) If the motor carrier is removed from the right side, remove the lift arm bypass valve, (See Removal And Installation on Page 20-50-2.) and remove the control panel. (See Removal And Installation on Page 50-100-2.)

438 of 1311

NOTE: For removal and installation of the motor carrier secure the front drive chain to the chain case with wire (Item 1) [Figure 30-30-2]. Slide the motor carrier out of the chain case far enough to install a chain and chain hoist to the carrier (Item 2) [Figure 30-30-2]. Pull the motor carrier away from the chain case and out of the loader [Figure 30-30-2].

30-30-2

S650 Service Manual

Dealer Copy -- Not for Resale

•

HYDROSTATIC MOTOR CARRIER (CONT'D) Parts Identification Shaft Bearing Race Housing Seal (2) Race Bearing Snap Ring

Dealer Copy -- Not for Resale

1. 2. 3. 4. 5. 6. 7. 8.

1 2 3

4

5 6 7 8

TS-1227B

439 of 1311

30-30-3

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (CONT'D)

Figure 30-30-5

Disassembly Figure 30-30-3

1

1 P-76544

Remove the snap ring (Item 1) [Figure 30-30-5] from the shaft.

P5760

Figure 30-30-6

Dealer Copy -- Not for Resale

Remove the large O-ring from the groove (Item 1) [Figure 30-30-3] in the housing. Figure 30-30-4

P5766

Use a hydraulic press to remove the shaft from the housing [Figure 30-30-6]. P5768

Put the motor carrier in a hydraulic press [Figure 30-304]. Put a small amount of pressure on the shaft to release the preload on the snap ring.

440 of 1311

30-30-4

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (CONT'D) Disassembly (Cont’d) Figure 30-30-7

P5761

Dealer Copy -- Not for Resale

Install the bearing puller tool under the bearing flange, use the hydraulic press to remove the bearing from the shaft [Figure 30-30-7]. Figure 30-30-8

2 1

P5763

Remove the two seals (Item 1) [Figure 30-30-8] from the housing. NOTE: Some machines use a one piece double lip seal. Inspect the bearing cup (Item 2) [Figure 30-30-8] (both sides) and replace as needed.

441 of 1311

30-30-5

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (CONT'D)

Figure 30-30-11

Assembly 1

Clean all parts in solvent and dry with compressed air. Replace any worn or damaged parts. Apply oil to and install new O-rings. The tool listed will be needed to the following procedure: MEL1431 - Seal Driver Tool Figure 30-30-9

2 P5767

1 Install the bearing on the shaft [Figure 30-30-11].

Dealer Copy -- Not for Resale

Use a pipe (Item 1) [Figure 30-30-11] with O.D. that seats on the I.D. of the bearing. Figure 30-30-12 P5764

1

Install the first seal (Item 1) [Figure 30-30-9] into the housing with the seal lip facing down. Use the tool (Item 2) [Figure 30-30-9] to install the seal. Figure 30-30-10

2 P135120

1

Install the seal protector tool (Item 1) [Figure 30-30-12] over the splines on the shaft to protect the seal during installation.

P5762

Install the second seal (Item 1) [Figure 30-30-10] into the housing with the seal lip facing up. Use the tool (Item 2) [Figure 30-30-10] to install the seal.

442 of 1311

30-30-6

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (CONT'D) Assembly (Cont’d) Figure 30-30-13 2

1

Dealer Copy -- Not for Resale

P5769

install the shaft/bearing assembly into the housing. Install the bearing (Item 1) using the tool (MEL1431)(Item 2) [Figure 30-30-13]. After the bearing is seated. Install the snap ring on the shaft and reposition the motor carrier to allow back press operation. NOTE: Slight press pressure may be used to preload both bearings. After installation of the snap ring a back press operation may be necessary to reduce the preload and remove the clearance from between the snap ring and the main bearing. Use the press and apply pressure to the end of the spline shaft to reduce preload and clearance.

443 of 1311

30-30-7

S650 Service Manual

Dealer Copy -- Not for Resale 444 of 1311

30-30-8

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (SJC) Description The hydrostatic motor carrier is the mating connection from the hydrostatic drive motor to the transmission chaincase. 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. The hydrostatic motor carrier with (SJC) uses a speed sensor installed in the motor carrier housing. The speed sensor senses a disc that is fixed to the shaft in the motor carrier.

Dealer Copy -- Not for Resale

NOTE: Speed sensors have been eliminated on late model machines. Earlier models may or may not have been upgraded to allow the removal of the speed sensors. Disconnecting speed sensors requires updating the software version (79.7 or newer) and hydrostatic pump calibration. A brake disc is installed on each hydrostatic motor carrier. The brake disc is mounted to the shaft in the motor carrier (single speed loaders only). The hydrostatic motor carriers are made to fit on both the right and left hand side of the loader.

445 of 1311

30-31-1

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)

Figure 30-31-1

Removal And Installation

DANGER

1 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.

P5467A

Remove the six mounting bolts (Item 1) [Figure 30-31-1] from the carrier. Installation: Tighten the mounting bolts to 461 - 488 N•m (340 - 360 ft-lb) torque. Figure 30-31-2

Dealer Copy -- Not for Resale

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

W-2059-0598

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

P5489A

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Slide the motor carrier toward the rear and remove the rear drive chain.

Raise the operator cab. (See Raising on Page 10-30-2.)

NOTE: For removal and installation of the motor carrier secure the front drive chain to the chain case with wire (Item 1) [Figure 30-31-2].

Remove the fluid from the chaincase. (See Removing And Replacing Fluid on Page 10-130-2.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-2.) Remove the brake disc. (Single speed loaders only) (See Disc Removal And Installation on Page 40-10-1.) Remove the front axle sprocket. (See Axle, Sprocket And Bearings Removal And Installation on Page 40-20-4.)

Slide the motor carrier out of the chaincase far enough to install a chain and chain hoist to the carrier (Item 2) [Figure 30-31-2]. NOTE: When installing the motor carrier into the loader, use caution to protect the wheel speed washer from damage.

If the motor carrier is removed from the right side, remove the lift arm bypass valve, (See Removal And Installation on Page 20-50-2.) and remove the control panel. (See Removal And Installation on Page 50-100-2.)

446 of 1311

30-31-2

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Parts Identification Ref.

Description

1. 2. 3. 4. 5. 6. 7. 8.

Snap Ring Bearing Race Seal Housing Speed Washer Shaft Cover

8

6 2

5

3 4

3

2 1

* Speed washer (Item 6) and cover (Item 8) have been removed on late model machines. * Housing (Item 5) will no longer be machined to allow the installation of speed sensors.

PE3328SA

447 of 1311

30-31-3

S650 Service Manual

Dealer Copy -- Not for Resale

7

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)

Figure 30-31-5

Disassembly Figure 30-31-3

1

1 P-28155

Remove the snap ring (Item 1) [Figure 30-31-5] from the shaft.

P5760

Figure 30-31-6

Dealer Copy -- Not for Resale

Remove the large O-ring from the groove (Item 1) [Figure 30-31-3] in the housing. Figure 30-31-4

P5766

Use a hydraulic press, remove the shaft from the housing [Figure 30-31-6].

P-76540

Put the motor carrier in a hydraulic press [Figure 30-314]. Put a small amount of pressure on the shaft to release the preload on the snap ring.

448 of 1311

30-31-4

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)

Figure 30-31-9

Disassembly (Cont’d) Figure 30-31-7

1

2 P-28158

Use the hydraulic press to remove the bearing from the shaft [Figure 30-31-9].

P-76462

NOTE: The wheel speed washer (Item 2) [Figure 3031-7] 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.

1

Figure 30-31-8 P-76464

1

Remove the wheel speed washer (Item 1) [Figure 30-3110] from the shaft.

P-28157

Install the bearing puller tool (Item 1) [Figure 30-31-8] under the bearing flange, between the bearing and the speed washer.

449 of 1311

30-31-5

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-31-10 NOTE: The bearing (Item 1) [Figure 30-31-7] and the wheel speed washer (Item 2) [Figure 30-31-7], must both be replaced, due to damage to the wheel speed washer from removing the bearing.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Disassembly (Cont’d) Figure 30-31-11

2

1

P-28164

Dealer Copy -- Not for Resale

Remove the two seals (Item 1) [Figure 30-31-11] from the housing. NOTE: Some machines use a one piece double lip seal. Inspect the bearing cup (Item 2) [Figure 30-31-11] (both sides) and replace as needed.

450 of 1311

30-31-6

S650 Service Manual

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)

Models With One Piece Double Lip Seal

Assembly

Clean all parts in solvent and dry with compressed air. Replace any worn or damaged parts. Apply oil to and install new O-rings.

Models With Two Seals Clean all parts in solvent and dry with compressed air. Replace any worn or damaged parts. Apply oil to and install new O-rings.

The tool listed will be needed to the following procedure:

The tool listed will be needed to the following procedure:

Figure 30-31-14

7304800 - Seal Driver Tool

MEL1431 - Seal Driver Tool Figure 30-31-12

2

2

1

P127119

Apply grease to the seal driver tool (Item 1) and install the seal (Item 2) [Figure 30-31-14] onto the tool.

P5764

Figure 30-31-15 Install the first seal (Item 1) [Figure 30-31-12] into the housing with the seal lip facing down.

1

Use the tool (Item 2) [Figure 30-31-12] to install the seal. Figure 30-31-13

2

1 P127120

Use the tool (Item 1) [Figure 30-31-15] to install the seal.

P5762

Install the second seal (Item 1) [Figure 30-31-13] into the housing with the seal lip facing up. Use the tool (Item 2) [Figure 30-31-13] to install the seal.

451 of 1311

30-31-7

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)

Figure 30-31-18

Assembly (Cont'd) Figure 30-31-16

1

1

P-76539

Install the bearing on the shaft [Figure 30-31-18]. P-76541

Inspect the new wheel speed washer with a straight edge, to be sure it is square [Figure 30-31-16]. If the washer is more than 2,03 mm (0.080 in) out of square, it must be replaced.

Use a pipe (Item 1) [Figure 30-31-18] with O.D. that seats on the I.D. of the bearing. Seat the bearing on the shaft, down against the wheel speed washer. NOTE: The wheel speed washer should be tight on the shaft. Figure 30-31-19

Figure 30-31-17

1

2 1

P135120

P-76542

Inspect the wheel speed washer for damage to the magnetic surface (Item 1) [Figure 30-31-17]. NOTE: Do not contact the magnetic surface of the wheel speed washer (Item 1) [Figure 30-3117], with a magnet. This may cause damage to the magnetic surface.

Install the seal protector tool (Item 1) [Figure 30-31-19] over the splines on the shaft to protect the seal during installation.

Install the wheel speed washer on the shaft [Figure 3031-17]. Align the one pin (Item 2) [Figure 30-31-17] in the sprocket.

452 of 1311

30-31-8

S650 Service Manual

Dealer Copy -- Not for Resale

The wheel speed washer, has one alignment pin (Item 1) [Figure 30-31-16].

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Assembly (Cont'd) Figure 30-31-20

2

Dealer Copy -- Not for Resale

1

P-5769

Install the shaft / bearing assembly into the housing. Install the bearing (Item 1) using the tool (MEL1431) (Item 2) [Figure 30-31-20]. After the bearing is seated. Install the snap ring on the shaft and reposition the motor carrier to allow back press operation. NOTE: Slight press pressure may be used to preload both bearings. After installation of the snap ring a back press operation may be necessary to reduce the preload and remove the clearance from between the snap ring and the main bearing. Use the press and apply pressure to the end of the spline shaft to reduce preload and clearance.

453 of 1311

30-31-9

S650 Service Manual

Dealer Copy -- Not for Resale 454 of 1311

30-31-10

S650 Service Manual

CHARGE PRESSURE

Testing

Description

Figure 30-40-1

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.

2 1

3

4

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.

The tools needed to test charge pressure, hydraulic hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic gauge 6895 kPa (68,9 bar) (1000 psi) (Item 3), adapter fitting (P/ N 93F-5) (Item 4) [Figure 30-40-1] and MEL1563 or 7217666 Remote Start Tool Kit.

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 loader lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Place the loader on jackstands. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

455 of 1311

30-40-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-43196

CHARGE PRESSURE (CONT’D)

Figure 30-40-4

Testing (Cont’d) Figure 30-40-2 1 1

2 3

3

2

P-90301

Install the tee-fitting (P/N 13K-5) (Item 1) [Figure 30-404].

Connect the gauge (Item 1), to the adapter fitting (P/N 93F5) (Item 2) [Figure 30-40-2]. Connect the hydraulic hose (Item 3) [Figure 30-40-2] to the adapter fitting. Tighten all connections.

Install the hose (Item 2) [Figure 30-40-4], that was disconnected from the motor, to the tee-fitting. Install the hose (Item 3) [Figure 30-40-4], that is attached to the pressure gauge, to the tee-fitting. Tighten the hydraulic fittings.

Figure 30-40-3 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.) Start the loader and warm the hydraulic fluid to 140 degrees Farenheit. On non-SJC equipped loaders the charge pressure at high idle, with the fluid temperature of 140 degree Farenheit is 2688 - 3378 kPa (27 - 33 bar) (390 - 490 psi) with the pump in neutral.

1

P-90302

Disconnect the hydraulic hose (Item 1) [Figure 30-40-3].

456 of 1311

NOTE: If the machine is equipped with SJC option the charge pressure should be set at 2930 3620 kPa (29,3 - 36,2 bar) (425 - 525 psi) at 60°C (140°F) fluid @ High idle.

30-40-2

S650 Service Manual

Dealer Copy -- Not for Resale

P-43197

CHARGE PRESSURE (CONT’D) Sender Removal And Installation Figure 30-40-5

1

2

P-90302

Dealer Copy -- Not for Resale

Disconnect the wire (Item 1) [Figure 30-40-5] from the sender. Remove the sender (Item 2) [Figure 30-40-5] from the motor. Installation: Tighten the charge pressure sender to 10 10,9 N•m (7.4 - 8.1 ft-lb) torque. NOTE: Replace the O-ring on the sender.

457 of 1311

30-40-3

S650 Service Manual

CHARGE PRESSURE (CONT'D)

Figure 30-40-7

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.

N-17231

I-2003-0888

Remove the plug, spring and poppet [Figure 30-40-7].

Figure 30-40-6

Inspect the poppet, spring and poppet seat for wear or damage.

1

Dealer Copy -- Not for Resale

Figure 30-40-8

P-43856

1 If the charge pressure is not correct loosen the charge relief valve plug (Item 1) [Figure 30-40-6]. N-19568

Always use a new O-ring. Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb) torque. There are several different thickness of the shims (Item 1) [Figure 30-40-8] and are used to adjust the charge pressure. NOTE: 0,254 mm (0.010 in) is approximately 55,2 kPa (0,55 bar) (8 psi) increase in pressure. Do not add more than 5 shims without retesting. If testing is still low more shims may be added. On non-SJC equipped loaders the charge pressure at high idle, with the fluid temperature of 60°C (140°F) is 2688 - 3378 kPa (27 - 33 bar) (390 - 490 psi) with the pump in NEUTRAL.

458 of 1311

30-40-4

S650 Service Manual

Figure 30-40-10

CHARGE PRESSURE (CONT'D) Adjusting (Cont’d) 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

P-64435

I-2003-0888

Inspect the poppet and spring for wear or damage.

Figure 30-40-9

There are several different thickness of shims (Item 1) [Figure 30-40-10] used to adjust the charge pressure. NOTE: 1,0 mm (0.039 in) shim (Item 1) [Figure 30-4010] = 390 kPa (3,9 bar) (56.6 psi) in pressure change. Adding shims increases charge pressure. Removing shims decreases charge pressure.

1

The charge pressure should be set at 2930 - 3620 kPa (29,3 - 36,2 bar) (425 - 525 psi).

P-64431

If the charge pressure is not correct remove the charge relief valve (Item 1) [Figure 30-40-9]. NOTE: The pump has been removed for photo clarity. The charge pressure relief valve is located on the engine side of the hydrostatic pump when installed in the loader. Assembly: Always use a new O-ring. Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb) torque.

459 of 1311

30-40-5

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the seat inside the hydrostatic pump case for wear or damage.

Dealer Copy -- Not for Resale 460 of 1311

30-40-6

S650 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.

461 of 1311

30-50-1

S650 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 70-10-7.) Remove the Hydraulic Pump. (See Removal And Installation on Page 20-60-6.) Remove the Drive Belt. (See DRIVE BELT on Page 3060-1.)

1

P-90222

IMPORTANT Use a puller (Item 1)

I-2003-0888

[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.

Figure 30-10-1

Remove the pump pulley and key from the pump drive shaft. Figure 30-50-3

1

P-90221

1 1

Loosen the nut (Item 1) [Figure 30-10-1] on the hydrostatic pump drive shaft. P-90223

Installation: Tighten the nut to 258 - 325 N•m (190 - 240 ft-lb) torque Remove the two mounting bolts and nuts (Item 1) [Figure 30-50-3]. Installation: Tighten the mounting bolts and nuts to 88 95 N•m (65 - 70 ft-lb) torque.

462 of 1311

30-50-2

S650 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 20-60-8.)

Figure 30-50-4

1

P-90224

Dealer Copy -- Not for Resale

Remove the two mounting bolts (Item 1) [Figure 30-50-4] at the hydraulic pump mounting bracket. Installation: Tighten mounting bolt to 125 - 135 N•m (90 - 100 ft-lb) 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 Hydraulic Pump Startup on Page 20-60-8.)

463 of 1311

30-50-3

S650 Service Manual

HYDROSTATIC PUMP (CONT’D)

If the high pressure relief valve must be replaced, it must be replaced as a complete unit.

Replenishing / High Pressure Relief Valve Removal And Installation

The pressure setting for a new high pressure relief valve is 36197 kPa (365 bar) (5294 psi).

Figure 30-50-5

1

P-43857

Dealer Copy -- Not for Resale

There are four replenishing / high pressure relief valves (Item 1) [Figure 30-50-5] 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. Figure 30-50-6

1

2

P-66670

Remove the high pressure relief valve (Item 1) [Figure 30-50-5] and [Figure 30-50-6] from the pump. Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb) torque. Inspect for damage and replace as needed. Replace the O-ring (Item 2) [Figure 30-50-6].

464 of 1311

30-50-4

S650 Service Manual

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 Wear 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

42 9

9 8 12

4

9

25

9

9

12

24 9

465 of 1311

11

30-50-5

D-2428C

S650 Service Manual

Dealer Copy -- Not for Resale

Parts Identification (Left Half)

HYDROSTATIC PUMP (CONT'D) Parts Identification (Right Half)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Description Bolt End Cap Plug O-ring Replenishing/High Pressure Relief Valve Gasket Bearing Pin Valve Plate Washer Spring Block Retainer Piston Assembly Wear 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

Dealer Copy -- Not for Resale

Ref.

8 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

466 of 1311

30-50-6

S650 Service Manual

HYDROSTATIC PUMP (CONT'D)

Figure 30-50-9

Disassembly Figure 30-50-7 3

1 1 1

2

3

N-19571

1

Remove the pump coupler (Item 1) [Figure 30-50-9]. P-43858

Remove the large O-ring (Item 2) [Figure 30-50-9]. Remove the two small O-rings (Item 3) [Figure 30-50-9].

Dealer Copy -- Not for Resale

Remove the four mounting bolts (Item 1) [Figure 30-507].

Figure 30-50-10 Figure 30-50-8 1

1

N-19550 N-19570

Separate the two hydrostatic pumps [Figure 30-50-8].

467 of 1311

Remove the four bolts (Item 1) [Figure 30-50-10] from the pump housing end cap.

30-50-7

S650 Service Manual

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-13

Disassembly (Cont’d) 2

1

Figure 30-50-11

1 N-17194

2 Inspect the valve plate locating pin (Item 1) [Figure 3050-13] for wear and replace if needed.

Remove the pump housing end cap (Item 1) [Figure 3050-11].

Inspect the needle bearing (Item 2) [Figure 30-50-13] for wear and replace if needed.

Dealer Copy -- Not for Resale

N-19551

Figure 30-50-14 Remove the gasket (Item 2) [Figure 30-50-11]. Figure 30-50-12 1

1

N-17197

N-17193

Remove the rotating group (Item 1) [Figure 30-50-14] from the pump.

Remove the valve plate (Item 1) [Figure 30-50-12]. Inspect the valve plate for wear. (Both Sides.)

468 of 1311

30-50-8

S650 Service Manual

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-17

Disassembly (Cont’d) 3

3

Figure 30-50-15 1 3

3

1

2

2 N-17200

Inspect the ball guide retainer (Item 1) and washer (Item 2) [Figure 30-50-17] for wear and replace as needed.

Remove the slipper guide and pistons (Item 1) [Figure 30-50-15] from the cylinder block. Inspect all the pistons (Item 2) [Figure 30-50-15] for wear and replace the rotating group as needed.

Remove the four pins (Item 3) [Figure 30-50-17] from the cylinder block. Inpsect the cylinder block for wear and replace as needed. Inspect pins (Item 3) [Figure 30-50-17] to see if they are all the same length.

Figure 30-50-16

Figure 30-50-18 1

1

N-17199

N-17201

Remove the ball guide retainer (Item 1) [Figure 30-5016] from the cylinder block.

Remove the thrust plate (Item 1) [Figure 30-50-18] from the pump housing.

469 of 1311

30-50-9

S650 Service Manual

Dealer Copy -- Not for Resale

N-17198

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-21

Disassembly (Cont’d) Figure 30-50-19

1

1

2

N-17240

3 Remove the snap ring (Item 1) [Figure 30-50-21] from the pump housing and remove the drive shaft and bearing from the housing.

Remove the drive shaft key (Item 1) the snap ring (Item 2) and the support washer (Item 3) [Figure 30-50-19] from the drive shaft end of the pump.

Figure 30-50-22

Dealer Copy -- Not for Resale

N-17481

Figure 30-50-20

1

1

N-17241

Remove the snap ring (Item 1) [Figure 30-50-22] from the drive shaft and remove the bearing.

N-17239

Inspect the bearing for wear and replace if worn. Use a seal puller and remove the seal (Item 1) [Figure 30-50-20] from the pump housing.

470 of 1311

30-50-10

S650 Service Manual

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-25

Disassembly (Cont’d) Figure 30-50-23 2 1

1

N-17244

Remove the O-ring (Item 1) and bearing race (Item 2) [Figure 30-50-25] from the pump housing.

N-17242

Figure 30-50-26

Figure 30-50-24 1

2

N-17245

1

1 Inspect the bearing race (Item 1) and O-ring (Item 2) [Figure 30-50-26] for wear and replace as needed.

N-17243

Remove the four mount bolts (Item 1) [Figure 30-50-24] from the lower trunnion cover. Remove the cover.

471 of 1311

30-50-11

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the pump shaft (Item 1) [Figure 30-50-23] for wear and replace if needed.

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-29

Disassembly (Cont’d) Figure 30-50-27

1 2 1

1

N-17250

Inspect the seal (Item 1) [Figure 30-50-29] in the upper trunnion cover and replace if needed.

N-17246

Figure 30-50-30 Remove the four mount bolts (Item 1) from the pump housing and remove the linkage bracket (Item 2) [Figure 30-50-27]. Figure 30-50-28

1 2 N-17248

Remove the O-ring (Item 1) and bearing race (Item 2) [Figure 30-50-30] from the pump housing.

1

N-17247

Remove the upper trunnion cover (Item 1) [Figure 30-5028].

472 of 1311

30-50-12

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the dust seal on the pintle shaft.

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-33

Disassembly (Cont’d) 1 Figure 30-50-31

1 N-17252

2 Tilt the swash plate (Item 1) [Figure 30-50-33] and remove the swash plate and lower bearing from the pump housing.

N-17249

Dealer Copy -- Not for Resale

Inspect the bearing race (Item 1) and O-ring (Item 2) [Figure 30-50-31] and replace as needed. Figure 30-50-32

1

N-17251

Slide the swash plate from side to side and remove the tapered roller bearing (Item 1) [Figure 30-50-32] from the swash plate shaft.

473 of 1311

30-50-13

S650 Service Manual

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-36

Assembly Figure 30-50-34 1 1 2

3 N-17249

Install the tapered bearing (Item 1) [Figure 30-50-36] on the swash plate shaft.

N-17253

Figure 30-50-37

Figure 30-50-35

N-17248

Install the bearing race (Item 2) [Figure 30-50-36] and Oring (Item 3) [Figure 30-50-36] as shown in [Figure 3050-37].

N-17252

Install the swash plate and bearing into the pump housing [Figure 30-50-35].

474 of 1311

30-50-14

S650 Service Manual

Dealer Copy -- Not for Resale

Install the lower bearing (Item 1) [Figure 30-50-34] on the swash plate.

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-40

Assembly (Cont’d) Figure 30-50-38 1

2

1

N-17245

Figure 30-50-41 N-17247

Figure 30-50-39

2 N-17244

1

Install the bearing race (Item 1) and O-ring (Item 2) [Figure 30-50-40] at the lower trunnion as shown in [Figure 30-50-41].

1

N-17246

Install the linkage bracket (Item 2) and the four mounting bolts (Item 1) [Figure 30-50-39] and tighten to 24 - 30 N•m (18 - 22 ft-lb) torque. Install the dust seals onto the pintle shafts

475 of 1311

30-50-15

S650 Service Manual

Dealer Copy -- Not for Resale

Install the upper trunnion seal (Item 1) [Figure 30-50-38] and cover.

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-44

Assembly (Cont’d) Figure 30-50-42

1

1

N-17241

1

Install the bearing and snap ring (Item 1) [Figure 30-5044] on the pump shaft.

N-17243

Figure 30-50-45

Install the four mounting bolts (Item 1) [Figure 30-50-42] and tighten to 24 - 30 N•m (18 - 22 ft-lb) torque. Figure 30-50-43

1

1

N-17240

Install the pump shaft into the pump housing [Figure 3050-45]. Install the snap ring (Item 1) [Figure 30-50-45]. N-17242

Install the snap ring (Item 1) [Figure 30-50-43] on the pump shaft.

476 of 1311

30-50-16

S650 Service Manual

Dealer Copy -- Not for Resale

Align the marks on the lower trunnion cover and pump housing as shown in [Figure 30-50-42].

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-48

Assembly (Cont’d)

1 1

Figure 30-50-46

1

1

1

2

3

N-17200

Install the seal (Item 1) [Figure 30-50-46] into the pump housing.

Apply a small amount of grease to the washer (Item 2) and install into the ball guide retainer (Item 3) [Figure 3050-48].

Figure 30-50-47

Figure 30-50-49 1

3 2

1 N-17481

N-17199

Install the washer (Item 1), snap ring (Item 2) and the drive shaft key (Item 3) [Figure 30-50-47].

477 of 1311

Install the ball guide retainer and washer (Item 1) [Figure 30-50-49] onto the slipper holddown pins.

30-50-17

S650 Service Manual

Dealer Copy -- Not for Resale

Install the four slipper pins (Item 1) [Figure 30-50-48] into the cylinder block.

N-17239

HYDROSTATIC PUMP (CONT’D)

Figure 30-50-52

Assembly (Cont’d) 1

2

Figure 30-50-50

N-17194

Replace the needle bearing (Item 1) and valve plate locating pin (Item 2) [Figure 30-50-52] in the charge pump.

Assemble the piston assemblies into the slipper guide. Lubricate the pistons and cylinder block bores and insert the piston assemblies into the cylinder bores [Figure 3050-50].

Figure 30-50-53

Lay the pump housing on its side and install the cylinder block, piston assembly into the housing.

2

Dealer Copy -- Not for Resale

N-17198

1

Figure 30-50-51

N-17196

The bearing cage (Item 1) [Figure 30-50-53] will protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the surface of the charge pump. The valve plate locating spring pin (Item 2) [Figure 3050-53] will protrude from 4,19 - 4,70 mm (0.165 - 0.185 in) from the surface of the charge pump.

N-17197

Place the pump on a work surface with the end cap opening up [Figure 30-50-51].

478 of 1311

30-50-18

S650 Service Manual

Figure 30-50-56

HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d)

1

1

Figure 30-50-54

1

N-19550

Install the valve plate and end cap on the pump housing. Tighten the bolts (Item 1) [Figure 30-50-56] to 47 - 61 N•m (35 - 45 ft-lb) torque.

Coat the backside of the valve plate with petroleum jelly to hold it in position and install the valve plate onto the charge pump, bronze face up [Figure 30-50-54].

Figure 30-50-57

Dealer Copy -- Not for Resale

N-17193

The notch (Item 1) [Figure 30-50-54] on the valve plate must engage the locating pin. Figure 30-50-55

1 3

2 1 N-19571

1 Install the two small O-rings (Item 1) [Figure 30-50-57]. Install the large new O-ring (Item 2) [Figure 30-50-57]. Install the pump coupler (Item 3) [Figure 30-50-57].

N-19551

Coat a new end cap gasket (Item 1) [Figure 30-50-55] with petroleum jelly and install onto the end cap.

479 of 1311

30-50-19

S650 Service Manual

HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d) Figure 30-50-58

N-19570

Dealer Copy -- Not for Resale

Install the two pumps together [Figure 30-50-58]. Figure 30-50-59

1

1 P-43858

Tighten the four bolts (Item 1) [Figure 30-50-59] to 47 61 N•m (35 - 45 ft-lb) torque.

480 of 1311

30-50-20

S650 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

481 of 1311

30-51-1

S650 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 10-20-1.) Place the loader on jack stands. (See LIFTING AND BLOCKING THE LOADER 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. Installation: Tighten to 10,4 N•m (7.7 ft-lb) torque.

482 of 1311

30-51-2

S650 Service Manual

Dealer Copy -- Not for Resale

Removal:

WARNING

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-7

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.

NOTE: When a hydraulic controller is replaced, the hydrostatic pumps must be calibrated. (See Hydraulic Controller Neutral Adjustment on Page 30-51-26.)

Remove the controller gaskets (Item 2) [Figure 30-51-5] from the pump. Installation: Figure 30-51-6

2

2

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]. Use a small amount of grease on a new gasket and install the gasket on the hydraulic controller (Item 1) [Figure 30-51-5].

483 of 1311

30-51-3

S650 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 30-51-9

Removal And Installation Remove the hydrostatic pump / engine assembly from the loader. (See Engine Removal And Installation on Page 70-10-7.) Remove the Hydraulic Pump. (See Removal And Installation on Page 20-60-6.) Remove the Drive Belt. (See DRIVE BELT on Page 3060-1.)

1

P-90222

IMPORTANT

I-2003-0888

Use a puller (Item 1) [Figure 30-51-9] 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 30-51-8

Figure 30-51-10

1

1 1 P-90221 P-90223

Loosen the nut (Item 1) [Figure 30-51-8] 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 30-51-10]. Installation: Tighten the mounting bolts and nuts to 88 95 N•m (65 - 70 ft-lb) torque.

484 of 1311

30-51-4

S650 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) (Earlier Model) Figure 30-51-11

1

P-90224

Dealer Copy -- Not for Resale

Remove the two mounting bolts (Item 1) [Figure 30-5111] at the hydraulic pump mounting bracket. Installation: Clean threads and apply Loctite® 242 to the mounting bolts and tighten to 125 - 135 N•m (90 - 100 ftlb) 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.)

485 of 1311

30-51-5

S650 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 30-51-12

1

P-90226

Remove the air bleed plugs (Item 1) [Figure 30-51-12]. BEFORE STARTUP: Fill one of the air bleed ports with new hydraulic fluid until the hydraulic fluid flows out of the other air bleed port. This will remove trapped air in the hydrostatic pumps before startup. Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

486 of 1311

30-51-6

S650 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

9 10 12

8

21

1

1

1 11 2 2

487 of 1311

P-90240

30-51-7

S650 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 30-51-15

High Pressure Relief And Bypass Valve Figure 30-51-13

1 2 1 1

P-64437

Inspect the valve seat surface (Item 1) [Figure 30-51-15] for scratches and replace as needed.

There are four system check relief valves (Item 1) [Figure 30-51-13] in the back of the hydrostatic pump.

Inspect the spring (Item 2) [Figure 30-51-15] for breakage. Inspect seats inside case housing.

Remove the relief valve cap (Item 1) [Figure 30-51-13]. Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) torque.

Factory setting on the relief valve is 36197 kPa (365 bar) (5294 psi).

Figure 30-51-14

4

2

Do not disassemble the relief valve assembly. If replacement is required, replace as an assembly.

3

1

P-64436

Inspect the valve cap O-ring (Item 1) and back-up ring (Item 2) [Figure 30-51-14], replace as needed. Remove relief valve assembly (Item 3) [Figure 30-51-14] from the valve cap. Inspect the conical spring (Item 4) [Figure 30-51-14] to ensure it is not broken or flattened.

488 of 1311

30-51-8

S650 Service Manual

Dealer Copy -- Not for Resale

P-64431

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-17

Charge Relief Valve Figure 30-51-16

1

4 2

3

6

5

P-64435

1 Inspect the O-ring (Item 1) [Figure 30-51-17]. P-64431

Inspect the sealing ring (Item 4) [Figure 30-51-17] and the mating seat in the pump housing for damage or foreign material.

Remove the charge relief valve. Assembly: Tighten charge relief valve to 70 N•m (52 ftlb) torque.

Inspect the spring (Item 5) and the charge relief valve shims (Item 6) [Figure 30-51-17]. NOTE: 1,0 mm shim (Item 6) [Figure 30-51-17] = 300 kPa (3,0 bar) (43.5 psi) in pressure change. Adding shims increases charge pressure. Removing shims decreases charge pressure.

489 of 1311

30-51-9

S650 Service Manual

Dealer Copy -- Not for Resale

The charge relief valve (Item 1) [Figure 30-51-16] is located on the back of the hydrostatic pump.

Inspect the poppet (Item 2) and the mating seat (Item 3) [Figure 30-51-17] for damage or foreign material. Ensure the poppet moves freely in it’s bore.

HYDROSTATIC PUMP (SJC) (CONT'D)

Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.

Disassembly And Assembly

Note the connectors facing each other.

Remove the hydrostatic pump / engine assembly from the loader. (See Engine Removal And Installation on Page 70-10-7.)

Figure 30-51-20

Remove the hydrostatic pump. (See Removal And Installation on Page 30-51-4.)

1

Figure 30-51-18

1

2 P-90228

1

Remove the mounting bolts (Item 1) for the swash plate angle sensor (Item 2) [Figure 30-51-20]. Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque. P-90226

Remove the hydraulic controllers (Item 1) [Figure 30-5118]. (See Hydraulic Controller Removal And Installation on Page 30-51-2.) Figure 30-51-19 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 30-51-19]. Remove the two bolts (Item 3) and the steel cover (Item 2) [Figure 30-51-19] from both sides.

490 of 1311

30-51-10

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDROSTATIC PUMP (SJC) (CONT'D)

Right End Housing

Disassembly And Assembly (Cont'd)

Figure 30-51-23

Figure 30-51-21

3

1

2 2

1 1 P-64445 P-90217

Left End Housing Figure 30-51-24 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 30-5121].

1

Figure 30-51-22 1

2

1 P-64447

Remove the four mount bolts (Item 1) securing the end housing (Item 2) to the main case housing (Item 3) [Figure 30-51-23] and [Figure 30-51-24].

P-90218

Inspect and replace the O-ring (Item 1) [Figure 30-5122].

491 of 1311

Assembly: Alternately, tighten mount bolts to 130 N•m (96 ft-lb) torque.

30-51-11

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-27

Disassembly And Assembly (Cont'd) Figure 30-51-25

1

P-64466

Ensure servo follower (Item 2) [Figure 30-51-26] is swung out for proper engagement with the notch in the servo piston (Item 1) [Figure 30-51-27].

Pull the end housings from the case housing [Figure 3051-25].

Figure 30-51-28

Dealer Copy -- Not for Resale

P-64464

Figure 30-51-26 1

1

2

2

P-64463

P-64465

Assembly: Ensure dowel pin (Item 1) is aligned with hole in case housing (Item 2) [Figure 30-51-28] before tightening screws.

Replace O-ring (Item 1) [Figure 30-51-26].

492 of 1311

30-51-12

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-51-29 RIGHT SIDE

1

2 P-64454

Dealer Copy -- Not for Resale

Figure 30-51-30 LEFT SIDE

1

2

P-64501

Remove valve plate (Item 1) [Figure 30-51-29] and [Figure 30-51-30] 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 30-51-29] and [Figure 30-51-30] in the valve plate for assembly reasons. There are different valve plates for the left and right side. The valve plates are NOT interchangeable.

493 of 1311

30-51-13

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-34

Disassembly And Assembly (Cont'd)

LEFT SIDE

Figure 30-51-31

1 2

RIGHT SIDE

1

P-64503

2 P-64455

Assembly: Align the timing pin (Item 1) [Figure 30-5131] and [Figure 30-51-32] in the case housing with the notch (Item 1) [Figure 30-51-33] and [Figure 30-51-34] that does not go through the valve plate. Align the shoulder of the roller bearing (Item 2) [Figure 30-51-31] and [Figure 30-51-32] with the beveled edge on the valve plate (Item 2) [Figure 30-51-33] and [Figure 30-51-34].

LEFT SIDE

NOTE: Valve plate should sit FLUSH with the case housing when properly installed.

1 2 P-64502

Figure 30-51-33 RIGHT SIDE 1 2

P-64456

494 of 1311

30-51-14

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-51-32

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-37

Disassembly And Assembly (Cont'd) Figure 30-51-35 1

P-64469

Remove the piston assembly (Item 1) [Figure 30-51-37]. B25012

Figure 30-51-38

Figure 30-51-36

1

P-64475

B25011

Remove the pistons (Item 1) [Figure 30-51-38] from the rotating block.

Left Side Rotating Group [Figure 30-51-36].

495 of 1311

30-51-15

S650 Service Manual

Dealer Copy -- Not for Resale

Right Side Rotating Group [Figure 30-51-35].

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-41

Disassembly And Assembly (Cont'd) 1 Figure 30-51-39

1

P-64471

Remove the spherical washer (Item 1) [Figure 30-5141].

P-64476

1

Figure 30-51-40

1

1

P-64472

Inspect the pins (Item 1) [Figure 30-51-42]. 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 30-51-40].

496 of 1311

30-51-16

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-51-42 Inspect the pistons for scoring and scratches. Ensure the holes (Item 1) [Figure 30-51-39] in the slippers, are not plugged.

Figure 30-51-45

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd)

3 Figure 30-51-43 1 1

2

P-64479

Inspect mating surface for the slippers on the swash plate (Item 1) [Figure 30-51-45].

Inspect the spherical washer for scoring and wear (Item 1) [Figure 30-51-43].

Remove the swash plate from the end cap housing (Item 2) [Figure 30-51-45]. Remove the slide ring (Item 3) [Figure 30-51-45], ensure it pivots freely.

Figure 30-51-44

Figure 30-51-46 1 2 1

3

2

P-64478

Inspect the back surface of the rotating block (Item 1) [Figure 30-51-44] 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 30-51-46].

Visually ensure spring (Item 2) and c-clip (Item 3) [Figure 30-51-44] are not bent or damaged.

497 of 1311

30-51-17

S650 Service Manual

Dealer Copy -- Not for Resale

P-64474

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-49 2

Disassembly And Assembly (Cont'd)

1

1

Figure 30-51-47

2

3

1

P-64483

Assembly: Ensure bearing pins are in the holes of the swash plate (Item 1) [Figure 30-51-47].

Assembly: Note shell bearing races have an edge (Item 2) [Figure 30-51-49] on them. The edges face towards the outside of the end cap housing

Figure 30-51-48

Inspect bearing surfaces for scratches or scoring. Remove the positioning pin (Item 3) [Figure 30-51-49]. 2 Figure 30-51-50

1

1

2

P-64482

Remove the shell bearing (Item 1) [Figure 30-51-48]. P-64485

Inspect individual roller bearings and machined surfaces (Item 2) [Figure 30-51-48] on swash plate. Replace O-ring (Item 1) [Figure 30-51-50].

Inspect wear surfaces (Item 2) [Figure 30-51-50] for scratches or scoring. Ensure positioning pin can rotate smoothly in the end housing without excessive play.

498 of 1311

30-51-18

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the shell bearing races (Item 1) [Figure 30-5149].

P-64481

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-53

Disassembly And Assembly (Cont'd) Figure 30-51-51

LEFT SIDE

1 1 P-76742

The pump seal (Item 1) [Figure 30-51-53] is removed by inserting a screw into the seal and prying out.

P-64486

Figure 30-51-54

RIGHT SIDE

1

2 1

P-64488 P-76743

Remove the snap ring (Item 1) [Figure 30-51-51] and [Figure 30-51-52] 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 30-51-54] and remove bearing.

499 of 1311

30-51-19

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-51-52

Figure 30-51-57

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-51-55

1

1

P-90232

Remove servo piston mounting bolts (Item 1) [Figure 3051-57]. Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.

Dealer Copy -- Not for Resale

Figure 30-51-58

B25013

Servo Piston Assembly [Figure 30-51-55]. 1

The Servo Piston Assembly [Figure 30-51-55] cannot be removed unless the hydraulic controller and rotating group is removed first. Figure 30-51-56

P-90231

Use a rubber mallet to rotate servo piston cover (Item 1) [Figure 30-51-58].

P-64490

Measure and record servo piston depth at the adjustment screw [Figure 30-51-56].

500 of 1311

30-51-20

S650 Service Manual

Figure 30-51-61

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-51-59

1

P-64466

Assembly: Align the servo piston so the guide slot (Item 1) [Figure 30-51-61] is parallel to the drive shaft centerline. Measure with a straight-edge [Figure 30-5160].

Slide the servo piston assembly out of the bore. [Figure 30-51-59].

Figure 30-51-62

Dealer Copy -- Not for Resale

P-90237

Figure 30-51-60 1 2 1 2

P-64493 P-64467

Remove the bushings (Item 1), seals and O-rings (Item 2) [Figure 30-51-62] from the pump housing.

501 of 1311

30-51-21

S650 Service Manual

Figure 30-51-65

HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-51-63

1

1 2 2 P-64496

3

Remove the servo cover (Item 1) [Figure 30-51-65] from the servo piston.

Each servo has a pair of bushings (Item 1), O-rings (Item 2) and square-cut seals (Item 3) [Figure 30-51-63].

Remove the O-ring (Item 2) [Figure 30-51-65] from the cover.

Dealer Copy -- Not for Resale

P-64494

Figure 30-51-66 Figure 30-51-64

1

1

P-64497 P-64495

Remove the locknut (Item 1) [Figure 30-51-64] from the servo piston.

Remove snap ring (Item 1) [Figure 30-51-66] from the servo piston.

Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.

502 of 1311

30-51-22

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D)

Mechanical Neutral Adjustment

Disassembly And Assembly (Cont'd)

The tools listed will be needed to do the following procedure:

Figure 30-51-67 MEL1563 or 7217666 - Remote Start Tool Kit 1

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.

2

Place the loader on jack stands. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

WARNING Remove the piston stop adjustment mechanism (Item 1) [Figure 30-51-67] from the servo piston.

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

Inspect mechanism for broken parts. Replace O-ring (Item 2) [Figure 30-51-67].

Raise the lift arms, and install an approved lift arm support device. (See Installing on Page 10-20-1.)

Figure 30-51-68

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.) 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

Bearings (Item 1) [Figure 30-51-68] in case housing are replaced by using a press and bearing driver.

WARNING

Inspect center coupler (Item 2) [Figure 30-51-68].

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

503 of 1311

30-51-23

S650 Service Manual

Dealer Copy -- Not for Resale

P-64498

Figure 30-51-71

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment (Cont’d) Figure 30-51-69 1 1

1

P-64438

Remove the plugs (Item 1) [Figure 30-51-71] from the MA ports on the bottom of the pump, and install 51711 kPa (517 bar) (7500 psi) pressure gauges.

Connect a hydraulic hose (Item 1) [Figure 30-51-69] 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 30-51-72

Figure 30-51-70 1

1

1 1

1

1 P-90243

P-90242

Remove the plugs (Item 1) [Figure 30-51-70] from the MB ports on the front side of the pump, and install 51711 kPa (517 bar) (7500 psi) pressure gauges.

504 of 1311

Remove drive hoses from the A and B ports (Item 1) [Figure 30-51-72]. Plug the ports with metal caps. The caps must be able to handle at least 51711 kPa (517 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

S650 Service Manual

Dealer Copy -- Not for Resale

P-64973

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-75

Mechanical Neutral Adjustment (Cont’d) Figure 30-51-73

1

1

P-90238

Turn the adjustment screw (Item 1) [Figure 30-51-75] 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 30-51-73].

Figure 30-51-76

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 30-51-74 P-90238

Turn the adjustment screw (Item 1) [Figure 30-51-76] 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 30-51-74] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw.

505 of 1311

30-51-25

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D)

Hydraulic Controller Neutral Adjustment

Mechanical Neutral Adjustment (Cont’d)

The tools listed will be needed to do the following procedure:

Figure 30-51-77 MEL1563 or 7217666 - Remote Start Tool Kit 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.

2

P-90238

While holding the adjustment screw (Item 1) in position, tighten the locknut (Item 2) [Figure 30-51-77] to 30 N•m (22 ft-lb) torque.

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. Place the loader on jack stands. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

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. 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. 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.)

WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

Raise the lift arms, and install an approved lift arm support device. (See Installing on Page 10-20-1.) 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.)

506 of 1311

30-51-26

S650 Service Manual

Dealer Copy -- Not for Resale

1

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-80

Hydraulic Controller Neutral Adjustment (Cont’d)

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 P-64975

Figure 30-51-78 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. 1

1

Dealer Copy -- Not for Resale

Figure 30-51-81

1 P-90239

Disconnect the hydraulic controller connectors (Item 1) [Figure 30-51-78] from the loader wiring harness for the hydraulic controller you are adjusting. P-90236

Figure 30-51-79 Loosen the locking screw (Item 1) [Figure 30-51-81]. Start the loader using the Remote Start Tool and run at an idle. 1

WARNING

2

Stay clear of the loader wheels. They will turn whenever the pump is not centered. W-2276-1297 P-90226

Remove the X1 plug (Item 1) and X2 plug (Item 2) [Figure 30-51-79] pertaining to the side of the hydrostatic pump you are adjusting.

507 of 1311

30-51-27

S650 Service Manual

HYDROSTATIC PUMP (SJC) (CONT'D)

Figure 30-51-84

Hydraulic Controller Neutral Adjustment (Cont’d) Figure 30-51-82

1

1

P-90236

Turn the adjustment screw (Item 1) [Figure 30-51-84] clockwise, to a position halfway between the recorded positions. The pressure gauges should read equal pressures.

Turn the adjustment screw (Item 1) [Figure 30-51-82] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw.

Figure 30-51-85

Dealer Copy -- Not for Resale

P-90236

Figure 30-51-83

1

2

1 P-90236

While holding the adjustment screw (Item 1) in position, tighten the locking screw (Item 2) [Figure 30-51-85] to 6,1 N•m (4.5 ft-lb) torque.

P-90236

Turn the adjustment screw (Item 1) [Figure 30-51-83] 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.)

508 of 1311

30-51-28

procedure.

(See

S650 Service Manual

DRIVE BELT

Belt Replacement

Belt Adjustment

Stop the engine and open the rear door.

The drive belt does not need adjustment. The belt has a spring loaded idler which constantly maintains the correct belt tension.

Remove the battery. (See Removal And Installation on Page 60-20-1.) Figure 30-60-3

Stop Adjustment Stop the engine and open the rear door. Figure 30-60-1 1

1

2

Remove the drive belt shield bolt (Item 1) [Figure 30-603]. P-90470

Figure 30-60-4 Loosen the spring loaded idler adjustment bolt (Item 1) and insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30-60-1] into the slot provided in the stop arm as shown.

1

Figure 30-60-2

2 1 P-90467

Do NOT loosen the drive belt shield mounting bolts (top bolt shown) (Item 1). Slide the drive belt shield (Item 2) 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 30-60-4].

P109784A

Move the breaker bar to adjust the stop arm until a gap of 3,2 mm (0.125 in) (Item 1) [Figure 30-60-2] is achieved. Tighten the spring loaded idler adjustment bolt (Item 1) [Figure 30-60-1] to 105 - 115 N•m (78 - 85 ft-lb) torque.

509 of 1311

30-60-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-85518

Maintain torque on the stop arm and tighten the spring loaded idler adjustment bolts (Item 1) [Figure 30-60-6] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Belt Replacement (Cont’d) Figure 30-60-5

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.

1 Figure 30-60-7 Top Mounting Bolt 2 1

P-90470 P-90468A

Loosen the spring loaded idler adjustment bolts (Item 1). Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 3060-5] into the slot provided in the stop arm as shown and push breaker bar down to release tension on drive belt.

2 Tighten the adjustment bolts (Item 1) [Figure 30-60-5] to hold the spring loaded idler off the drive belt. Remove the drive belt from the hydrostatic pump pulley and flywheel pulley. Inspect the pulleys for wear. P-90469A

Install new drive belt. Loosen the spring loaded idler adjustment bolts (Item 1) [Figure 30-60-5] and allow the idler to contact the drive belt.

Position the drive belt shield over the drive belt shield mounting bolts and slide the drive belt shield toward the front of the loader to fully seat the shield onto the top and bottom mounting bolts (Items 1 and 2) [Figure 30-60-7].

Figure 30-60-6

1 2

P115669

Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the torque wrench (Item 2) [Figure 30-60-6] into the slot provided in the stop arm as shown and move the torque wrench up until the correct torque is indicated.

510 of 1311

30-60-2

S650 Service Manual

Dealer Copy -- Not for Resale

Bottom Mounting Bolt

DRIVE BELT (CONT’D) Belt Replacement (Cont’d) Figure 30-60-8

1

P-85518

Dealer Copy -- Not for Resale

Install the drive belt shield bolt (Item 1) [Figure 30-60-8]. Install the battery. (See Removal And Installation on Page 60-20-1.) Close the rear door. NOTE: The stop arm MUST be adjusted after 50 hours operation with the new drive belt. (See Stop Adjustment on Page 30-60-1.) See the SERVICE SCHEDULE for the correct service interval after the initial 50 hour adjustment. (See SERVICE SCHEDULE on Page 10-70-1.)

511 of 1311

30-60-3

S650 Service Manual

DRIVE BELT (CONT’D)

Figure 30-60-10

Tensioner Pulley Removal And Installation Remove the engine air cleaner. (See Housing Removal And Installation on Page 70-40-1.) 1 Remove the belt. (See Belt Replacement on Page 30-601.)

2

Figure 30-60-9

1 P-85741

Remove the two mounting bolts (Item 1) [Figure 30-6010].

2

Installation: Apply Loctite® 242 to the mounting bolts (Item 1) [Figure 30-60-10]. P-85520

Loosen the spring loaded idler adjustment bolt (Item 1). Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 3060-9] into the slot provided in the stop arm as shown and push breaker bar down to release tension on drive belt. Tighten adjustment bolt (Item 1) [Figure 30-60-9] to hold the spring loaded idler off the drive belt.

512 of 1311

30-60-4

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the tensioner pulley (Item 2) [Figure 30-60-10].

DRIVE BELT (CONT'D)

Figure 30-60-13

Tensioner Pulley Disassembly And Assembly Figure 30-60-11

1 1

2

1 P-90303

3

Disassembly the tensioner pulley as shown [Figure 3060-13].

P-90306

Release the spring tension by allowing the adjustment plate (Item 2) to slide past the tensioner pulley stop (Item 3) [Figure 30-60-11].

NOTE: The wheel and arm assembly (Item 1) [Figure 30-60-13] are not serviceable and must be replaced as a complete assembly.

Remove the two bolts (Item 1) and the adjustment plate (Item 2) [Figure 30-60-11]. Figure 30-60-12

1

P-90304

Remove the pivot sleeve (Item 1) [Figure 30-60-12].

513 of 1311

30-60-5

S650 Service Manual

Dealer Copy -- Not for Resale

Inspect the parts for wear and replace as needed. Loosen the two bolts (Item 1) [Figure 30-60-11] but do not remove.

Dealer Copy -- Not for Resale 514 of 1311

30-60-6

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) Description Figure 30-70-1

1

P-90507

Dealer Copy -- Not for Resale

The two-speed / brake valve (Item 1) [Figure 30-70-1] is located in front of the hydrostatic pump. The high range is selected by a switch located on the right handle for manual loaders and on the left joystick for SJC loaders. When the high range is selected, the two-speed solenoid is energized by the Bobcat Controller. The valve shifts and directs charge pressure fluid to the shift spool in each motor. The charge pressure hydraulic fluid shifts the spools allowing the motors to move into high range. When low range is selected, the solenoid is de-energized and the shift spools are spring returned to low range.

515 of 1311

30-70-1

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D)

Figure 30-70-2

1

Valve Block Removal And Installation

DANGER 2 2

P-90437

•

•

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 steering shock (Item 1) [Figure 30-70-2]. Mark all hydraulic hoses for proper installation. Disconnect the five hydraulic hoses (Item 2) [Figure 3070-2] from the two speed / brake valve block. Figure 30-70-3

D-1009-0409

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-90425

WARNING

Disconnect the three hydraulic hoses (Item 1) [Figure 30-70-3] from the two speed/brake valve block.

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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

516 of 1311

30-70-2

S650 Service Manual

Dealer Copy -- Not for Resale

P-90328

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D) Valve Block Removal And Installation (Cont’d) Figure 30-70-4 1

2

P-90444

Dealer Copy -- Not for Resale

Disconnect the wire harness connector (Item 1) [Figure 30-70-4] from the two speed solenoid. Disconnect the wire harness connectors (Item 2) [Figure 30-70-4] from the brake solenoid and make-up valve. Figure 30-70-5

1

P-90446

Remove the two mounting bolts (Item 1) [Figure 30-70-5] from the valve block.

517 of 1311

30-70-3

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D)

Figure 30-70-8

Valve Block Disassembly And Assembly

1

Figure 30-70-6 1

2

1

N-22580

1

Replace the back-up rings (Item 1) and O-rings (Item 2) [Figure 30-70-8]. Figure 30-70-9

P-90548

Remove the hydraulic fittings (Item 1) [Figure 30-70-6] from the valve block.

4

Figure 30-70-7

2 3

1 2 P-90550

Remove the two bolts (Item 1) from the brake valve solenoid (Item 2) [Figure 30-70-9]. Remove the electrical solenoid nut (Item 3) from the make-up solenoid (Item 4) [Figure 30-70-9]. Assembly: Tighten the nut to 6,78 - 9,5 N•m (60 - 84 inlb) torque.

P-90549

Remove the check valves (Items 1 and 2) [Figure 30-707] from the two-speed valve. NOTE: The check valves (Items 1 and 2) [Figure 3070-7] are interchangeable.

518 of 1311

30-70-4

S650 Service Manual

Dealer Copy -- Not for Resale

1 Mark all hydraulic hoses and fittings for proper installation.

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D)

Figure 30-70-12

Valve Block Disassembly And Assembly (Cont'd) Figure 30-70-10 1

1

P-90552

Remove the make-up solenoid (Item 1) [Figure 30-7012] from the valve block.

Use a test meter and test the solenoid coils (Item 1) [Figure 30-70-10] for resistance. The resistance value for the solenoid coil can be found on the electrical schematic. Figure 30-70-11

1

N-22584

Assembly: Always install new O-rings and back-up rings [Figure 30-70-13]. Tighten the solenoid valve to 27,1 N•m (20 ft-lb) torque.

P-90551

Use a test meter and test the solenoid coils (Item 1) [Figure 30-70-10] for resistance. The resistance value for the solenoid coil can be found on the electrical schematic.

519 of 1311

30-70-5

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 30-70-13

P-90435

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 A3NV17774 AND S/N A3NW11001 - A3NW12724) (CONT’D)

Figure 30-70-16

Valve Block Disassembly And Assembly (Cont'd) 1

Figure 30-70-14

1

P-90547

1 Use a test meter and test the solenoid (Item 1) [Figure 30-70-16] for resistance.

Remove the plugs (Item 1) [Figure 30-70-14] from the two speed/brake valve block.

Assembly: Always install new O-rings and back-up rings.

Replace the O-ring [Figure 30-70-14] on the plugs. Figure 30-70-15

1

P-90554

Remove the two speed solenoid bolts (Item 1) [Figure 30-70-15].

520 of 1311

30-70-6

S650 Service Manual

Dealer Copy -- Not for Resale

The resistance value for the solenoid coil can be found on the electrical schematic.

P-90553

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) Description Figure 30-71-1

1

P-90507

Dealer Copy -- Not for Resale

The two-speed / brake valve (Item 1) [Figure 30-71-1] is located in front of the hydrostatic pump. The high range is selected by a switch located on the right handle for manual loaders and on the left joystick for SJC loaders. When the high range is selected, the two-speed solenoid is energized by the Bobcat Controller. The valve shifts and directs charge pressure fluid to the shift spool in each motor. The charge pressure hydraulic fluid shifts the spools allowing the motors to move into high range. When low range is selected, the solenoid is de-energized and the shift spools are spring returned to low range.

521 of 1311

30-71-1

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) (CONT'D)

Figure 30-71-2

Valve Block Removal And Installation

1

DANGER 2 2

P-90437

P-90328

•

D-1009-0409

Remove the steering shock (Item 1) [Figure 30-71-2]. Mark all hydraulic hoses for proper installation. Disconnect the five hydraulic hoses (Item 2) [Figure 3071-2] from the two speed / brake valve block. Figure 30-71-3

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-90425

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.

Disconnect the three hydraulic hoses (Item 1) [Figure 30-71-3] from the two speed/brake valve block.

W-2017-0286

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

522 of 1311

30-71-2

S650 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.

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) (CONT'D) Valve Block Removal And Installation (Cont’d) Figure 30-71-4 1

2

P-90444

Dealer Copy -- Not for Resale

Disconnect the wire harness connector (Item 1) [Figure 30-71-4] from the two speed solenoid. Disconnect the wire harness connectors (Item 2) [Figure 30-71-4] from the brake solenoid and make-up valve. Figure 30-71-5

1

P-90446

Remove the two mounting bolts (Item 1) [Figure 30-71-5] from the valve block.

523 of 1311

30-71-3

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) (CONT'D)

Figure 30-71-8

Valve Block Disassembly And Assembly Mark all hydraulic hoses and fittings for proper installation. 1

Figure 30-71-6

1

1

P107100

Use a test meter and test the solenoid coils (Item 1) [Figure 30-71-8] for resistance. The resistance value for the solenoid coil can be found on the electrical schematic.

Dealer Copy -- Not for Resale

P107098

Figure 30-71-9 Remove the hydraulic fittings (Item 1) [Figure 30-71-6] from the valve block. 1

Figure 30-71-7

1 4 P107101

2 3

Use a test meter and test the solenoid coils (Item 1) [Figure 30-71-9] for resistance. P107099

Remove the two bolts (Item 1) from the brake valve solenoid (Item 2) [Figure 30-71-7]. Remove the electrical solenoid nut (Item 3) from the make-up solenoid (Item 4) [Figure 30-71-7].

The resistance value for the solenoid coil can be found on the electrical schematic. Assembly: Always install new O-rings [Figure 30-71-9] and back-up rings.

Assembly: Tighten the bolts (Item 1) [Figure 30-71-7] to 2,7 N•m (2 ft-lb) torque. Assembly: Tighten the nut (Item 3) [Figure 30-71-7] to 6,78 - 9,49 N•m (60 - 84 in-lb) torque.

524 of 1311

30-71-4

S650 Service Manual

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) (CONT'D) Valve Block Disassembly And Assembly (Cont'd) Figure 30-71-10

1

P107104

Dealer Copy -- Not for Resale

Remove the make-up solenoid (Item 1) [Figure 30-7110] from the valve block. Assembly: Always install new O-rings and back-up rings [Figure 30-71-10]. Tighten the solenoid valve to 27,1 N•m (20 ft-lb) torque. Figure 30-71-11

1 1

2

2

2

P107103

Replace the back-up rings (Item 1) and O-rings (Item 2) [Figure 30-71-11].

525 of 1311

30-71-5

S650 Service Manual

Dealer Copy -- Not for Resale 526 of 1311

30-71-6

S650 Service Manual

DRAIN MANIFOLD

Figure 30-80-2

Description The drain manifold is an external assembly in the drain circuit that returns the hydraulic fluid to the reservoir. 2 Drain Manifold Removal And Installation 1

IMPORTANT

2 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. I-2003-0888

P100002

Disconnect the wiring harness from the fluid temperature switch (Item 1) [Figure 30-80-2]. Remove the three hoses (Item 2) [Figure 30-80-2].

Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-120-2.)

Mark and cap all hoses and tubelines.

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising on Page 10-30-2.)

Figure 30-80-3 Figure 30-80-1

1 1 1 2

P100003 P100001

Remove the two hoses (Item 1) [Figure 30-80-3]. Remove the tubeline (Item 1) [Figure 30-80-1] from the drain manifold.

Remove the two bolts and nuts (Item 2) [Figure 30-80-3].

Mark and cap all hoses and tubelines.

Mark and cap all hoses and tubelines.

527 of 1311

30-80-1

S650 Service Manual

Dealer Copy -- Not for Resale 528 of 1311

30-80-2

S650 Service Manual

DRIVE SYSTEM BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

529 of 1311

40-01

S650 Service Manual

Dealer Copy -- Not for Resale 530 of 1311

40-02

S650 Service Manual

BRAKE (SINGLE SPEED)

Disc Removal And Installation

Description

Raise the loader lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

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

1

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. For more information on the brake. (See Description 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.

531 of 1311

40-10-1

S650 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 (SINGLE SPEED) (CONT’D)

Figure 40-10-4

Disc Removal And Installation (Cont’d) Figure 40-10-3 1

2

N-19082A

1

Figure 40-10-5

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.)

1

N-19083A

A snap ring pliers with 90° tips are necessary for removing the parking brake disc. Remove the snap ring (Item 1) [Figure 40-10-4] from the end of the sprocket on the hydrostatic motor carrier. Slide the disc (Item 2) [Figure 40-10-4] off the sprocket (Item 1) [Figure 40-10-5] and remove the disc through the front chaincase cover. Reverse the removal procedure to install the disc in the loader.

532 of 1311

40-10-2

S650 Service Manual

Dealer Copy -- Not for Resale

N-19105

BRAKE (TWO-SPEED) Description Figure 40-11-1

1

P-85413F

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 40-11-1] located on the front accessory panel. The brake is a spring applied pressure release system, which is self contained on the end of each drive motor. The brake block solenoid is sent power from a relay to open the circuit which releases the charge pressure fluid to the brakes. The charge pressure fluid pushes the spring away from the brake discs allowing the drive motor to move. A signal from the main Bobcat controller holds the brake solenoid open to allow constant flow of the charge pressure fluid to hold the spring away from the brake discs. When the hold signal is interrupted the solenoid will close the circuit and the charge fluid will be shut off an the spring will apply the brakes. This will happen if the engine rpm drops below a set rpm, the seat bar sensor fails or if there is a break in the wires for the brake block solenoid.

533 of 1311

40-11-1

S650 Service Manual

Dealer Copy -- Not for Resale 534 of 1311

40-11-2

S650 Service Manual

DRIVE COMPONENTS

NA1285

The drive components consist of the chaincase, drive chains, sprockets, axles shafts, hubs, drive motor carrier and a brake (Single speed only). The two-speed brake is part of the two-speed drive motor. 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.

535 of 1311

40-20-1

S650 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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) 1 NOTE: If the axle and bearings are being replaced, also 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.)

P4849

Install puller (Item 1) [Figure 40-20-2] on the wheel 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 10-130-2.) 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

Remove the hub from the axle. Figure 40-20-3

2

1 1 2 P4850

Remove the bolts (Item 1) [Figure 40-20-1] and plate. Installation: Tighten the bolts to 240 - 260 N•m (175 190 ft-lb) torque. Remove the two wheel studs (Item 2) [Figure 40-20-1] across from each other.

536 of 1311

P4848

Remove the key (Item 1) [Figure 40-20-3] from the axle.

40-20-2

S650 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

P4817

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: Use a hammer, install the new axle seal until the tool (MEL1407) is flush with the edge of the axle tube [Figure 40-20-5].

537 of 1311

40-20-3

S650 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 10-130-2.) 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 backing washer (Item 2) [Figure 40-20-6]. Installation: Tighten the axle sprocket bolt to 699 - 726 N•m (515 - 535 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 10-20-1.) Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

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.)

538 of 1311

40-20-4

S650 Service Manual

Dealer Copy -- Not for Resale

1

DRIVE COMPONENTS (CONT’D)

NOTE: Hold the axle during removal because 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 Figure 40-20-8

1 2

P-4171

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.

Press the splined end of the axle free from the bearing [Figure 40-20-10].

Remove the drive chain from the sprocket. Remove the sprocket (Item 1) and inner bearing (Item 2) [Figure 40-20-8]. Installation: Pack the inner and outer bearing with grease before installing them. Figure 40-20-9

1

P-4170

A bearing puller (Item 1) [Figure 40-20-9] is needed to do the following procedure: Be sure the bearing puller makes good contact with the inner race and press the bearing off the mounting surface of the axle [Figure 40-20-9].

539 of 1311

40-20-5

S650 Service Manual

Dealer Copy -- Not for Resale

P5406A

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 tools provided in the MEL1202 Axle Bearing Service Set. A slide hammer is also needed.

Installation: Put the spline end of the axle shaft into the bearing and press the bearing onto the axle.

Use the long driver handle (Item 1) [Figure 40-20-12] and the bearing cup removal tool to remove the inner bearing cup. Figure 40-20-13

NOTE: Hold the axle during installation because it will slide freely after the bearing is pressed over the splined end of the shaft. Put a piece of tubing over the axle (Item 1) [Figure 4020-11] that contacts 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].

540 of 1311

40-20-6

S650 Service Manual

Dealer Copy -- Not for Resale

P-4175

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].

541 of 1311

40-20-7

S650 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) Figure 40-20-17

P4813

Dealer Copy -- Not for Resale

To install the outer bearing cup, install the bearing cup installation tool on the driver handle. Install the bearing cup into the axle tube, and put the tool into the bearing cup. Hit the driver handle with a hammer until the bearing cup is seated inside the axle tube [Figure 40-20-17].

542 of 1311

40-20-8

S650 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

Rear Drive Chain

Front Drive Chain

P-68194

NOTE: It is necessary to remove the rear axle and drive chain 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 10-20-1.) Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) 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 10-130-2.)

543 of 1311

40-20-9

S650 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

544 of 1311

40-20-10

S650 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 10-20-1.)

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

545 of 1311

40-30-1

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the front chaincase cover (Item 2) [Figure 4030-1] from the loader.

CHAINCASE (CONT’D)

Disconnect the lift control cross bar (Item 2) [Figure 4030-2] from the lift spool on the main control valve.

Center Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) 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].

546 of 1311

40-30-2

S650 Service Manual

CHAINCASE (CONT’D)

Figure 40-30-4

Rear Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) 1 Raise the loader operator cab. (See Installing on Page 10-20-1.)

3 2

DANGER

1 3

P-90056

Remove the rear chaincase cover mounting screws (Item 1) [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. D-1009-0409

Remove chain case cover (Item 2) [Figure 40-30-4]. 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.

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 30-70-2.) 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 Linkage Removal And Installation on Page 50-100-5.) Move the linkage bars to allow adequate space to remove the rear chaincase cover.

547 of 1311

40-30-3

S650 Service Manual

Dealer Copy -- Not for Resale

P-90328

Dealer Copy -- Not for Resale 548 of 1311

40-30-4

S650 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 (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-30-1 50-30-1 50-30-1 50-30-2 50-30-2 50-30-3 50-30-3 50-30-4 50-30-4

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 50-50-3

REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockable Handle Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamping Knob Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slide In Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-60-1 50-60-1 50-60-2 50-60-3 50-60-4

549 of 1311

50-01

S650 Service Manual

Dealer Copy -- Not for Resale

MAINFRAME

50-70-1 50-70-1 50-70-2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3 Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5 Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9 Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10 Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14 Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

550 of 1311

50-02

50-110-1 50-110-1 50-110-1 50-110-2

S650 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 (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . Latch Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-130-1 50-130-1 50-130-1 50-130-2 50-130-3 50-130-4

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 50-140-3 50-140-4 50-140-5 50-140-5

ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-150-1 50-150-1 50-150-2 50-150-3

LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-3

551 of 1311

50-03

S650 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

RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-2

Dealer Copy -- Not for Resale

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

552 of 1311

50-04

S650 Service Manual

SEAT BAR

Figure 50-10-2

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. The seat bar is located in the operator cab. 1 Removal And Installation Figure 50-10-1

P-85652

Remove the seat bar mounting nuts (Item 1) [Figure 5010-2] (both sides).

1

Lower the operator cab. (See Lowering on Page 10-303.)

2

P-85653

Figure 50-10-3

P-85654

Raise the seat bar (Item 1) [Figure 50-10-1]. Disconnect the seat bar sensor (Item 2) [Figure 50-10-1] from the cab harness. 1

Lower the seat bar. Raise the operator cab. (See Raising on Page 10-30-2.)

P-90021

Remove the seat bar (Item 1) [Figure 50-10-3] from the operator cab. Reverse the above procedure to install the seat bar into the operator cab.

553 of 1311

50-10-1

S650 Service Manual

Dealer Copy -- Not for Resale

Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ftlb) torque.

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.

554 of 1311

50-10-2

S650 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.

555 of 1311

50-10-3

S650 Service Manual

Dealer Copy -- Not for Resale 556 of 1311

50-10-4

S650 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 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

Figure 50-20-1 1

1

2

3 P-85652

Remove the retaining pin (Item 1), the 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).

557 of 1311

50-20-1

S650 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

Evacuate the A/C system. (See Reclamation And Charging With Recovery / Charging Unit on Page 80-402.)

Figure 50-20-4

Figure 50-20-5

3 2

1

1

1 2

P-85661

Installation: Apply a small amount of thread-locker on the threads of the gas spring rod before installing the clevis (Item 1) [Figure 50-20-4].

P100756

Unhook the four fasteners (Item 1) and remove the cover (Item 2) [Figure 50-20-5]. Installation: (See Installing on Page 80-150-1.) Figure 50-20-6

WARNING

1 2

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.

1

W-2112-0987

1 P100879

Disconnect the expansion / heater unit wiring connectors (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 with plugs to prevent coolant loss from the system.

558 of 1311

50-20-2

S650 Service Manual

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].

OPERATOR CAB (CONT’D)

Earlier Models

Removal And Installation (Cont’d)

Figure 50-20-8

Figure 50-20-7

1 1 1 P-85663 P103082

Disconnect the cab harness connector screw (Item 1) [Figure 50-20-8]. Cap and plug the hoses and expansion valve fittings with proper A/C caps and plugs.

Installation: Tighten the connector screw to 3,39 - 3,96 N•m (30 - 35 in-lb) torque. Later Models

Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb) torque.

Figure 50-20-9

1

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

Remove the engine speed control cable from the cab. (See Cable Removal And Installation on Page 70-20-2.) Remove the operator cab gas spring(s). (See Gas Spring Removal And Installation on Page 50-20-1.)

P107406

Disconnect the cab harness connectors (Item 1) [Figure 50-20-9].

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.

559 of 1311

50-20-3

S650 Service Manual

Dealer Copy -- Not for Resale

Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].

OPERATOR CAB (CONT’D) Removal And Installation (Cont’d) Figure 50-20-10

1

P-85658

Dealer Copy -- Not for Resale

Remove the two cab mount bolts and nuts (Item 1) [Figure 50-20-10] from both sides of the cab. Installation: Tighten the cab mount bolts and nuts to 24,4 - 29,8 N•m (18 - 22 ft-lb) torque. Figure 50-20-11

P-85662

Using a strap and a hoist remove the cab from the loader [Figure 50-20-11].

560 of 1311

50-20-4

S650 Service Manual

OPERATOR SEAT (SUSPENSION)

Slide Rail Removal And Installation

Removal And Installation

Figure 50-30-2

Figure 50-30-1

1

1

1

P-85769 P-85776

Remove the operator seat. Installation on Page 50-30-1.)

(See

Removal

And

Remove the four seat mounting nuts (Item 1) [Figure 5030-1] and washers from the operator seat mounting studs.

Remove the two slide rail mounting bolts (Item 1) [Figure 50-30-2]. Figure 50-30-3

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 50-30-3]. Remove the slide rail (Item 2) [Figure 50-30-3] from the bottom of the seat frame.

561 of 1311

50-30-1

S650 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 50-30-6

Figure 50-30-4

1

1

P-85773 P-85771

Lift up and push forward on the rear of the seat cushion (Item 1) [Figure 50-30-6].

Dealer Copy -- Not for Resale

Remove the nut (Item 1) [Figure 50-30-4] from the seat belt mount. Figure 50-30-5

1

P-85772

Remove the nut (Item 1) [Figure 50-30-5] from the seat belt mount. Remove the seat belt.

562 of 1311

50-30-2

S650 Service Manual

OPERATOR SEAT (SUSPENSION) (CONT’D)

Back Cushion Removal And Installation

Lower Cushion Installation

Figure 50-30-9

Figure 50-30-7

1

2 1

2 P-85774

P-85773 P-85778

Insert the tab (Item 1) into the slot (Item 2) [Figure 5030-7].

Remove the two screws (Item 1) [Figure 50-30-9] and tilt the seat back to the upright position.

Figure 50-30-8

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 50-30-8] to lock the seat into position.

563 of 1311

50-30-3

S650 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 50-30-1.)

(See

Removal

And

Figure 50-30-10 Figure 50-30-11

2

1

1 2 1

P-85777 P-85785

(See

Removal

And Remove the mounting nut (Item 1) [Figure 50-30-11].

Remove the seat shock clips (Item 1) [Figure 50-30-10]. (Both ends.)

Remove the end release buckle (Item 2) [Figure 50-3011].

Remove the seat shock (Item 2) [Figure 50-30-10].

Figure 50-30-12

2 1

P-85784

Remove the mounting nut (Item 1) [Figure 50-30-12]. Remove the seat belt retractor (Item 2) [Figure 50-3012].

564 of 1311

50-30-4

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the operator seat. Installation on Page 50-30-1.)

OPERATOR SEAT (SUSPENSION) (CONT’D)

Figure 50-30-15

3-Point Seat Belt Removal And Installation (Cont’d)

2

Figure 50-30-13

1

3

1 P-85788

Remove the nut (Item 1) [Figure 50-30-15]. P-85786

Remove the shoulder harness guide and bushing (Item 2) and hardened washer (Item 3) [Figure 50-30-15].

Dealer Copy -- Not for Resale

Remove the two mounting bolts (Item 1) [Figure 50-3013]. Figure 50-30-14

1

P-85787

Remove the shoulder harness retractor (Item 1) [Figure 50-30-14].

565 of 1311

50-30-5

S650 Service Manual

Dealer Copy -- Not for Resale 566 of 1311

50-30-6

S650 Service Manual

BOB-TACH (HAND LEVER)

Removal And Installation

Description

Figure 50-40-1

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. 1

The Bob-Tach is located on the front of the loader connected to the loader lift arms.

P-85554

Lower the Bob-Tach onto the blocks. Remove the retainer bolt and nut (Item 1) [Figure 50-401] from the rod end pivot pin. Installation: Tighten the retainer nut to 48 - 54 N•m (35 40 ft-lb) torque. Figure 50-40-2 1

P-85649

Remove the rod end pivot pin (Item 1) [Figure 50-40-2].

567 of 1311

50-40-1

S650 Service Manual

Dealer Copy -- Not for Resale

Tilt the Bob-Tach forward, so it is parallel to the floor. Put blocks (approximately 76,2 mm [3 in]) under each side of the Bob-Tach [Figure 50-40-1].

BOB-TACH (HAND LEVER) (CONT'D)

Figure 50-40-5

Removal And Installation (Cont’d) Figure 50-40-3

1 1

P-31405

Replace O-ring (Item 1) [Figure 50-40-5] on the grease plug.

P-31402

Figure 50-40-6

Figure 50-40-4

1

P-31403

1

Remove the nut (Item 1) [Figure 50-40-6] from the BobTach pivot pin retaining bolt (both sides).

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].

568 of 1311

50-40-2

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the snap ring (Item 1) [Figure 50-40-3] from the Bob-Tach pivot pin grease plug (both sides).

BOB-TACH (HAND LEVER) (CONT'D)

Lever And Wedge Disassembly And Assembly

Removal And Installation (Cont’d)

Figure 50-40-9

Figure 50-40-7

1

1

P-85664 P-31406

Remove the retainer bolt (Item 1) [Figure 50-40-7] from the Bob-Tach pin. Installation: Tighten the retainer nut and bolt (Item 1) [Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 ft-lb) torque.

Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb) torque. Figure 50-40-10

Figure 50-40-8

1

2 P-85665

1 Remove the washer and spring, (Item 1) and the lever assembly (Item 2) [Figure 50-40-10].

P-31407

With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-40-8] and a hammer, drive the pivot pin out of the lift arm and Bob-Tach. NOTE: MEL1685 - Pivot Point Tapered Reamer is available to ream out tapered bore if necessary.

569 of 1311

50-40-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the lever mounting nut (Item 1) [Figure 50-409].

BOB-TACH (HAND LEVER) (CONT'D)

Earlier Design

Lever And Wedge Disassembly And Assembly (Cont'd)

Figure 50-40-13

Figure 50-40-11

4 3

1 1

2

2

P-85666

Use a punch and hammer to remove the roll pin (Item 1) [Figure 50-40-11] from the Bob-Tach wedge and spring clevis. Remove the spring clevis assembly (Item 2) [Figure 5040-11].

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 50-40-13] and replace the damaged parts as needed. Assembly: Clean the threads and apply Loctite® 242 to the bolt (Item 1) [Figure 50-40-13], tighten to 125 - 135 N•m (90 - 100 ft-lb) torque. Later Design

Figure 50-40-12 Figure 50-40-14 4

1 1

3 P-85667

2 P121303

Remove the wedge (Item 1) [Figure 50-40-12] 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 50-40-14] 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 48 - 54 N•m (35 - 40 ft-lb) torque.

570 of 1311

50-40-4

S650 Service Manual

Dealer Copy -- Not for Resale

P19287

BOB-TACH (HAND LEVER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation Figure 50-40-15

2

1

P-85669

Dealer Copy -- Not for Resale

Remove the Bob-Tach. (See Removal And Installation on Page 50-40-1.) Use a seal pick to remove seal (Item 1) [Figure 50-4015] from the Bob-Tach. Remove and replace bushing (Item 2) [Figure 50-40-15] with a driver tool and hammer. Figure 50-40-16 3

2

1 NA5472

Installation: The seal (Item 1) needs to be seated in the Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item 3) [Figure 50-40-16].

571 of 1311

50-40-5

S650 Service Manual

Dealer Copy -- Not for Resale 572 of 1311

50-40-6

S650 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.

Tilt the Bob-Tach forward, so it is parallel to the floor. Put 2x4 blocks under each side of the Bob-Tach [Figure 5041-1]. Lower the Bob-Tach onto the blocks. Mark the hoses (Item 1) [Figure 50-41-1] for correct installation. Remove and cap the hoses from the cylinder. Remove the washers and bolts (Item 2) [Figure 50-41-1] from the cylinder (both ends). Installation: Tighten the retainer nut to 48 - 54 N•m (35 40 ft-lb) torque. Remove the cylinder from the Bob-Tach.

573 of 1311

50-41-1

S650 Service Manual

Dealer Copy -- Not for Resale

The Bob-Tach is located on the front of the loader connected to the loader lift arms.

P-85570

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] at the Bob-Tach pivot pin grease plug (both sides).

P-85554

Figure 50-41-5

Installation: Tighten the retainer nut 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] (both sides). P-85649

Remove the rod end pivot pin (Item 1) [Figure 50-41-3].

574 of 1311

50-41-2

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the retainer bolt and nut (Item 1) [Figure 50-412] 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

Replace the O-ring (Item 1) [Figure 50-41-6] on the grease plug.

Installation: Tighten the retainer nut and bolt (Item 1) [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330 ft-lb) torque.

Figure 50-41-7

Figure 50-41-9

1

1 P-31403

P-31407

Remove the nut (Item 1) [Figure 50-41-7] from the BobTach pivot pin retaining bolt (both sides).

With a 22,2 mm (7/8 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). NOTE: MEL1685 - Pivot Point Tapered Reamer is available to ream out tapered bore if necessary. Remove the Bob-Tach from the loader.

575 of 1311

50-41-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the retainer bolt (Item 1) [Figure 50-41-8] from the Bob-Tach pivot pin (both sides).

P-31405

Figure 50-41-12

BOB-TACH (POWER) (CONT'D) Lever And Wedge Disassembly And Assembly Figure 50-41-10

1

1

2

1

P-85665

Remove the washer and spring, (Item 1) and the lever assembly (Item 2) [Figure 50-41-12].

P-85570

Figure 50-41-13

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ftlb) torque. Remove the cylinder from the lever pivots. 1

Figure 50-41-11 2

P-85666

Use a punch and hammer to remove the roll pin (Item 1) [Figure 50-41-13] from the Bob-Tach wedge and spring clevis.

1

Remove the spring clevis assembly (Item 2) [Figure 5041-13]. P-85664

Remove the lever mounting nut (Item 1) [Figure 50-4111]. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb) torque.

576 of 1311

50-41-4

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the washers and bolts (Item 1) [Figure 50-4110] from the cylinder (both ends).

BOB-TACH (POWER) (CONT'D)

Earlier Design

Lever And Wedge Disassembly And Assembly (Cont'd)

Figure 50-41-15

Figure 50-41-14

4 3

1 2 1

P-85667

Remove the wedge (Item 1) [Figure 50-41-14] 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 50-41-15] and replace the damaged parts as needed. Assembly: Clean the threads and apply Loctite® 242 to the bolt (Item 1) [Figure 50-41-15], tighten to 125 - 135 N•m (90 - 100 ft-lb) torque. Later Design Figure 50-41-16 4

1

3 2 P121303

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. Assembly: Clean the threads and apply Loctite® 242 to the bolt (Item 1) [Figure 50-41-16], tighten to 48 - 54 N•m (35 - 40 ft-lb) torque.

577 of 1311

50-41-5

S650 Service Manual

Dealer Copy -- Not for Resale

P19287

BOB-TACH (POWER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation Figure 50-41-17

2

1

P-85669

Dealer Copy -- Not for Resale

Remove the Power Bob-Tach. (See Removal And Installation on Page 50-41-1.) Use a seal pick to remove seal (Item 1) [Figure 50-4117] from the Bob-Tach. Remove and replace bushing (Item 2) [Figure 50-41-17] with a driver tool and hammer. Figure 50-41-18 3

2

1 NA5472

Installation: The seal (Item 1) needs to be seated in the Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item 3 [Figure 50-41-18].

578 of 1311

50-41-6

S650 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

P-90591

1 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 P-90592A

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.

579 of 1311

50-50-1

S650 Service Manual

Figure 50-50-7

LIFT ARMS (CONT'D) Link Removal And Installation

1

Figure 50-50-5

P-90594

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.

580 of 1311

50-50-2

S650 Service Manual

LIFT ARMS (CONT'D)

Removal And Installation

Link Removal And Installation (Cont’d)

Put jackstands under the rear corners of the loader.

Figure 50-50-9

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.) Figure 50-50-10

1

1

P-90610

P-90600

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.

At the right side upright disconnect and cap the two tilt cylinder hoses (Item 1) [Figure 50-50-10]. NOTE: Mark the hoses for proper installation. Figure 50-50-11

1

P-90599

At the left side upright disconnect and cap the three auxiliary hydraulic hoses (Item 1) [Figure 50-50-11]. NOTE: Mark the hoses for proper installation.

581 of 1311

50-50-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the lift arm link pivot pin (Item 1) [Figure 50-509] (both sides).

Figure 50-50-14

LIFT ARMS (CONT'D) Removal And Installation (Cont’d) Figure 50-50-12

1

1 P-90611

With a slide hammer, remove the pin (Item 1) [Figure 5050-14] from the rod end of the lift cylinder (both sides).

P-85692

Figure 50-50-15

Figure 50-50-13 1 1

1

1

P-90606

Install slings (Item 1) [Figure 50-50-15] on the lift arms and connect to a chain hoist.

P-90602

Remove the retaining bolt and nut (Item 1) [Figure 5050-13] from the pin on the rod end of the lift cylinder (both sides). Installation: Tighten the retainer bolt and nut to 48 - 54 N•m (35 - 40 ft-lb) torque.

582 of 1311

50-50-4

S650 Service Manual

Dealer Copy -- Not for Resale

Disconnect the electrical controls harness (Item 1) [Figure 50-50-12]. (If equipped.)

LIFT ARMS (CONT'D)

Figure 50-50-18

Removal And Installation (Cont’d) Figure 50-50-16 1 2

1 P-90609

2 Remove the retaining bolt and nut (Item 1) and the pin (Item 2) [Figure 50-50-18] (both sides).

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].

Installation: Tighten the retainer bolt and nut to 48 - 54 N•m (35 - 40 ft-lb) torque. Remove the lift arms from the loader.

Disconnect the stabilizer bar from both sides of the lift arms (Item 2) [Figure 50-50-16]. Figure 50-50-17

1

P-90605

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.

583 of 1311

50-50-5

S650 Service Manual

Dealer Copy -- Not for Resale

P-90604

Dealer Copy -- Not for Resale 584 of 1311

50-50-6

S650 Service Manual

REAR GRILLE

Slide In

Identification

Figure 50-60-3

Review the following photographs to identify the rear grille installed in your machine. Follow the instructions below the photograph to find the correct rear grille removal and installation instructions for the rear grille. Lockable Handle Figure 50-60-1

P109720

Dealer Copy -- Not for Resale

This rear grille [Figure 50-60-3] is identified by the lack of a handle or a knob. (See Slide In Rear Grille on Page 5060-4.)

P100808

This rear grille [Figure 50-60-1] is identified by a lockable handle. (See Lockable Handle Rear Grille on Page 5060-2.) Clamping Knob Figure 50-60-2

P100808C

This rear grille [Figure 50-60-2] is identified by a clamping knob. (See Clamping Knob Rear Grille on Page 50-60-3.)

585 of 1311

50-60-1

S650 Service Manual

REAR GRILLE (CONT’D)

Installing

Lockable Handle Rear Grille

Figure 50-60-6 Front Tab And Slot

Removing Figure 50-60-4

P100807

Rear Tab And Slot 1

Flip the lockable handle (Item 1) [Figure 50-60-4] up and turn the handle 90° counterclockwise. Lift and pull the rear grille backward to remove from the loader. Figure 50-60-5

P109761

Align the front tabs of the two side covers into the slots in the loader frame [Figure 50-60-6]. Align the rear tabs of the two side covers into the slots in the loader frame and lower [Figure 50-60-6]. Figure 50-60-7

1

P100809

Lift and remove the two side covers (Item 1) [Figure 5060-5]. P109170

Align the edge of the rear grille under the loader frame and slide rear grille in while lowering [Figure 50-60-7]. Turn the lockable handle 90° clockwise and fold the handle down [Figure 50-60-4].

586 of 1311

50-60-2

S650 Service Manual

Dealer Copy -- Not for Resale

P100808

REAR GRILLE (CONT’D)

Installing

Clamping Knob Rear Grille

Figure 50-60-10 Front Tab And Slot

Removing Figure 50-60-8

P100807

2

Rear Tab And Slot

1

Remove the clamping knob (Item 1). Lift using the handle (Item 2) [Figure 50-60-8] and pull the rear grille backward to remove from the loader. Figure 50-60-9

P109761

Align the front tabs of the two side covers into the slots in the loader frame [Figure 50-60-10]. Align the rear tabs of the two side covers into the slots in the loader frame and lower [Figure 50-60-10]. Figure 50-60-11

1

P100809

Lift and remove the two side covers (Item 1) [Figure 5060-9]. P109170

Align the edge of the rear grille under the loader frame and slide rear grille in while lowering [Figure 50-60-11]. Install the clamping knob (Item 1) [Figure 50-60-8].

587 of 1311

50-60-3

S650 Service Manual

Dealer Copy -- Not for Resale

P100808C

REAR GRILLE (CONT’D) Slide In Rear Grille Removing Stop the engine and open the rear door. Figure 50-60-12

Dealer Copy -- Not for Resale

P109720

Lift and pull the rear grille backward to remove from the loader [Figure 50-60-12]. Figure 50-60-13

1

P109719

Lift and remove the two side covers (Item 1) [Figure 5060-13].

588 of 1311

50-60-4

S650 Service Manual

Figure 50-60-16

REAR GRILLE (CONT’D) Slide In Rear Grille (Cont’d) Installing Figure 50-60-14

P109722

Align the edge of the rear grille under the loader frame and slide rear grille in while lowering [Figure 50-60-16].

Align the front tabs of the two side covers into the slots in the loader frame and lower [Figure 50-60-14]. (Right side shown.) Figure 50-60-15

P109721

Align the tabs of the rear grille into the slots in the two side covers [Figure 50-60-17]. (Left side shown.) Close the rear door. P109718

Align the rear tabs of the two side covers into the slots in the loader frame and lower [Figure 50-60-15]. (Left side shown.)

589 of 1311

50-60-5

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-60-17

P100807

Dealer Copy -- Not for Resale 590 of 1311

50-60-6

S650 Service Manual

REAR DOOR (TAILGATE)

Figure 50-70-3

Removal And Installation Figure 50-70-1

1

2 3

2

P-85695

1

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) in the top hinge as shown [Figure 50-70-3].

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 mounting bolts and nuts to 34 38 N•m (25 - 28 ft-lb) torque.

Figure 50-70-2

Lift the door away from the loader frame and put the door flat on the floor. 2

1

1

P-90585

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.

591 of 1311

50-70-1

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the top and bottom door hinge mounting bolts and nuts (Item 1) [Figure 50-70-3].

P-85697

REAR DOOR (TAILGATE) (CONT’D)

Striker (Adjusting)

Striker Removal And Installation

WARNING

Figure 50-70-4 1

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

1 1

P-85698A

Remove the striker assembly from the loader. Striker Disassembly And Assembly

P-85698A

Figure 50-70-5 Loosen the striker assembly mount bolts (Item 1) [Figure 50-70-6].

5

3 2

Align the striker assembly in the center of the mounting holes.

4 1

NOTE: Tighten the striker assembly, top mount 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. P106584

Tighten both striker mount bolts (Item 1) [Figure 50-706] to 125 - 135 N•m (90 - 100 ft-lb) torque.

Remove the locknut (Item 1) [Figure 50-70-5]. Remove the bolt (Item 2), spacer (Item 3) and roller (Item 4) from the bracket (Item 5) [Figure 50-70-5].

Close the rear door.

Inspect the parts for wear and replace as needed. Installation: Tighten the bolt (Item 4) and nut (Item 1) to 34 - 38 N•m (25 - 28 ft-lb) torque.

592 of 1311

50-70-2

S650 Service Manual

Dealer Copy -- Not for Resale

1

Remove the two striker mount bolts (Item 1) [Figure 5070-4].

REAR DOOR (TAILGATE) (CONT’D)

Figure 50-70-9

Latch Removal And Installation (Earlier Models) Figure 50-70-7 1

2

1 P-85701

Remove the door handle (Item 1) [Figure 50-70-9] from the rear door from the rear door.

P-85699

Dealer Copy -- Not for Resale

Disconnect the spring (Item 1) [Figure 50-70-7] from the rear door. Remove the bolt and nut (Item 2) [Figure 50-70-7] from the latch. Figure 50-70-8

3

2

1

P-85700

Remove the spring (Item 1) [Figure 50-70-8] from the door handle. Remove the spring (Item 2) [Figure 50-70-8] from the door latch. Remove the door latch (Item 3) [Figure 50-70-8] from the door handle.

593 of 1311

50-70-3

S650 Service Manual

REAR DOOR (TAILGATE) (CONT’D)

Figure 50-70-12

Latch Removal And Installation (Later Models) Figure 50-70-10 1

2

1

P109094

Remove the door handle (Item 1) [Figure 50-70-12] 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 50-7010] from the latch. Installation: Tighten the bolt (Item 1) and nut (Item 2) to 34 - 38 N•m (25 - 28 ft-lb) torque. Figure 50-70-11

2

1

P109093

Remove the spacer (Item 1) [Figure 50-70-11] from the latch. Remove the spring (Item 2) [Figure 50-70-11] from the latch.

594 of 1311

50-70-4

S650 Service Manual

FUEL TANK

Figure 50-80-3

Removal And Installation Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) 1

Remove the engine / hydrostatic pump assembly from the loader. (See Engine Removal And Installation on Page 70-10-7.)

2

Figure 50-80-1

P-85707

Disconnect the fuel vent hose (Item 1) and remove the two bolts (Item 2) [Figure 50-80-3]. 1

Figure 50-80-4

1

P-85714

2

3

Remove the three mount bolts (Item 1) [Figure 50-80-1] from the access cover at the rear of the loader frame. Remove the access cover. Figure 50-80-2

1 P-85708

Disconnect the two fuel lines (Item 1) [Figure 50-80-4].

1

Disconnect the wire harness connector (Item 2) [Figure 50-80-4] from the fuel level sender. Remove the two mounting bolts (Item 3) and remove the bracket (Item 4) [Figure 50-80-4].

P-85713

Remove the drain plug (Item 1) [Figure 50-80-2]. Drain the fuel into a container.

595 of 1311

50-80-1

S650 Service Manual

Dealer Copy -- Not for Resale

4

FUEL TANK (CONT'D)

Figure 50-80-7

Removal And Installation (Cont'd) Figure 50-80-5

1 1 1

1

P-85711

At the right side of the loader, remove the two main frame mount bolts and nuts (Item 1) [Figure 50-80-7].

Remove the bolts (Item 1) [Figure 50-80-5] from the battery hold down plate.

Installation: Tighten the main frame mount bolts to 542 583 N•m (400 - 430 ft-lb) torque.

Dealer Copy -- Not for Resale

P-85710

Figure 50-80-8 Remove the hold down plate from the loader. Figure 50-80-6

1

1

1

1 P-85712

2

At the left side of the loader, remove the two main frame mount bolts and nuts (Item 1) [Figure 50-80-7].

P-85709

Remove the two mounting bolts (Item 1) and the bracket (Item 2) [Figure 50-80-6].

Installation: Tighten the main frame mount bolts to 542 583 N•m (400 - 430 ft-lb) torque. Lift the fuel tank and remove it from the loader frame. NOTE: When installing the fuel tank, avoid striking the tank with heavy objects to prevent damage.

596 of 1311

50-80-2

S650 Service Manual

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 2

P-85707 P-85708

Remove the two bolts (Item 1) and disconnect the fuel fill hose (Item 2) [Figure 50-80-11]. Figure 50-80-12

Dealer Copy -- Not for Resale

Disconnect the wire harness connector (Item 1) [Figure 50-80-9] from the fuel level sender. Remove the fuel level sender. Figure 50-80-10

1

P-85715

Remove the fuel fill screen (Item 1) [Figure 50-80-12]. P-85716

Inspect and replace as needed. Inspect the fuel level sender [Figure 50-80-9] and replace if worn or damaged.

597 of 1311

50-80-3

S650 Service Manual

Dealer Copy -- Not for Resale 598 of 1311

50-80-4

S650 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

Inspect 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 10-20-1.) 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

599 of 1311

50-90-1

S650 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.

600 of 1311

50-90-2

S650 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.

601 of 1311

50-90-3

S650 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].

602 of 1311

50-90-4

S650 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 10-20-1.) 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

603 of 1311

50-91-1

S650 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.

604 of 1311

50-91-2

S650 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].

605 of 1311

50-91-3

S650 Service Manual

Dealer Copy -- Not for Resale 606 of 1311

50-91-4

S650 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. 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.

607 of 1311

50-100-1

S650 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

P-85846

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

P-85847

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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

608 of 1311

50-100-2

S650 Service Manual

Dealer Copy -- Not for Resale

•

CONTROL PANEL (CONT'D)

Disassembly And Assembly

Removal And Installation (Cont'd)

Remove Control Panel. (See Removal And Installation on Page 50-100-2.)

Figure 50-100-4 Figure 50-100-6

2 1 1

1 2

2

2

P-90612

1

1

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 nuts (Item 1) and the steering stabilizers (Item 2) [Figure 50-100-6].

Remove the four steering linkage mounting 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 mounting bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque. Figure 50-100-5

3

3

2

1

4 3

3

P-85848

Remove the two bracket mounting 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].

609 of 1311

50-100-3

S650 Service Manual

Dealer Copy -- Not for Resale

P-85864

CONTROL PANEL (CONT'D)

Figure 50-100-9

Disassembly And Assembly (Cont’d) 2

Figure 50-100-7

2

2

1

1 3

1

3

P-85867

3

Remove the four bolts (Item 1) [Figure 50-100-9] from the control panel.

P-85865

Remove the control handle assembly (Item 2) [Figure 50-100-9].

Figure 50-100-8

Dealer Copy -- Not for Resale

3

Figure 50-100-10

4 3

2 1 1 P-85861

Remove the bolt and nut (Item 1) [Figure 50-100-7] and [Figure 50-100-8], steering link (Item 2), and washers (Item 3) [Figure 50-100-7]. Installation: Verify correct orientation of components [Figure 50-100-7] and [Figure 50-100-8].

610 of 1311

P-85868

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].

50-100-4

S650 Service Manual

CONTROL PANEL (CONT'D)

Linkage Removal And Installation

Disassembly And Assembly (Cont’d)

WARNING

Figure 50-100-11

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

2

WARNING

P-85872

Remove the two bolts (Item 1) from the bellcrank (Item 2) [Figure 50-100-11].

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286

Remove the bellcrank from the bracket [Figure 50-10011].

Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

Figure 50-100-12

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) Raise the operator cab. (See Raising on Page 10-30-2.)

2

1

3

P-85873

Inspect the shaft (Item 1), the bellcrank (Item 2), and the bushings (Item 3) [Figure 50-100-11] for wear and replace as need. Repeat the procedure for the other control handle assembly.

611 of 1311

50-100-5

S650 Service Manual

Dealer Copy -- Not for Resale

1

CONTROL PANEL (CONT'D)

Figure 50-100-14

Linkage Removal And Installation (Cont’d) 1 Figure 50-100-13

2 1

2

P-48631

2 Remove the nut (Item 1) from the end of the centering spring shoulder bolt (Item 2) [Figure 50-100-14].

P-90612

Remove the four steering linkage mounting bolts, nuts and rubber isolators (Item 2) [Figure 50-100-13].

Installation: Tighten the centering spring bolt and a NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque. Figure 50-100-15

Inspect and replace any damaged parts.

1

Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting 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 50-100-10.)

P-48632

Slide the centering plate (Item 1) [Figure 50-100-15] to the right to remove it from the hydrostatic pumps. NOTE: Directions are shown and stated as if you were sitting in the operator’s seat.

612 of 1311

50-100-6

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the bolt / spring assembly. Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-100-13] which are connected to the steering shaft on the control panel.

CONTROL PANEL (CONT'D)

Figure 50-100-17

Linkage Removal And Installation (Cont’d) Figure 50-100-16 2 7 3

1

8

6

4

1 1

2

P-48629

2

2

Inspect for wear on the centering blocks (Item 1) [Figure 50-100-17].

P-48630

The centering plate / centering spring assembly consists of the following parts:

If the centering blocks need replacement, remove the bolts (Item 2) [Figure 50-100-17]. Remove the centering blocks.

ITEM

Installation: Tighten the centering block bolts to 47,5 54,2 N•m (35 - 40 ft-lb) torque.

DESCRIPTION

1

Bolt

2

Bushings

3

Washer

4

Bushing Spacer

5

Spring

6

Locknut

7

Centering Plate

8

Guide Bushings

613 of 1311

NOTE: The washers go between the bolts and the centering plate. NOTE: If the centering blocks are worn, they can be removed and rotated 180 degrees and reinstalled.

50-100-7

S650 Service Manual

Dealer Copy -- Not for Resale

5

CONTROL PANEL (CONT'D)

Figure 50-100-20

Linkage Removal And Installation (Cont’d) Figure 50-100-18 2

1

2 1 P-54615

3 Loosen the bolt (Item 1) [Figure 50-100-20]. P-54617

Remove the pintle base (Item 2) [Figure 50-100-20]. Figure 50-100-21

Dealer Copy -- Not for Resale

Remove the bolts and washers (Item 1) [Figure 50-10018] 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 50-100-18]. Figure 50-100-19

2 3

1

1 P-48659

2 4

NOTE: When installing the pintle base (Item 1) onto the pump shaft, the cutouts on the pump shaft will not line up with the bolt (Item 3) [Figure 50-100-21].

3 2 1

Installation: Install the pintle base (Item 1) onto the pump shaft (Item 2) [Figure 50-100-21]. The top of the pintle base should be level with the top of the pump shaft. Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.

P-48624

Remove the bolt and nut (Item 1) [Figure 50-100-19]. Inspect the washers (Item 2), pintle arm (Item 3) and the steering control lever (Item 4) for damage and replace as needed [Figure 50-100-19].

NOTE: After installing the linkage onto the hydrostatic pumps the Linkage Neutral Adjusting procedure must be performed. (See Linkage Neutral (Adjusting) on Page 50-10010.)

NOTE: The washers (Item 2) [Figure 50-100-19] are hardened, and should only be replaced through Bobcat Parts.

614 of 1311

50-100-8

S650 Service Manual

CONTROL PANEL (CONT'D) Pintle Arm Disassembly And Assembly

NOTE: Anti-seize should be used on the adjusting screw to prevent corrosion and allow free movement while adjusting.

Figure 50-100-22

Figure 50-100-24 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) [Figure 50-100-22] for damage. Inspect the torsion bushing (Item 4) [Figure 50-100-22] for damage and replace as needed. Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque. Figure 50-100-23

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) [Figure 50100-24] to catch the torsion bushing. Installation: Install the torsion bushing (Item 2) [Figure 50-100-24] 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 base pintle (Item 1) [Figure 50-100-23] from the pump shaft. Remove the retaining bolt (Item 2), adjusting screw (Item 3) and neoprene dampener (Item 4) [Figure 50-100-23] from the base pintle. Inspect parts for wear and damage, replace as needed.

615 of 1311

50-100-9

S650 Service Manual

Dealer Copy -- Not for Resale

P-54624

CONTROL PANEL (CONT'D)

Figure 50-100-26

Linkage Neutral (Adjusting) The following tool listed will be needed to do the following procedure: 1

MEL1563 or 7217666 Remote Start Tool Kit. 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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.)

P-85845

Figure 50-100-25 Loosen the bolt / nut (Item 1) [Figure 50-100-26] only until the tension is released from the torsion bushing.

3

1 2

1

2

P-48450A

Tool that may assist in the Neutral adjustment [Figure 50-100-25]. 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 50-100-25] to a small rounded edge. A steering centering block (Item 3) [Figure 50-100-25] is also needed. The centering block can be placed as shown and welded to the C-clamp if desired.

P-54613

Loosen the nut (Item 1) only until the tension is released from the torsion bushing (Item 2) [Figure 50-100-27]. NOTE: The bolt must be loose enough to allow the torsion bushing (Item 2) [Figure 50-100-27] 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

616 of 1311

50-100-10

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-100-27

CONTROL PANEL (CONT'D)

WARNING

Linkage Neutral (Adjusting) (Cont’d) Figure 50-100-28

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 50-100-28] 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 50-100-29

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 bolts (Item 3) [Figure 50-100-29] 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 50-100-28] and [Figure 50-100-29].

1 2

P-48451

A modified locking grip C-clamp and steering block shown in [Figure 50-100-25] may be used to help in aligning the centering blocks. Install the centering block (Item 1) on the inside of the pintle cams and the C-clamp (Item 2) [Figure 50-100-29] around both centering blocks. Lock the C-clamp in place.

617 of 1311

50-100-11

S650 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)

NOTE: This procedure is shown for Neutral Adjustment on the left side of the loader. The procedure is the same for the right side Neutral Adjustment.

Linkage Neutral (Adjusting) (Cont’d) 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 50-100-30

Turn the adjustment screw (Item 1) [Figure 50-100-31] counterclockwise until forward creep is seen. Turn the adjustment screw (Item 1) [Figure 50-100-31] to a point between forward and reverse where there is zero creep. 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. Verify 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.

1

2

Dealer Copy -- Not for Resale

P-48632

Loosen the left pump pintle adjustment lock bolts (Item 1). (The right pump pintle adjustment lock bolts are (Item 2) [Figure 50-100-30].) Loosen the bolts enough to allow free movement between the pintle arm and the pintle base. NOTE: If the bolts are too loose or too tight, the Neutral Adjustment may be affected. Figure 50-100-31

1 P-54610

Move the engine speed control to high idle. NOTE: The NEUTRAL range (dead-band) will vary between the hydrostatic pumps.

618 of 1311

50-100-12

S650 Service Manual

CONTROL PANEL (CONT'D) Linkage Neutral (Adjusting) (Cont’d) Figure 50-100-32

2

2

1

1

P-48632

Dealer Copy -- Not for Resale

Torque the left pump pintle adjustment lock bolts (Item 1) [Figure 50-100-32] 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 lock bolts (Item 2) [Figure 50-100-32] 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 wheels / tracks do not come to a complete stop, repeat the adjustment procedure again. Stop the engine. Remove one pintle adjustment bolt (Item 1) [Figure 50100-32] 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 50-100-14.)

619 of 1311

50-100-13

S650 Service Manual

Figure 50-100-33

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 they are not binding or too loose, which will affect the procedure.

1

WARNING

W-2059-0598

P-85845

Loosen the bolt / nut (Item 1) [Figure 50-100-33] only until the tension is released from the torsion bushing. Figure 50-100-34 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 LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) P-54613

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.) 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.

620 of 1311

Loosen the nuts (Item 1) only until the tension is released from the torsion bushings (Item 2) [Figure 50-100-34]. The bolts must be loose enough to allow the torsion bushing (Item 2) [Figure 50-100-34] to turn freely between the torsion bushing and the linkage bar.

50-100-14

S650 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 50-100-37

Linkage Travel (Adjusting) (Cont’d) Figure 50-100-35 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 50-100-35] (one on each control lever) out until they no longer contact the bellcrank. Figure 50-100-36

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 50-100-38

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 50-100-36].

Before adjusting the linkage, verify the base pintle arm mounting bolt (Item 1) and both of the upper pintle mount bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb) torque. There should be no play between the pintle arm and the square pump shaft [Figure 50-100-38]. Verify the cam mounting nuts (Item 4) [Figure 50-100-36] are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

621 of 1311

50-100-15

S650 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 50100-37].

P-85878

CONTROL PANEL (CONT'D)

Figure 50-100-41

Linkage Travel (Adjusting) (Cont'd) Figure 50-100-39

1 1 1

P-51132

Remove the spacer (Item 1) [Figure 50-100-41]. P-85844

Figure 50-100-42 Loosen the two bolts and nuts (Item 1) [Figure 50-10039] on each steering linkage bar. Figure 50-100-40

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 50-100-42]. 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 50-10040]. 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.

622 of 1311

50-100-16

S650 Service Manual

Dealer Copy -- Not for Resale

2

CONTROL PANEL (CONT'D)

Figure 50-100-45

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 50-100-43

P-85878

Push the control lever to full stroke and turn drift adjustment bolt (Item 1) [Figure 50-100-44] and [Figure 50-100-45] 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 50-100-44] and [Figure 50-100-45] in.

P-85845

Tighten the two bolts and nuts (Items 1) [Figure 50-10043] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering bell cranks. Installation: After removal, installation, and adjusting of the linkage, the Back-up Alarm must be inspected. (See Inspecting on Page 60-220-1.)

If the drift is excessive to the right, turn the left adjustment bolt in. NOTE: When using the drift adjustment bolts, only adjust one bolt for each test drive. In addition, only move each bolt a maximum of one turn for each test drive. This will help prevent over-correction and excessive reduction in travel speed.

Figure 50-100-44

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

623 of 1311

50-100-17

S650 Service Manual

Dealer Copy -- Not for Resale

Repeat steps on the other control lever.

CONTROL PANEL (CONT'D) Shock Removal And Installation Figure 50-100-46

2

1 1

2 P-85845

Dealer Copy -- Not for Resale

Remove the mounting nuts (Item 1) [Figure 50-100-46] from the end of the shocks connected to the steering linkages. Remove the mounting nuts (Item 2) [Figure 50-100-46] from the other end of the shocks connected to the brackets on the control panel. Installation: Tighten the nuts to torque.

624 of 1311

50-100-18

S650 Service Manual

CONTROL PANEL (SJC)

Raise the lift arms and install an approved lift arm support device. (See Installing on Page 10-20-1.)

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 mount 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 10 panel mount bolts (Item 1) [Figure 50101-2].

WARNING

Remove the lift arm bypass knob and rubber washer (Item 2) [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.

Remove the control panel (Item 3) [Figure 50-101-2].

W-2059-0598

625 of 1311

50-101-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-85879

Dealer Copy -- Not for Resale 626 of 1311

50-101-2

S650 Service Manual

CONTROL HANDLE / LEVER

Lever Removal And Installation

Description

Figure 50-110-1 2

The control handles / levers are used to control the forward and reverse travel.

3

The control handles / levers are mounted to the control panel assembly. 4 1

P-85882

Remove the four nuts (Item 2) and the plate (Item 3) [Figure 50-110-1] used to mount the control lever. 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 so the lever cannot be moved either right or left when seated in the operator’s seat.

627 of 1311

50-110-1

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the tie strap and disconnect the electrical connectors (Item 1) [Figure 50-110-1] from the control lever.

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]. Install the new boot and reinstall the steering lever.

628 of 1311

50-110-2

S650 Service Manual

CONTROL HANDLE / LEVER (ACS)

Handle Sensor Removal And Installation

Description

Figure 50-111-2 1

Figure 50-111-1

1

P-85882

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. The control handles / levers are mounted to the control panel.

629 of 1311

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.) Loosen the nuts (Item 1) [Figure 50-111-2]. Installation: Tighten the nuts so the lever cannot be moved either right or left when seated in the operator seat.

50-111-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-21879

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 mounting screws (Item 1) [Figure 50-111-6] 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.

630 of 1311

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

S650 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, inspect the routing of the switch handle wire harness (Item 1) [Figure 50-111-9] and [Figure 50111-10] to assure 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.

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.)

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.

631 of 1311

50-111-3

S650 Service Manual

Dealer Copy -- Not for Resale

Remove one of the two mounting screws (Item 1) [Figure 50-111-7] 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 handle cover (Item 1) [Figure 50111-13] 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 Allen head 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 60-130-3.)

632 of 1311

Installation: Tighten the Allen head screws to 4 N•m (35 in-lb) torque.

50-111-4

S650 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] used to mount the control lever.

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 so 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.

633 of 1311

50-111-5

S650 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]. Install the new boot and reinstall the steering lever.

634 of 1311

50-111-6

S650 Service Manual

CONTROL HANDLE / LEVER (SJC)

Joystick Testing

Description

See Bobcat Advanced Troubleshooting System (B.A.T.S.) or connect to service analyzer to test function.

Dealer Copy -- Not for Resale

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.

635 of 1311

50-112-1

S650 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 10-20-1.)

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 47,5 - 54,2 N•m (35 - 40 in-lb) torque.

636 of 1311

50-112-2

S650 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 mounting screws, (Item 1), washer (Item 2), and remove the left access panel (Item 3) [Figure 50120-1].

Remove the top mounting screw (Item 1), washer (Item 2), and loosen the two bottom mounting screws (Item 3) [Figure 50-120-2] from the front access panel. Remove the front access panel from the loader.

Remove the front access panel from the loader.

637 of 1311

50-120-1

S650 Service Manual

Dealer Copy -- Not for Resale

P-85677

Dealer Copy -- Not for Resale 638 of 1311

50-120-2

S650 Service Manual

ACCESS PANEL (INSIDE) (SJC)

Removal And Installation (Right)

Removal And Installation (Left)

Figure 50-121-3

Figure 50-121-1

2

1

1 2 P-90587 P100731

Remove the two mounting nuts (Item 1), and remove the footrest (Item 2) [Figure 50-121-3]. Figure 50-121-4

Dealer Copy -- Not for Resale

Remove the two mounting nuts (Item 1), and remove the footrest (Item 2) [Figure 50-121-1]. Figure 50-121-2

2 3

2 2

1 1

1 2 P-90588 P100732

NOTE: Mark the location of the foot pedal before removal for correct assembly. Remove the mounting screws (Item 1), and remove the inside left access panel (Item 2) [Figure 50-121-2].

Loosen the bolt, remove the engine speed control pedal (Item 1), and remove the mounting screws (Item 2) [Figure 50-121-4]. Remove the right inside access panel (Item 3) [Figure 50-121-4].

639 of 1311

50-121-1

S650 Service Manual

Dealer Copy -- Not for Resale 640 of 1311

50-121-2

S650 Service Manual

WINDOW (REAR)

Removal And Installation (Latches)

Rear Window Identification

WARNING

Figure 50-130-1 Latches

Rubber Cord 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.

2 1 P-85309B

P-64994D

W-2019-0907

There are two different procedures for removing the rear window from the machine:

Figure 50-130-2

2. This window is equipped with a rubber cord and tag (Item 2) [Figure 50-130-1].

1

1

P-85706

Remove the rear window assembly by turning the two latches (Item 1) [Figure 50-130-2] in until they disengage from the window frame. Push the rear window out the rear of the operator cab. NOTE: If rear window is broken, remove all glass fragments from the rubber molding before installing a new window. Clean the area before installing the rear window assembly. Reverse the procedure to install the rear window.

641 of 1311

50-130-1

S650 Service Manual

Dealer Copy -- Not for Resale

1. This window is equipped with latches (Item 1) [Figure 50-130-1].

Figure 50-130-4

WINDOW (REAR) (CONT’D) Disassembly And Assembly (Latches)

8 Figure 50-130-3

7 1

6

1 2 3

4

5 P-85704

Inspect and replace any damaged parts. P-85705

Remove the screw (Item 1) from the latch [Figure 50130-3].

1. Latch

Installation: Tighten the screw (Item 1) [Figure 50-1303] to 21 - 23 N•m (180 - 200 in-lb) torque.

3. Bushing

2. Spacer 4. O-ring (factory installed on later models) 5. Washer 6. Screw 7. Rear Window 8. Seal

642 of 1311

50-130-2

S650 Service Manual

Dealer Copy -- Not for Resale

The items listed below refer to [Figure 50-130-4].

WINDOW (REAR) (CONT’D) Removal (Rubber Cord)

WARNING 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

Dealer Copy -- Not for Resale

Figure 50-130-5

P-64994

Pull on the tag on the top of the rear window to remove the rubber cord [Figure 50-130-5]. Push the rear window out of the rear of the operator cab. NOTE: If rear window is broken, remove all glass fragments from the rubber molding before installing a new window.

643 of 1311

50-130-3

S650 Service Manual

WINDOW (REAR) (CONT’D)

Figure 50-130-8

Installation (Rubber Cord) Figure 50-130-6

1

1 P109581

Install the rubber molding (Item 1) [Figure 50-130-6] around the edge of the rear window. Figure 50-130-7

Install a lower corner of the rear window assembly into the corner of the window frame (Item 1) [Figure 50-1308]. Work the window assembly downward until the window is fully seated in the lower portion of the window frame. Figure 50-130-9

2

1

1

P-85228

Apply liquid soap to the rubber molding (Item 1) [Figure 50-130-7] for installation. NOTE: Install the window assembly with the narrow edge (Item 2) [Figure 50-130-7] towards the inside of the loader.

P109582

Apply light pressure to the outside of the window assembly holding it tight up against the window frame. Use a multipurpose tool (Item 1) [Figure 50-130-9] under the molding lip to guide the window assembly into the window frame. NOTE: Tapping the window with a rubber hammer will help seat the window assembly in the window frame.

644 of 1311

50-130-4

S650 Service Manual

Dealer Copy -- Not for Resale

Install the rear window assembly from the outside of the operator cab into the window frame.

P109560

WINDOW (REAR) (CONT’D) Installation (Rubber Cord) (Cont’d) Figure 50-130-10

1

P109583A

Dealer Copy -- Not for Resale

Apply liquid soap on the rubber cord to make installation easier. Install the rubber cord (Item 1) [Figure 50-13010] with the safety tag into the molding on the outside of the operator cab. NOTE: Verify the safety tag is located in the top center of the window.

645 of 1311

50-130-5

S650 Service Manual

Dealer Copy -- Not for Resale 646 of 1311

50-130-6

S650 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

P-85807 P-85807

Remove the bolts (Item 1). Separate the window adhesive [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.

647 of 1311

50-131-1

S650 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 50-131-1]. Tighten the nuts (Item 1) [Figure 50-131-1] 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.

648 of 1311

50-131-2

S650 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 10-20-1.)

1

1

Figure 50-132-1 1 1 1

1

2

P-90586

Installation: Tighten the six bolts (Item 1) [Figure 50132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.

P-85821

Figure 50-132-2

Remove the window assembly. NOTE: The window assembly can only be replaced as a complete unit.

1

2

3

4

5

P-85819

From inside the operator cab, remove the plastic cap (Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2] from the window assembly. Installation: Tighten the nut (Item 2) [Figure 50-132-1] flush to the end of the bolt.

649 of 1311

50-132-1

S650 Service Manual

Dealer Copy -- Not for Resale

Support the window assembly and remove the six bolts (Item 1) [Figure 50-132-3] from the window frame and the operator cab.

Dealer Copy -- Not for Resale 650 of 1311

50-132-2

S650 Service Manual

CAB DOOR

Removal And Installation

Description

Figure 50-140-1 1

The standard cab door is available as an option or dealer installed kit.

2

P-85781A

Disconnect electrical connector (Item 2) and washer fluid hose (Item 1) [Figure 50-140-1]. Figure 50-140-2

2 3

1

P-85588A

P-85589A

Rotate and pull the clip (Item 1) out of the gas spring socket. Pull the gas spring socket (Item 3) straight off the ball stud fitting (Item 2) [Figure 50-140-2].

651 of 1311

50-140-1

S650 Service Manual

Dealer Copy -- Not for Resale

Open the cab door.

CAB DOOR (CONT’D)

Installation: Install the hinges (Item 1) on the cab and use the bolts and nuts (Item 2) [Figure 50-140-4] to secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 inlb) torque.

Removal And Installation Figure 50-140-3

1

P-85828

Lift the door (Item 1) [Figure 50-140-3] off the hinges.

Dealer Copy -- Not for Resale

Figure 50-140-4

1

2

2

1

P-85837

Remove the four bolts and nuts (Item 2) [Figure 50-1404] from the cab. Remove the hinges (Item 1) [Figure 50-140-4] from the cab.

652 of 1311

50-140-2

S650 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 and 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), the latch (Item 2), and spring (Item 3) [Figure 50-140-8]. 2 Remove the two nuts and bolts (Item 4) [Figure 50-1408]. 1

1

Installation: Tighten the nuts (Item 4) to 31 - 34 N•m (270 - 300 in-lb) torque.

1

P-85841

Remove the three tie straps (Item 1) and the wiper motor assembly cover (Item 2) [Figure 50-140-6].

653 of 1311

50-140-3

S650 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

WRONG

WRONG

Figure 50-140-9 2 1

1 1 4 3

P-85832A

P-85839A

4 P-85836

Figure 50-140-12

CORRECT

CORRECT

Remove the two nuts and bolts (Item 4) [Figure 50-1409]. Installation: Tighten the nuts (Item 4) to 31 - 34 N•m (270 - 300 in-lb) torque. Figure 50-140-10 1

1 3 P-85833A

P-85838A

1 When the striker or latch is NOT adjusted properly there will be a gap (Item 1) [Figure 50-140-11] between the door and the cab or the striker and the latch. If adjustment is needed. (See Adjusting on Page 50-1405.) 2

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.

P-85830A

Disconnect the harness (Item 1) [Figure 50-140-10].

After verifying alignment check for proper operation. (See Checking Operation on Page 50-140-5.)

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.

654 of 1311

50-140-4

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the bolt (Item 1), the latch (Item 2), and spring (Item 3) [Figure 50-140-9].

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

P-85831

Loosen the striker and adjust as needed (Item 1) [Figure 50-140-14]. After adjusting the striker and latch recheck the alignment of the door sensor. (See Aligning on Page 50-140-4.)

655 of 1311

50-140-5

S650 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 key ON, lower seat bar and close the door. Press the PRESS TO OPERATE LOADER button (Item 1) [Figure 50-140-15].

Dealer Copy -- Not for Resale 656 of 1311

50-140-6

S650 Service Manual

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].

657 of 1311

50-150-1

S650 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 50-30-2.) 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 connector (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.

658 of 1311

50-150-2

S650 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 armrest cover (Item 1) [Figure 50-150-5]. Figure 50-150-6

1 2

1

P-90841

Remove the two nuts and bolts (Item 1) and the support tube (Item 2) [Figure 50-150-8].

1

P-90839

Remove the two bolts and washers (Item 1) and the armrest shell (Item 2) [Figure 50-150-6].

659 of 1311

50-150-3

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-150-8

Figure 50-150-11

ARMREST (CONT’D)

Later Models

Disassembly And Assembly (Cont’d) Figure 50-150-9 Earlier Models

3 2 1 3 2 P100825

1 Figure 50-150-12 P-90842

Later Models

Earlier Models

7

4 6

3 2

5 3 6 5

1

2 4

P100824

1 Remove the nut (Item 1), washer (Item 2), spring (Item 3) [Figure 50-150-11] and [Figure 50-150-12].

P-90843

Remove the nut (Item 1), washer (Item 2), and the plastic washer (Item 3) [Figure 50-150-9] and [Figure 50-15010].

Remove the spacer (Item 4), washer (Item 5), plastic washer (Item 6) and the bolt (Item 7) [Figure 50-150-12]. Installation: Tighten the nut to 21 - 23 N•m (80 - 200 inlb) torque.

Remove the spacer (Item 4), plastic washer (Item 5), and the bolt (Item 6) [Figure 50-150-10]. Installation: Tighten the nut to 21 - 23 N•m (180 - 200 inlb) torque.

660 of 1311

50-150-4

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-150-10

ARMREST (CONT’D) Disassembly And Assembly (Cont’d) Figure 50-150-13 All Models

1

1 2 P-90844

Dealer Copy -- Not for Resale

Remove the two nuts and bolts (Item 1) and the slide rail (Item 2) [Figure 50-150-13] from the armrest mount. Repeat for the other side.

661 of 1311

50-150-5

S650 Service Manual

Dealer Copy -- Not for Resale 662 of 1311

50-150-6

S650 Service Manual

LEFT SIDE LOWER PANEL

Figure 50-160-3

Removal And Installation Raise the operator’s cab. Figure 50-160-1

1 1

1 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

Remove the five plastic rivets (Item 1) [Figure 50-160-1]. Remove the seat. (See Removal And Installation on Page 50-30-1.) 1

Remove the 3-Point seat belt retractor (if equipped). (See 3-Point Seat Belt Removal And Installation on Page 5030-4.)

1 1

Lower the operator’s 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.

663 of 1311

50-160-1

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-160-4

P-90897

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].

664 of 1311

NOTE: Pull the left side lower panel away from the side of the cab far enough to access the wire harness.

50-160-2

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the three plastic rivets and anchors (Item 1) and the screw (Item 2) [Figure 50-160-5].

LEFT SIDE LOWER PANEL (CONT’D)

Disassembly And Assembly

Removal And Installation (Cont’d)

Figure 50-160-10

Figure 50-160-9

1 1 1

1

1

1

1

1 1

P-90860 P-90859

Press the four tabs (Item 1) [Figure 50-160-10] and remove the HVAC control out of the left side lower panel. Figure 50-160-11

Dealer Copy -- Not for Resale

Disconnect the HVAC or radio wire harnesses (Item 1) [Figure 50-160-9] (if equipped).

1

P-90865

NOTE: If the three clips (Item 1) [Figure 50-160-11] are removed the cup holder will need to be replaced.

665 of 1311

50-160-3

S650 Service Manual

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly (Cont’d) Figure 50-160-12

1

1

1

1

P-90866

Dealer Copy -- Not for Resale

Remove the four screws (Item 1) [Figure 50-160-12] and remove the speaker from the left side lower panel. Figure 50-160-13

1

P-90864

Remove the three screws (Item 1) [Figure 50-160-13] and remove the washer tank from the left side lower panel.

666 of 1311

50-160-4

S650 Service Manual

Figure 50-170-3

RIGHT SIDE LOWER PANEL Removal And Installation

2

Raise the operator’s cab. 1 Figure 50-170-1 1 1 1

1 1

P-90870

1 Remove the three plastic rivets and anchors (Item 1) and the screw (Item 2) [Figure 50-170-3].

1

Remove the five plastic rivets (Item 1) [Figure 50-170-1]. Remove the seat. (See Removal And Installation on Page 50-30-1.) 1

Lower the operator’s 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.

667 of 1311

50-170-1

S650 Service Manual

Dealer Copy -- Not for Resale

Figure 50-170-4

P-90897

RIGHT SIDE LOWER PANEL (CONT’D)

Disassembly And Assembly

Removal And Installation (Cont’d)

Figure 50-170-7

Figure 50-170-5

1

1 P-90879 P-90872

NOTE: Pull the right side lower panel away from the side of the cab far enough to access the wire harness.

NOTE: The power port lockwasher must be replaced with a new lockwasher when it has been removed. Figure 50-170-8

Figure 50-170-6 1

2

1 2

P-90877

1

1 P-90881 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.

668 of 1311

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.

50-170-2

S650 Service Manual

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.

Remove the plastic nut and the lockwasher (Item 1) [Figure 50-170-7] from power port and remove the power port from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly (Cont’d) Figure 50-170-9

1

P-90875

Dealer Copy -- Not for Resale

Remove the nut, washer, and cover, (Item 1) [Figure 50170-9] from the input. Remove the input from the right side lower panel. Figure 50-170-10

1 1

1 1 P-90876

Remove the four screws (Item 1) [Figure 50-170-10] and remove the speaker from the right side lower panel.

669 of 1311

50-170-3

S650 Service Manual

Dealer Copy -- Not for Resale 670 of 1311

50-170-4

S650 Service Manual

HEADLINER

Figure 50-180-3

Removal And Installation Figure 50-180-1

1

1 1

P-90895

2

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 underneath side, lift vertically to disengage.

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 50-180-4

Installation: Tighten the screws to 2,3 N•m (20 in-lb) torque. Figure 50-180-2

1

1

1

1

1

2 P-90896

Remove the four retainers (Item 1) and remove the headliner (Item 2) [Figure 50-180-4]. P-90894

Remove the air duct (Item 1) [Figure 50-180-2] (if equipped).

Installation: Route the cab light wire harness in the groove on the topside of the headliner (if equipped with HVAC). NOTE: Replace the retainers if needed.

671 of 1311

50-180-1

S650 Service Manual

Dealer Copy -- Not for Resale

Remove the air duct (Item 1) [Figure 50-180-3] (if equipped).

P-90893

Dealer Copy -- Not for Resale 672 of 1311

50-180-2

S650 Service Manual

ELECTRICAL SYSTEM

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-20-1 60-20-1 60-20-2 60-20-2 60-20-2 60-20-3 60-20-3 60-20-4

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 60-30-1 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

673 of 1311

60-01

S650 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8 Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9 Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-13

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Light Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . Cab Light Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . .

60-60-1 60-60-1 60-60-2 60-60-2 60-60-3

BOBCAT CONTROLLER (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

SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-80-1 60-80-1 60-80-1 60-80-3

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

674 of 1311

60-02

S650 Service Manual

Dealer Copy -- Not for Resale

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Left Panel (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Left Panel (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3 Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5 Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6 Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7 Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8 Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11 Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11 Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12 Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-12 Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-13 Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-13 Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14 Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14 Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15 Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-100-1 60-100-1 60-100-2

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . .

60-110-1 60-110-1 60-110-1 60-110-2 60-110-3 60-110-6

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-120-1 60-120-1 60-120-2 60-120-3

CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1 Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-2 Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3 Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6 Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9 Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9 Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10 Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11 Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12 Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

675 of 1311

60-03

60-140-1 60-140-1 60-140-2 60-140-3 60-140-4 60-140-5 60-140-6

S650 Service Manual

Dealer Copy -- Not for Resale

60-100-2 60-100-2 60-100-2 60-100-2 60-100-2 60-100-3

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

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 FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-2 CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1 Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

676 of 1311

60-04

60-200-1 60-200-1 60-200-1 60-200-2 60-200-2

S650 Service Manual

Dealer Copy -- Not for Resale

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

60-201-1 60-201-1 60-201-1 60-201-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-210-1 60-210-1 60-210-1 60-210-5

BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-220-1 60-220-1 60-220-1 60-220-2 60-220-3 60-220-4 60-220-5 60-220-5

FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60-230-1 60-230-1 60-230-2 60-230-3

677 of 1311

60-05

S650 Service Manual

Dealer Copy -- Not for Resale

PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dealer Copy -- Not for Resale 678 of 1311

60-06

S650 Service Manual

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C209 C212 C250 C251 C252 C277 C278 C279 C308 C350 C355 C362 C404 C405 C406 C408 C409 C410 C411 C412 C413 C414 C415 C416 C417 C418 C419

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN ACCESSORY DOME LIGHT POWER SOCKET DOOR SENSOR WIPER WASHER AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS REAR AUX SOLENOID BACKUP ALARM AIR FILTER SWITCH FUEL SENDER CAB CONNECTOR RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY HANDLE(HORN) REAR ROD REAR BASE HIGH FLOW SOLENOID DIVERTER SOLENOID REAR AUX RELIEF FRONT ROD FRONT BASE

C420

HYD LOCK

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 3 2 2 5 2

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9 9 9 9

6 2 2 2 2 6 8 2 2 2 48 10 10 5 2 2 2 2 2 2 2 2

9 9 9 7 12 6,12,13 7 3,10 6 6 3-5, 8-13 10 10 10,13 10,13 7 7 7 7 7 7 7

C421 C422 C423 C425 C426 C434-1 C434-2 C435-1 C435-2 C437 C441 C446 C449 C450 C479 C480 C482 C483 C486 C489

2

7

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS TILT SPOOL LOCK 3 LIFT SPOOL LOCK 3 2 BUCKET POSITION 3 BRAKE SOLENOID CAN (Remote Start Tool, ACD) 7 LEFT WORKLIGHT 1 2 LEFT WORKLIGHT 2 2 2 RIGHT WORKLIGHT 1 RIGHT WORKLIGHT 2 2 TWO SPEED MAKEUP 2 TWO SPEED 2 2 HYDRAULIC FAN 4 LEFT JOYSTICK RIGHT JOYSTICK 4 LEFT PANEL(BLACK) 12 12 LEFT PANEL(GRAY) 3 SEATBAR SENSOR TEMP CONTROL SWITCH 3 AC COMPRESSOR 2 ACCESSORY 2

C499 C500 C503 C602 C603 C606 C607 C611 C630 C635 C667 C670 C676

PTOL RH KEY SWITCH RH DLX PANEL LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT POWER BOBTACH OPEN POWER BOBTACH CLOSE BLOWER MOTOR THERMOSTAT HEATER VALVE DOOR KIT EXTERIOR BEACON RADIO

J1A J1B J2A J2B

GATEWAY COTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

4 6 6 2 2 2 2 4 Dealer 3 6 6 6 6

34 26 34 26

SHEET 10 10 13 7 5 11 11 11 11 7 7 7 5 5 5,8 8 9 12 12 3,4 8 8 5,8 11 11 13 13 12 Copy 12 12 9 13 9

NUM OF PINS

CONN

DESCRIPTION

FC1 FC2 FRC1

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

3 3 3,6,7,11,12

T1 T2 T3

BATT GROUND BUZZER GROUND FLASHER

T6 T8 T13 T14 T15 T16

BATT GROUND BATT GROUND BUZZER POWER PRE HEATER RIGHT REAR WORK LIGHT(+) RIGHT REAR WORK LIGHT(-) LEFT REAR WORK LIGHT (+) LEFT REAR WORK LIGHT (-) BACKUP ALARM BACKUP ALARM (GND)

4 8 13 4 4 8 6 11 11 11 11 10 10

T17 T18 T19 T20

SHEET

-- Not for Resale SW1 SW2 SW3 SW4 SW5 SW6 SW8 SW9 SW10 SW11

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CABIN PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13

BRAKE SWITCH BEACON SWITCH HAZARD SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH BUCKET POSITION SWITCH FRONT WIPER SWITCH TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

9 13 13 9 13 13 9 8 12 12

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 1 of 13 (PRINTED MARCH 2011) 7175752

Printed In U.S.A. 679 of 1311

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) 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 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 FAN 1 RELAY TILT SPOOL LOCK RETURN SPARE DIGITAL, ECU SINKS SPARE DIGITAL, ECU SOURCES TRACTION PULL RELAY FDBK GLOW PLUG RELAY FDBK ENGINE SPEED AIR FILTER SWITCH LIGHT 2 RELAY FAN 2 RELAY PTOL LED PTOL SWITCH SWITCHED POWER OUT RELAY FDBK STATER RELAY FDBK HYD OIL FILTER SW2 START ENGINE ENGINE OIL PRESS SPARE SPARE LIGHT 2 RELAY FDBK FAN 1 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP SPARE ANALOG HYD OIL FILTER SW1

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 SPOOL LOCK SENSOR 2 SEAT BAR FUEL LEVEL BICS HYD LOCK HOLD CAN HI 2 GROUND P1 GROUND P2 GROUND P3, SENSOR ENGINE COOLANT TEMP FAN 2 OUTPUT CAN LO 2 REMOTE KEY RUN/ENTER SENSOR SUPPLY 8V SENSOR SUPPLY 5V TWO SPEED MAKEUP TWO SPEED COIL

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) 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 AUX (F) RETURN REAR AUX (F) RETURN LEFT BLINKER RELAY RIGHT BLINKER RELAY HORN RELAY OUTPUT SPARE

REAR AUX (M) RETURN LH PADDLE RIGHT LH PADDLE LEFT RH RIGHT BUTTON UP DIGITAL INPUT SPARE

FRONT AUX (M) RETURN LH FLOAT BUTTON HYDRAULIC DETENT LH RIGHT BUTTON DOWN RH CENTER BUTTON DIGITAL INPUT SPARE

Dealer Copy Not RETURN for Resale HIGH -FLOW

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 DIVERTED SOLENOID REAR AUX (F) RELIEF SOLENOID REAR AUX (M) CAN LO 1 CAN HI 1

FRONT AUX (F) CAN HI 2 GROUND GROUND HANDLE POT GND RH PVM POT SIGNAL FRONT AUX (M) CAN LO 2 RH TRIGGER SWITCHED POWER HANDLE POT POWER BUCKET POSITION (SPARE) HIGH FLOW

BUCKET POSITION(SPARE) RETURN LH RIGHT BUTTON RH RIGHT BUTTON DOWN RH LEFT UP RH LEFT DOWN

DIGITAL INPUT SPARE HARNESS PART NUMBER MAIN FRAME 7174782 STD CAB 7165991 7176098 DLX CAB DLX FUEL 7175293 STD FUEL 7149219 DOOR 7155024 S/R 6733370 7175271 TAILGATE DOM TAILGATE EUR 7175287 2 SPD ADP 7159366 BACKUP ALARM 7175017 BRAKE ADAPTER 7165061

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV1100 1 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 2 of 13 (PRINTED MARCH 2011)

Printed In U.S.A. 680 of 1311

7175752

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 WHITE ACCESSORIES 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

POWER BATTERY BATT_CABLE

MEGAFUSE 100.0 Amps 1025 RED

1070 RED

FC1 FUSE 2 25 A FC1 FUSE 1 25 A

SHEET 6 1290 RED

1040 RED

1190 RED

1120 RED/WHT

FC2 FUSE 4 15 A FC2 FUSE 2 25 A FC2 FUSE 1 25 A

1370 RED/WHT

FRC 1 FUSE 6 30 A

1300 RED

1340 RED

FRC1 FUSE 11 25 A FRC1 FUSE 10 20 A

1490 RED/WHT

1165 RED/WHT

1360 RED/WHT

SHEET 13 SHEET 13

1330 RED/WHT

SHEET 12

SHEET 11

SHEET 11 SHEET 6 SHEET 6 C408 43

1660 RNG/WHT 1570 RNG/WHT

FRC1 FUSE 2 25 A 1850 RNG/WHT FRC1 FUSE 3 15 A 1550 RNG/WHT

SHEET 6 SHEET 12

85

1790 RNG/WHT

86 1795 RNG/WHT

1730 RNG/WHT

FRC1 FUSE 8 25 A 1580 RNG/WHT 8000 TAN 1920 RNG/WHT

J1A 4

C408 6

Printed In U.S.A. 681 of 1311

1920 RNG/WHT

1840 RNG/WHT 1830 RNG/WHT

SHEET 5 SHEET 5

SHEET 8 SHEET 8 SHEET 8 SHEET 9 SHEET 8 SHEET 9 SHEET 8 SHEET 8

Printable Version Click Here

SHEET 13

SHEET 12 FRC1 FUSE 7 25 A

RNG/WHT RNG/WHT RNG/WHT RNG/WHT RNG/WHT RNG/WHT RNG/WHT RNG/WHT

SHEET 9

1720 RNG/WHT

SWITCHED POWER

1660 RNG/WHT

1620 1940 1930 1775 1960 1785 1950 1590

SHEET 10

FRC1 FUSE1 25 A 1750 RNG/WHT 1780 RNG/WHT

2055 BLK 2030 BLK

J1B 2 J1B 3

SHEET 8 SHEET 9 SHEET 8 SHEET 8

Dealer Copy -- Not for Resale 1140 RED/WHT

1760 RNG/WHT

1765 RNG/WHT

1450 RED/WHT

RED/WHT RED/WHT RED/WHT RED/WHT

SHEET 6

FRC1 FUSE 4 5A

87

C408 17

1240 1400 1420 1440

SHEET 7

1060 RED 1030 RED

30

J2B 2 J2B 3

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

SHEET 5

FRC1 FUSE 9 15 A 1320 RED/WHT

1050 RED

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

SHEET 9

FRC1 FUSE 5 30 A 1350 RED/WHT

1050 RED

1450 RED/WHT 1110 RED/WHT 1130 RED/WHT

1460 RED/WHT 1410 RED/WHT

1010 RED 1310 RED

1180 RED/WHT 1150 RED/WHT

1160 RED/WHT

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SHEET 5

SHEET 9

C489 A C404 B

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 3 of 13 (PRINTED MARCH 2011) 7175752

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SHEET 5 SHEET 5 SHEET 8 SHEET 8 SHEET 8 SHEET 8

2080 BLK 2070 BLK 2940 BLK 2960 BLK 2920 BLK 2250 BLK

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

2950 BLK

C408 32 J1B 16 J1B 15 J2B 16 J2B 15

SHEET 11 SHEET 12 SHEET 9 SHEET 13 SHEET 9 SHEET 11 SHEET 11 SHEET 10 SHEET 11 SHEET 11

SHEET 13 SHEET 9 SHEET 13 SHEET 8

2620 BLK 2630 BLK 2650 BLK 2640 BLK 2610 BLK

2785 BLK 2930 BLK 2830 BLK 2700 BLK

C489 B

C103 B

2600 BLK

SHEET6

2900 BLK

SHEET 7 SHEET 13 SHEET 7 SHEET 13 SHEET 5 SHEET 7

C408 42

SHEET 11

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

2950 BLK 2510 BLK 2500 BLK 2540 BLK 2550 BLK

GROUND 2110 BLK

T6 BATT GND

2090 BLK

2765 BLK 2745 BLK 2790 BLK 2780 BLK 2730 BLK

T8 BATT GND

Dealer Copy -- Not for Resale 2720 BLK 2600 BLK 2810 BLK 2200 BLK 2751/BLK OR 2770/BLK 2450 BLK 2741 BLK 2710 BLK 2480 BLK

2390 BLK

2300 BLK

T1 BATT GND

2900 BLK 2000 BLK

Printable Version Click Here SHEET 7 SHEET 6 SHEET 9 SHEET 7 SHEET 7 SHEET 6 SHEET 6 SHEET 6

Printed In U.S.A.

3530 LBL 3800 LBL 2370/BRN OR 3910 LBL 3310/LBL OR 2180/BRN 3410 LBL 3110/LBL OR 2180/BRN 3510 LBL 3710 LBL

3010 LBL

J1B 17

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 4 of 13 (PRINTED MARCH 2011) 7175752

682 of 1311

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION BATT FEED, GENERAL 1000 THROUGH 1499 RED BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 WHITE ACCESSORIES 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

CAN BUS 9160 PUR/WHT 9260 PUR

GWY CTRLR

J1B 8 J1B 9

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9230 PUR 9130 PUR/WHT

120 OHM RESISTOR

C408 8

9230 PUR 9130 PUR/WHT

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

C408 7

9560 PUR/WHT 9660 PUR

SHEET 3 SHEET 4

9630 PUR 9530 PUR/WHT

120 OHM RESISTOR 1830 RNG/WHT 2070 BLK

C450

1 2 3 4

C503 2 C503 4

RH DLX PANEL

C479 4 C479 3

LEFT PANEL

# RIGHT JOYSTICK

9220 PUR 9120 PUR/WHT

J2B 8 J2B 9

AUX CTRLRCopy Dealer

C449

-- Not for Resale 9540 PUR/WHT 9640 PUR

SHEET 3 SHEET 4

1840 RNG/WHT 2080 BLK

1 2 3 4

# LEFT JOYSTICK

C426

J1B 14 J1B 20 J1B 21 SHEET 3 SHEET 3 SHEET 4

9500 PUR/WHT 9600 PUR 9400 PUR 1730 RNG/WHT 1165 RED/WHT 2710 BLK

A B D C E F G

CAN (Remote Start Tool, ACD)

#

CONNECTOR DOES NOT EXIST IN 7165991 Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV1100 1 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 5 of 13 Printed In U.S.A. 683 of 1311

(PRINTED MARCH 2011) 7175752

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION BATT FEED, GENERAL 1000 THROUGH 1499 RED BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

SHEET 12

1030 RED

30 8200 TAN

87 2005 BLK

85

86

8210 TAN

B A

8250 TAN

J1A 22

ENGINE STARTER

C109

STARTER SHEET 3

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

8250 TAN 8200 TAN

R S

M

B

SHEET 3 1015 RED C110

B

J1A 7

G

ALTERNATOR

S L

SHEET 3 SHEET 7

1350 RED/WHT 2025 BLK

Dealer Copy -- Not D5 for Resale

8120 TAN

30

8150 TAN

87 85

86

J1B 4

J1A 30 SHEET4

8110 TAN

2810 BLK

B A C

J1A 15 SHEET 4

A B

SIG GND

3210 LBL 3200 LBL

B A

SIG GND

ENGINE SPEED SENSOR

SHEET 3

3800 LBL

J1B 18

8100 TAN 8800 TAN 2800 BLK

PULL HOLD

24.5 OHM 0.33 OHM

J1A 3

C106

3600 LBL 3610 LBL

FUEL SHUTOFF SOLENOID

C101

8100 TAN 8800 TAN 2800 BLK

SHEET 12

EXCITATION

2015 BLK

FUEL PULL

FRC1 FUSE 12 15 A 1815 RNG/WHT

1020 RED 1800 RNG/WHT

ENGINE COOLANT SENSOR (500-3000 OHM)

C104

SHEET 3

1060 RED 2016 BLK 2055 BLK

GLOW PLUG 30 87 85

8550 TAN 8500 TAN

86

8510 TAN

J1A 14 T14 PRE HEATER

J1A 6

Printable Version Click Here C107

SHEET 9 J1A 25 SHEET 4

J1B 12 SHEET 4

3500 LBL 3520 LBL 3510 LBL

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5 ~ 4.5V)

C355 C 3100/LBL OR 3180/LBL 3100/LBL OR 3180/LBL 3110/LBL OR 2180/BRN 3110/LBL OR 2180/BRN

C406

A B

SIG GND

C355 D C405

Printed In U.S.A.

SHEET 4 J1A 16

3710 LBL 3700 LBL

B A

GND SIG

AIR FILTER SWITCH

FUEL SENDER

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 6 of 13 (PRINTED NOVEMBER 2010) 7175752

684 of 1311

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION RED BATT FEED, GENERAL 1000 THROUGH 1499 BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE 8000 THROUGH 8999 TAN COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SHEET 3 SHEET 6 SHEET 11

1360 RED/WHT 2025 BLK 2035 BLK

TRACTION LOCK 30 87 85

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

C425

4150 LGN 4100 LGN

86

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

J1A 13

4110 LGN

J1A 8

J1B 6 SHEET 4

B A C

4200 LGN 2200 BLK

C425

B A C C362

J2B 5 J2A 2

4440 LGN 2440 BLK

A B

C414

4440 LGN 2440 BLK

1 2

SIG GND

HYDRAULICS TRACK MACHINES C308

4200 RED 2200 BLK

A B

BRAKE SOLENOID 9.8 OHM 12 V

HARN BRAKE ADAPTER 7165061 WHEEL MACHINES PULL HOLD

0.3 OHM 10.9 OHM

TRACTION LOCK

OPTIONAL REAR AUX DIRECTIONAL SOLENOID FEMALE COUPLER 7.5 OHM 12V

C420

C413

J2B 7 J2A 10

4430 LGN 2430 BLK

C D

4430 LGN 2430 BLK

1 2

SIG GND

C416

J2B 4 SHEET 4

4450 LGN 2450 BLK

E F

4450 LGN 2450 BLK

4480 LGN 2480 BLK

G H

4480 LGN 2480 BLK

1 2

SIG GND

OPTIONAL REAR AUX BLEED / LOCK VALVE SOLENOID MALE COUPLER 7.5 OHM 12 V

SIG GND

OPTIONAL REAR AUX BLEED / LOCK VALVE SOLENOID FEMALE COUPLER

C417

J2B 6 SHEET 4

1 2

OPTIONAL REAR AUX DIRECTIONAL SOLENOID MALE COUPLER 7.5 OHM 12V

J1A 1 J1B 13

2460 BLK 4460 LGN

B A

B A C105

Dealer Copy -- Not for Resale

3410 LBL 3420 LBL 3400 LBL

J1B 1 J1B 23 +8V

SHEET 4 J1A 32

B C A C108

3310/LBL OR 2180/BRN 3300 LBL

B A

HYD LOCK SOLENOID 9.8 OHM 12V HYDRAULIC CHARGE PRESSURE 0.5-7.5V

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM

C112

C415

J2A 26 J2B 26

2410 BLK 4410 LGN

GND SIG

OPTIONAL HIGH FLOW SOLENOID 7.5 OHM 12 V

J1A 34 SHEET 4

3430 LBL 3530 LBL

A B

HYDRAULIC FILTER SWITCH

C418

J2A 18 J2B 19

2330 BLK 4330 LGN

2 1

GND SIG

FRONT ROD SOLENOID (MALE) 3.3 OHM PWM

C419

J2A 1 J2B 13

2340 BLK 4340 LGN

2 1

GND SIG

FRONT BASE SOLENOID (FEMALE) 3.3 OHM PWM

GND SIG

TWO SPEED MAKEUP SOLENOID

GND SIG

TWO SPEED SOLENOID

C437

J1A 27 J1B 25

2360 BLK 4360 LGN

2 1 C441

J1A 26 J1B 26

2350 BLK 4350 LGN

2 1 C446

J1A 18 J1B 19

2910 BLK 4010 LGN

2 1

GND SIG

HYDRAULIC FAN SOLENOID 7.2 OHM 12 V

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 7 of 13 (PRINTED NOVEMBER 2010)

Printed In U.S.A. 685 of 1311

7175752

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE 8000 THROUGH 8999 TAN PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SHEET 3

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

CAB DISPLAY

T13 BUZZER (+)

1940 RNG/WHT

T2 BUZZER (-)

LEFT PANEL (BLACK)

9320/PUR OR 7040/WHT C479 10 2920 BLK

SHEET 4 SHEET 3 SHEET 3

1960 RNG/WHT

SHEET 3

SW9 TRAVEL CONTROL SWITCH (OPTIONAL)

SHEET 4

2700 BLK

GROUND Battery (+) Copy -- Not for Resale Dealer

1620 RNG/WHT C479 5

SHEET 13 SHEET 9

C479 2

1440 RED/WHT C479 1

SHEET 13

5 6 4 2 3 1

C479 11

6550 PNK

C479 8

J1A 20 J1A 19

SHEET 3 SHEET 4

Printed In U.S.A.

C408 37 1930 RNG/WHT 2940 BLK

5 1 3 6

RUN/ENTER SW

Switched Power Battery (+) GROUND

Park Break Input Travel Control Input

12 2

2 4 1 3

LEFT PANEL (GRAY) Reserved Output 5 Park Break Output

PTOL (Press To Operate Loader) PTOL OUTPUT PTOL LED

SWITCH POWER GROUND

RH DLX PANEL

SHEET 3 SHEET 3 SHEET 4

1590 RNG/WHT

C503 5

1240 RED/WHT

C503 1

2250 BLK

C503 3

Switched Power Battery (+) GROUND

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 8 of 13 (PRINTED NOVEMBER 2010) 7175752

686 of 1311

RH KEY SWITCH START

C479 7

C499

9380/PUR OR 3030/LBL 9370/PUR OR 2380/BRN

2 4

Right Blinker Input

4500/LGN OR 3600/LBL C479 9

4750 LGN 9310/PUR OR 3610/LBL

SHEET 3 SHEET 3 SHEET 4

C408 40 1950 RNG/WHT 1420 RED/WHT 2960 BLK

C500

Left Blinker Input

C480

C408 1 9380/PUR OR 3030/LBL 9370/PUR OR 2380/BRN

Switched Power

6450 PNK

4730 LGN

SHEET 9 SHEET 9

BUZZER

J1A 24 J1B 22

C408 4 9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 9350/PUR OR 3040/LBL 9350/PUR OR 3040/LBL

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 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 CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

7176098 ONLY

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH 1785 RNG/WHT 1 2 3 2060 BLK 5 6 4

SHEET 3

4550 LGN C408 5 4275 LGN C408 3 4235 LGN C408 2

C212

2795 BLK 1375 RED/WHT

SHEET 3

C408 23

1370 RED/WHT

1370 RED/WHT

C408 24

2790 BLK

SHEET 4

1 + 2

POWER SOCKET

-

C209

2790 BLK

2010 BLK 1390 RED/WHT 4760 LGN

*

B A C

DOME LIGHT

C676

1885 RNG/WHT 2885 BLK

1 2

C129

SHEET 3

C408 16

1580 RNG/WHT

*

1580 RNG/WHT

1210 RED/WHT 1865 RNG/WHT 2820 BLK

C279

A B C

LEFT SPEAKER

C408 33

J1B 11 J1B 24 SHEET 6

+5V

C408 45 2370/BRN OR 3910 LBL

A

GND

3920/LBL OR 3370/LBL

C408 46 3920/LBL OR 3370/LBL

B

SIG

C

PWR

3900/LBL OR 5370/YEL

2 1

-

6 5

3900/LBL OR 5370/YEL

Dealer Copy -- Not for Resale

C277

1510 RNG/WHT 2210 BLK

4 5

SEATBAR SENSOR

C250

C667

SHEET 8 SHEET 3

4750 LGN 1400 RED/WHT

4740 LGN

4 5

4740 LGN 1400 RED/WHT

DOOR SENSOR

7330 WHT 1570 RNG/WHT

7300 WHT

C408 44 1850 RNG/WHT

1850 RNG/WHT

1

1850 RNG/WHT

3

7310 WHT

C408 27 SW1 BRAKE SWITCH 4500/LGN OR 3600/LBL 9310/PUR OR 3610/LBL 1775 RNG/WHT 2930 BLK

3 1 4

2 2840 BLK

5

6

2

2840 BLK 7310 WHT

3 1 6 4

C251

D C A B E

In U.S.A.

*

SPLICE DOES NOT EXIST IN 7165991

WIPER MOTOR

5

SW8 FRONT WIPER SWITCH

C252

L X

WASHER MOTOR

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV1100 1 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 9 of 13 Printable Version Click Here (PRINTEDNOVEMBER 2010)

Printed 687 of 1311

SW PWR PARK LOW GND

2

2845 BLK

7165991Standard Cab Harness 7176098 Deluxe Cab Harness

AIR RIDE SEAT SOLENOID

SENSOR SHOWN WITH DOOR OPEN

1 2

1860 RNG/WHT 6

SHEET 3

SHEET 8 SHEET 8 SHEET 3 SHEET 4

7810 WHT 7800 WHT

RADIO CONN

+

2370/BRN OR 3910 LBL

3930 LBL 3500 LBL

3 4

2730 BLK

C482

SHEET 4

7820 WHT 7830 WHT

C278

RIGHT SPEAKER 2730 BLK

+ -

ACCESSORY CONN

SHEET 4

1 2

7175752

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE TAN 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

MANUAL CONTROLS

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

C409

1590 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

J2A 30 J2A 31 J2B 21 J2A 13 J2B 17 J2B 18 J2B 23

K G A H J E F C D B

RIGHT HANDLE

SKI CTRL DETENT FLOW +

TWO SPD PWM

C410

Dealer 1570 RNG/WHT 1560 RNG/WHT

SHEET 3 J2B 22

J2A 28 J2A 22 Copy -J2A 12 J2A 11

Not

4840 LGN 4830 LGN for Resale 4820 LGN 4810 LGN 1710 RNG/WHT

K D C B G F A J H E

LEFT HANDLE

SKI CTRL SIDE SHIFT

C411

E C A D B

C404 A

7100 WHT

C103 C

SHEET 4

7100 WHT 2650 BLK

C412

T19 1 +

-

BACKUP ALARM 7001923

J1A 10 J1B 7

3 1 2

J1A 2 J1B 5

HORN

Printable Version Click Here TILT SPOOL LOCK SOLENOID

C422

2380 BLK 4380 LGN

B A

T20 1 C421

2370 BLK 4370 LGN

TURN SIGNAL

3 1 2

LIFT SPOOL LOCK SOLENOID

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 10 of 13 (PRINTED NOVEMBER 2010)

Printed In U.S.A.

688 of 1311

7175752

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

LIGHTS C434-1

2735 BLK 6100 PNK

SHEET 4

B A

LEFT FRONT WORK LIGHT 37.00 Watts

C434-2

2765 BLK

C408 28

2765 BLK

2750 BLK 6110 PNK

6000 PNK

C408 25

6000 PNK

6120 PNK 2760 BLK

B A

LEFT FRONT WORK LIGHT 50.00 Watts

C435-1

A B

RIGHT FRONT WORK LIGHT 37.00 Watts

C435-2

6130 PNK 2705 BLK FRONT WORK LIGHTS SHEET 3 SHEET 4 J1A 5 J1A 31

1330 RED/WHT

30 87

2000 BLK 2045 BLK 6320 PNK 6330 PNK

85

SHEET 4 6340 PNK

A Dealer Copy -- Not forC103 Resale 6310 PNK

6310 PNK

SHEET 3

SHEET 7 J1A 17 J1A 28

Printed In U.S.A.

2045 BLK 2035 BLK 6210 PNK 6230 PNK

SHEET 4

85

86

2 1

RIGHT REAR TAIL LIGHT

C602

SHEET 4

1320 RED/WHT

RIGHT FRONT WORK LIGHT 50.00 Watts

C603

2610 BLK 6320 PNK

86

REAR LIGHT 30 87

A B

6330 PNK 2640 BLK

1 2

2620 BLK 6210 PNK

T16 1

LEFT REAR TAIL LIGHT

RIGHT REAR WORK LIGHT

T15 1 6200 PNK

C103 H

T17 1

6200 PNK SHEET 4

LEFT REAR WORK LIGHT

2630 BLK T18 1

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 11 of 13 Printable Version Click Here (PRINTED NOVEMBER 2010) 7175752

689 of 1311

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

HVAC C630

7021 WHT 7023 WHT

J1A 11

7020 WHT

C408 34

7020 WHT 2570 BLK 3320 LBL

B C A

THERMOSTAT

C350

B A

7024 WHT

C355 A

SHEET 13

C483

EVAPORATOR (AC PRESS SWITCH)

2560 BLK 1980 RNG/WHT 7220 WHT

C486

7025 WHT

7024 WHT 2290 BLK

1 2

2280 BLK

MAGNET CLUTCH (COMPRESSOR) 2130 BLK 1900 RNG/WHT

Dealer Copy -- Not for Resale SHEET 3 SHEET 3 SHEET 6 SHEET 3 SHEET 6 J1A 21 SHEET 4

1140 RED/WHT 2030 BLK 2005 BLK 1790 RNG/WHT 1815 RNG/WHT 8020 TAN 2745 BLK

85

BLK DBL WHT

POTENTIOMETER (TEMP CONTROL SWITCH)

C635

D4

HVAC 30 87

C A B

SW10 BLOWER SWITCH OFF 5 2 1 4 6 3

1500 RNG/WHT C408 21 1500 RNG/WHT

86

1910 RNG/WHT

D C A B E F

SIG GND 12V

HEATER VALVE

C611

1970 RNG/WHT 1520 RNG/WHT 7320 WHT 2580 BLK

2745 BLK

A 14.00 Amps B 7.50 Amps C 5.00 Amps D

High Med Low

BLOWER MOTOR

C408 22

2100 BLK

3

7040 WHT

SW11 AC SWITCH 1 C

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 12 of 13 Printed In U.S.A.

(PRINTEDNOVEMBER 2010) 7175752

690 of 1311

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

C411

LEFT HANDLE 5 PIN

B C A E D

C408 15

6010 PNK 6515 PNK 6415 PNK

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

6500 PNK 6400 PNK

C408 36

6010 PNK 6550 PNK 6500 PNK 6540 PNK 6400 PNK 6450 PNK

SHEET 8

C408 29 SHEET 8

C103 E

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS

1410 RED/WHT

SHEET 3 D1

1410 RED/WHT 1430 RED/WHT X

T3 FLASHER CONN

L D2

6430 PNK

6570 PNK 2725 BLK

(PINS 3 & 6 INTERNALLY INSULATED)

C103 D

OPTIONS

C408 26

6530 PNK

SW3 HAZARD SWITCH

6410 PNK 6510 PNK

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

2 5

1 3 4 6

2780 BLK C408 30

SHEET 4

C670

2850 BLK

6700 PNK 2420 BLK

2780 BLK 6440 PNK 6540 PNK

Dealer Copy -- Not for

SHEET 3

SHEET 4

C412 LEFT HANDLE 2 PIN

B A

7210 WHT 1460 RED/WHT

C408 38

E D C A F B

STROBE BEACON

B A

SW2 BEACON SWITCH 6 5 4 1 2 3

PWR BOB CLOSE C607

C355 E 7010/WHT OR 4470/LGN 2770 BLK OR 2470/BLK 2751/BLK OR 2770/BLK 2751/BLK OR 2770/BLK 2290 BLK SHEET 4 SHEET 12 C355 B A B

C606

B 2775/BLK OR 2480/BLK A 7000 WHT

C408 13

1550 RNG/WHT 7022 WHT

SHEET 4

C355 F

PWR BOB OPEN

RIGHT ResaleBLINKER

C126

2785 BLK 7210 WHT

1380 RED/WHT 1200 RED/WHT

LEFT BLINKER

1550 RNG/WHT

SW5 POWER BOBTACH SWITCH 7000/WHT OR 4480/LGN C408 97000/WHT OR 4480/LGN 1 2 3 C408 10 7010/WHT OR 4470/LGN 4 7010/WHT OR 4470/LGN 5 6

2830 BLK

3 1 4

2 5

SW6 BUCKET POSITION SWITCH C423

6

C408 35

7022 WHT

SHEET 3 SHEET 4

2741 BLK

D3

7030 WHT

A

2740 BLK

B

OPTIONAL BUCKET POSITION SOLENOID 9.8 OHM

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 13 of 13 Printed In U.S.A.

(PRINTEDNOVEMBER 2010) 7175752

691 of 1311

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C209 C212

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN CAB ACCESSORY DOME LIGHT POWER SOCKET

C252 C277 C278 C279 C308 C350 C355 C404 C405 C406 C408 C409 C410 C411 C412 C415 C418 C419 C420 C421 C422

WASHER AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS BU ALARM-MFR HARN AIR FILTER SWITCH FUEL SENDER CAB - MFR HARN CONNECTOR RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY (FLSHR) LEFT HANDLE 2 WAY (HORN) HIGH FLOW SOLENOID FRONT ROD (MALE) FRONT BASE (FEMALE) HYD LOCK TILT SPOOL LOCK TILT SPOOL LCOK

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 3 2

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9

C423 C425 C426 C434-1 C434-2 C435-1 C435-2 C437 C441 C446 C449 C450 C479 C480

2 6 2 2 2 2 6 2 2 2 48 10 10 5 2 2 2 2

9 13 13 13 7 12 6,12,13 3,10 6 6 3-5,8,9,11-13 10 10 13 13 13 7 7

C482 C483 C486 C489 C499 C500 C503 C602 C603 C606 C607 C610 C611 C630 C635 C667 C670 C676

2 3 3

7 10 10

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS BUCKET POSITION 2 BRAKE SOLENOID 3 7 CAN (Remote Start Tool, ACD) LEFT WORKLIGHT 1 2 2 LEFT WORKLIGHT 2 2 RIGHT WORKLIGHT 1 2 RIGHT WORKLIGHT 2 2 TWO SPEED MAKEUP 2 TWO SPEED 2 HYDRAULIC FAN 4 LEFT JOYSTICK (CAB HARN) 4 RIGHT JOYSTICK (CAB HARN) 12 LEFT PANEL(BLACK) 12 LEFT PANEL(GRAY) SEATBAR SENSOR TEMP CONTROL SWITCH AC COMPRESSOR MFR ACCESSORY PTOL RH KEY SWITCH RH DLX PANEL LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT POWER BOBTACH OPEN POWER BOBTACH CLOSE HVAC DUCT FAN BLOWER MOTOR THERMOSTAT HEATER VALVE DOOR EXTERIOR BEACON RADIO

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 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 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

3 3 2 2 4 6 6 2 2 2 2 2 4 3 6 6 6 Dealer 6

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

NUM OF PINS 8 8 64

3 3 3,6,7,11,12

J1A J1B J2A J2B

GATEWAY CONTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER

34 26 34 26

3,6-8,10-13 3-10,13 7,10,13 3,4,5,7,10,13

SW1 SW2 SW3 SW4 SW5

BRAKE SWITCH BEACON SWITCH HAZARD SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH

6 6 6 6 6

8 13 13 9 13

SW6 SW9 SW10 SW11

BUCKET POSITION SWITCH TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

6 6 5 3

13 8 12 12

SHEET

CONN

DESCRIPTION

13 7 5 11 11 11 11 13 13 7 5 5 5,8 8

FC1 FC2 FRC1

9 12 12 3,4 8 8 5,8 11 11 13 13 12 12 12 12 9 13 Copy -13

T1 T2 T3

Not

BATT GROUND BUZZER GROUND FLASHER T6 BATT GROUND T8 BATT GROUND T13 BUZZER POWER T14 PRE HEATER RIGHT REAR WORK LIGHT(+) T15 T16 RIGHT REAR WORK LIGHT(-) LEFT REAR WORK LIGHT (+) T17 LEFT REAR WORK LIGHT (-) T18 T19 BACKUP ALARM for Resale T20 BACKUP ALARM (GND)

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CAB PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13

1 1 2

SHEET

4

1 1

8 13 4 4

1 1

8 6

1 1 1 1 1 1

11 11 11 11 10 10

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 1 of 13 (PRINTED APRIL 2014)

Printed In U.S.A. 692 of 1311

7197683

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

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) FUNCTION PIN FUNCTION HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS LIFT SPOOL LOCK RETURN B-2 UNSW BATT FUEL PULL RELAY B-3 UNSW BATT B-4 SWITCHED POWER OUT RELAY FUEL HOLD B-5 LIGHT 1 RELAY LIFT SPOOL LOCK B-6 GLOW PLUG RELAY TRACTION LOCK HOLD B-7 STARTER RELAY TILT SPOOL LOCK B-8 TRACTION PULL RELAY CAN LO 1 B-9 CAN HI 1 TILT SPOOL LOCK RETURN B-10 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR FUEL LEVEL B-12 B-13 TRACTION PULL RELAY FDBK BICS HYD LOCK HOLD B-14 GLOW PLUG RELAY FDBK CAN HI 2 B-15 ENGINE SPEED GROUND P1 B-16 AIR FILTER SWITCH GROUND P2 B-17 LIGHT 2 RELAY GROUND P3, SENSOR FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) B-19 PTOL LED FAN 2 OUTPUT PTOL SWITCH B-20 CAN LO 2 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY STATER RELAY FDBK B-22 RUN/ENTER B-23 SENSOR SUPPLY 8V B-24 START ENGINE SENSOR SUPPLY 5V B-25 ENGINE OIL PRESS TWO SPEED MAKEUP B-26 SPARE TWO SPEED COIL SPARE LIGHT 2 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP (8 VOLT) HYD OIL FILTER SW1

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 Dealer A-32 A-33 A-34

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) FUNCTION PIN FUNCTION B-1 FRONT AUX (F) RETURN B-2 REAR AUX (F) RETURN UNSW BATT B-3 UNSW BATT B-4 DIVERTED SOLENOID B-5 REAR AUX (F) B-6 RELIEF SOLENOID B-7 REAR AUX (M) B-8 CAN LO 1 B-9 CAN HI 1 B-10 REAR AUX (M) RETURN B-11 LH PADDLE RIGHT LH PADDLE LEFT B-12 RH RIGHT BUTTON UP B-13 FRONT AUX (F) B-14 B-15 GROUND B-16 GROUND B-17 HANDLE POT GND B-18 FRONT AUX (M) RETURN RH PWM POT SIGNAL B-19 FRONT AUX (M) B-20 B-21 RH TRIGGER B-22 LH RIGHT BUTTON DOWN SWITCHED POWER B-23 HANDLE POT POWER (8 VOLT) B-24 B-25 B-26 HIGH FLOW RETURN HIGH FLOW LH RIGHT BUTTON RH LEFT UP RH LEFT DOWN

Copy -- Not for Resale

HARNESS PART NUMBER S630, S650, T630, T650 7199263 MAINFRAME A770 7196824 MAINFRAME S750, S770, T750, T770 7196823 MAINFRAME 7196753 DLX CAB STD CAB 7195991 DLX FUEL 7184255 STD FUEL 7149219 6733370 S/R 7175271 TAILGATE DOM TRK BRAKE ADP 7165061 7159366 WHL 2 SPD ADP

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 2 of 13 (PRINTED APRIL 2014) Printed In U.S.A. 693 of 1311

7197683

1240 RED/WHT

POWER

C408 CAB-MFR HARN

1450 RED/WHT

17

1110 RED/WHT 1130 RED/WHT

2 3

1400 RED/WHT

1450 RED/WHT

1420 RED/WHT 1440 RED/WHT

FC1 FUSE CENTER

FUSE 1 25 A 1070 RED

+12V BATTERY

1120 RED/WHT FUSE 2 25 A

1025 RED MEGAFUSE 100.0 Amps

1160 RED/WHT

J1B GWY CTRLR

1150 RED/WHT

3

1180 RED/WHT

2

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 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

SHEET 8 C503 RH DLX PANEL SHEET 9 C667 DOOR HARNESS SHEET 8 C500 RH KEY SWITCH SHEET 8 C479 LH PANEL

J2B AUX CTRLR

FUSE 3 OPEN

BATT_CABLE

LEGEND

1010 RED

FUSE 4 OPEN

SHEET 6 STARTER

PARTIAL CONNECTOR

FC2 FUSE CENTER

FUSE 1 25 A

1190 RED

FUSE 2 25 A

1040 RED

CONNECTOR

1165 RED/WHT

SHEET 5 C426 REMOTE RUN, ACD 1410 RED/WHT

1490 RED/WHT

FUSE 3 OPEN FUSE 4 15 A

1290 RED

1460 RED/WHT 1370 RED/WHT

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET 13 C408 CAB-MFR CONN (OPTIONS) SHEET 13 C412 LH HANDLE HORN

SHEET #

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES)

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS SJC

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

FRC1 FUSE RELAY CENTER

1050 RED

FUSE 5 30 A 1060 RED SHEET 6 FRC1 PRE HEATER RELAY

FUSE 6 30 A

1310 RED

1350 RED/WHT 1360 RED/WHT

1030 RED

SHEET 6 FRC1 STARTER RELAY

FUSE 9 15 A

1320 RED/WHT

FUSE 10 20 A 1330 RED/WHT

1340 RED

SHEET 6 FRC1 FUEL SHUTOFF RELAY SHEET 7 FRC1 TRACTION LOCK RELAY SHEET 11 FRC1 REAR LIGH RELAY

Dealer Copy -- Not for Resale SHEET 11 FRC1 FRONT LIGHT RELAY

FUSE 11 25 A

1300 RED

FUSE1 25 A 1760 RNG/WHT

FUSE 2 25 A FUSE 3 15 A

FUSE4 5 A

1140 RED/WHT 1750 RNG/WHT 1850 RNG/WHT 1550 RNG/WHT

SHEET 9 C408 CAB-MFR CONN (FR WIPER) SHEET 13 C408 CAB-MFR CONN (BKT POSITION)

43

FUSE 8 25 A FRC1 SWITCHED POWER RELAY 1050 RED

30 87

SHEET 6 SHEET 12

2055 BLK 2030 BLK

85

86

1765 RNG/WHT 1815 RNG/WHT

FUSE 12 15 A

J1A GWY CTRLR

3380 LBL

1560 RNG/WHT 1730 RNG/WHT 1580 RNG/WHT

1800 RNG/WHT 1790 RNG/WHT

C408 CAB-MFR HARN

4 1920 RNG/WHT

6

1520 RNG/WHT

1920 RNG/WHT

SHEET 10 C410 LEFT HANDLE SHEET 10 C409 RIGHT HANDLE

22

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)

SHEET 12 FRC1 HVAC RELAY

1840 RNG/WHT 1830 RNG/WHT

SHEET 5 C449 LH JOYSTICK SHEET 5 C450 RH JOYSTICK

C489 MFR ACCESSORY

1620 RNG/WHT 1940 RNG/WHT

1930 RNG/WHT 1775 RNG/WHT

1660 RNG/WHT

1590 RNG/WHT

1950 RNG/WHT

SHEET 5 C426 REMOTE RUN, ACD

SHEET 6 C110 ALT EXCITATION

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

C408 CAB-MFR HARN

1660 RNG/WHT

1570 RNG/WHT 1795 RNG/WHT

A

1780 RNG/WHT

1530 RNG/WHT

FUSE 7 25 A

B

1720 RNG/WHT

SHEET 12 FRC1 HVAC RELAY

J2B AUX CTRLR

1785 RNG/WHT

1960 RNG/WHT

SHEET 8 C479 LH PANEL SHEET 8 T13 LH PANEL BUZZER SHEET 8 C499 RH PANEL PTOL SHEET 8 SW1 BRAKE SWITCH SHEET 8 C503 RH DELUXE PANEL SHEET 8 C500 RH PANEL KEY SWITCH SHEET 9 SW4 H/ISO SWITCH SHEET 8 SW9 TRAVEL CONTROL SWITCH

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 3 of 13 Printable Version Click Here (PRINTED APRIL 2014)

Printed In U.S.A. 694 of 1311

7197683

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 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 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

2080 BLK SHEET 5 C449 LH JOYSTICK 2070 BLK SHEET 5 C450 RH JOYSTICK 2920 BLK SHEET 8 C479 LH PANEL 2940 BLK SHEET 8 C499 PTOL 2960 BLK SHEET 8 C500 RH PANEL KEY SWITCH 2250 BLK SHEET 8 C503 RH DELUXE PANEL

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

ACS SJC

PAGE 14 PAGE 15

2620 BLK SHEET 11 T16 RH REAR LIGHT 2630 BLK SHEET 11 T18 LH REAR LIGHT 2650 BLK SHEET 10 T20 BU ALARM 2640 BLK SHEET 11 C602 LH REAR LIGHT 2610 BLK SHEET 11 C603 RH REAR LIGHT

2950 BLK

32

2900 BLK

16

2510 BLK

J1B GWY CTRLR 15

2500 BLK

42

2140 BRN SHEET 6 C107 ENG OIL PRESS SENDER 2150 BRN SHEET 6 C405 AIR FILTER SWITCH

695 of 1311

Printed In U.S.A.

2110 BLK

T6 BATT GND

2765 BLK SHEET 11 C408 CAB-MFR CONN (FR LIGHTS) 2745 BLK SHEET 12 C408 CAB-MFR CONN (HVAC) 2790 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES) 2780 BLK SHEET 13 C408 CAB-MFR CONN (OPTIONS) 2730 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)

2540 BLK 2090 BLK

2550 BLK 2900 BLK

SHEET 11 FRC1 FRONT LIGHT RELAY C103 TAILGATE HARN

2600 BLK

B

J1B GWY CTRLR

2230 BRN

17

2105 BLK

T8 BATT GND

T1 BATT GND C489 MFR ACCESSORY

B

2720 BLK

2600 BLK 2400 BLK SHEET 6 C101 FUEL SHUTOFF SOLENOID 2200 BLK SHEET 7 C425 BRAKE 2770 BLK SHEET 13 C355 FUEL HARN (PWR BOB/AC) 2455 BLK SHEET 13 C423 BKT POSITION SOLENOID 2710 BLK SHEET 5 C426 REMOTE RUN, ACD

2320 BRN SHEET 7 C112 HYD OIL FILTER SWITCH 2370 BRN SHEET 9 C408 CAB-MFR CONN (SEATBAR SENSOR)

2180 BRN SHEET 6 C355 FUEL HARN (FUEL SENDER)

SHEET #

Dealer Copy -- Not for Resale

2160 BRN SHEET 6 C106 ENGINE SPEED SENSOR

2190 BRN SHEET 7 C105 HYD CHG PRESSURE SENDER

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

2950 BLK

J2B 15 AUX CTRLR

2170 BRN SHEET 6 C104 ENGINE COOLANT SENSOR

2220 BRN SHEET 7 C108 HYD TEMP SENDER

GROUND

CONNECTOR

C408 CAB-MFR HARN

16 2930 BLK SHEET 8 SW1 BRAKE SWITCH 2830 BLK SHEET 13 SW6 BKT POSITION SWITCH 2700 BLK SHEET 8 SW9 TRAVEL CONTROL SWITCH 2785 BLK SHEET 13 C126 HORN

PARTIAL CONNECTOR

2390 BLK

2300 BLK

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 4 of 13 (PRINTED APRIL 2014) 7197683

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS SJC

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 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 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

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

J1B GWY CTRLR

CAN LO CAN HI

8 9

PARTIAL CONNECTOR

CAN BUS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

* DLX CAB HARN 7196753 ONLY (NOT IN STD CAB HARN 7165991)

SHEET #

C408 CAB-MFR HARN

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9230 PUR 9130 PUR/WHT

9230 PUR 9130 PUR/WHT

8 7

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

120 OHM RESISTOR

C426 Remote Run Tool, ACD

14

CAN HI 20 CAN LO

21

SHEET 3 SHEET 3 SHEET 4

9500 PUR/WHT 9600 PUR 3090 LBL 1730 RNG/WHT 1165 RED/WHT 2710 BLK

A B D C E F G

4 3

C479 LEFT PANEL (BLACK)

4 2

C503 RIGHT DELUXE PANEL

120 OHM RESISTOR

9260 PUR 9160 PUR/WHT

Dealer Copy -- Not for Resale

REMOTE RUN KEY

SHEET 3 SHEET 4

SWITCHED POWER UNSWITCHED POWER GROUND

9630 PUR 9530 PUR/WHT

9220 PUR 9120 PUR/WHT

8 9

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1 2 3 4

C450 RIGHT JOYSTICK (SJC/AWS ONLY)

1840 RNG/WHT 2080 BLK 9540 PUR/WHT 9640 PUR

1 2 3 4

C449 LEFT JOYSTICK (SJC/AWS ONLY)

*

J2B AUX CTRLR

SHEET 3 SHEET 4

*

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 5 of 13 (PRINTED APRIL 2014) Printed In U.S.A. 696 of 1311

7197683

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

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 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 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

1030 RED

SHEET 3

FRC1 STARTER RELAY 30 87

ACS SJC

2005 BLK

SHEET 12

86

PARTIAL CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

C109 S/R ADAPTER

8200 TAN

ENGINE

CONNECTOR

PAGE 14 PAGE 15

3560 LBL 85

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

STARTER

A B

TAN TAN

S R

8210 TAN

M

B

SHEET 3 1015 RED C110

B ALTERNATOR

S L

G

1020 RED 1800 RNG/WHT

SHEET 3

EXCITATION

2015 BLK FRC1 FUEL PULL RELAY 1350 RED/WHT

SHEET 3

30 87

2025 BLK

SHEET 7

1060 RED

SHEET 3

2016 BLK 2055 BLK

SHEET 3 6

85

86

FRC1 GLOW PLUG RELAY 30 87 85

C101 D5

8120 TAN 3410 LBL SHEET 4

2400 BLK

FUEL SHUTOFF SOLENOID

8100 TAN

B

PULL

2800 BLK

C

GND

8800 TAN

A

HOLD

0.33 OHM

8110 TAN 24.5 OHM

T14 PRE HEATER

8500 TAN

Dealer Copy -- Not for Resale

86

8510 TAN

14

3420 LBL

3

8110 TAN

30

3410 LBL

7

8210 TAN

22

3560 LBL C107

SHEET 9

J1A GWY CTRLR 25

SHEET 4

5140 YEL 3140 LBL 2140 BRN

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

C405

SHEET 4

16

2150 BRN 3150 LBL

B A

GND SIG

AIR FILTER SWITCH (NC)

Printable Version Click Here

C106

15

3160 LBL 2160 BRN

SHEET 4

A B

SIG GND

ENGINE SPEED SENSOR (163 OHM)

C104

18 4

GND SIG

C355 FUEL HARN

12 SHEET 4

Printed In U.S.A.

B A

ENGINE COOLANT SENSOR (500-3000 OHM) (8 VOLT)

8800 TAN

J1B GWY CTRLR

697 of 1311

2170 BRN 3170 LBL

SHEET 4

3180 LBL 2180 BRN

C D

C406

3180 LBL OR 3100, LBL 2180 BRN OR 3110, LBL

A B

SIG GND

FUEL SENDER (30 - 270 OHM)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 6 of 13 (PRINTED APRIL 2014) 7197683

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 LIGHT GREEN LGN 4000 THROUGH 4999 YEL CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW PINK PNK LIGHTS 6000 THROUGH 6999 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN TAN COMMUNICATION 9000 THROUGH 9999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

SHEET 3 SHEET 6 SHEET 11

FRC1 TRACTION LOCK RELAY 30 1360 RED/WHT 3430 LBL 87 2025 BLK 85 86 2035 BLK 4110 LGN

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS SJC

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

PARTIAL CONNECTOR

HYDRAULICS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

4100 LGN SHEET 4

4200 LGN 2200 BLK

C425

B A C

C308

4200 LGN 2200 BLK

A B

BRAKE SOLENOID 9.8 OHM 12 V

WHEEL 2 SPD ADAPTER HARNESS 7159366 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

C425

B A C

8

PULL HOLD

0.3 OHM 10.9 OHM WHEEL SINGLE SPEED TRACTION LOCK

13 C108

SHEET 4

32

2220 BRN 3220 LBL

B A

GND SIG

C112 J1A GWY CTRLR

34 SHEET 4

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

Dealer Copy -- Not for Resale

HYDRAULIC FAN SOLENOID 7.2 OHM 12 V

C420

B A

GND SIG

HYDRAULIC LOCK SOLENOID 9.8 OHM 12 V

C105

SHEET 4

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

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. 698 of 1311

2 1

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 7 of 13 (PRINTED APRIL 2014) 7197683

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 TAN TAN ENGINE 8000 THROUGH 8999 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 ACS SJC

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

CAB DISPLAY

CONNECTOR

* DLX CAB HARN 7196753 ONLY (NOT IN STD CAB HARN 7165991)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

PAGE 14 PAGE 15

T13 BUZZER (+)

SHEET 3

1940 RNG/WHT

7040 WHT OR 9320, PUR

C479 LEFT PANEL (BLACK)

T2 BUZZER (-)

7040 WHT OR 9320, PUR

10

2920 BLK

2

1440 RED/WHT

1

1620 RNG/WHT

5

3400 LBL

11

3500 LBL

8

3650 LBL

7

3600 LBL OR 4500, LGN

9 6

SHEET 4 SHEET 3

1960 RNG/WHT

SHEET 3

*

SW9 TRAVEL CONTROL SWITCH (OPTIONAL)

SHEET 4

2700 BLK

SHEET 3 SHEET 13

5 6 4 2 3 1

3610 LBL OR 9310, PUR 1775 RNG/WHT SHEET 3 2930 BLK SHEET 4

C499 Press To Operate Loader (PTOL)

LEFT PANEL BUZZER

SHEET 13

3 1 4

SW1 2 BRAKE SWITCH

BUZZER

UNSWITCHED POWER

20

3030 LBL

1

3030 LBL OR 9380, PUR

2

SWITCHED POWER

19

2380 BRN

37

2380 BRN OR 9370, PUR

4

J1A GWY CTRLR

LEFT BLINKER INPUT RIGHT BLINKER INPUT

24

8130 TAN

4

8130 TAN OR 9360, PUR

PARK BRAKE INPUT

22

3040 LBL

40

3040 LBL OR 9350, PUR

6 3620 LBL

3610 LBL OR 9310, PUR

12 11 10 9 2 8 7 6 5 4 3 1

DOOR SIGNAL

PTOL LED

2

START

6 J1B GWY CTRLR

C480 LEFT PANEL (GRAY)

PTOL OUTPUT

C500 RIGHT KEY SWITCH PANEL

Dealer Copy -- Not for Resale

TRAVEL CONTROL INPUT

12

SWITCHED POWER GROUND

C408 CAB-MFR HARN

GROUND

5

SHEET 9

1 3

1930 RNG/WHT 2940 BLK

SHEET 3 SHEET 4

SHEET 3 SHEET 3 SHEET 4

1950 RNG/WHT 1420 RED/WHT 2960 BLK

4 5 1 3

RUN/ENTER SWITCH

SWITCHED POWER UNSWITCHED POWER GROUND

C503 RIGHT DELUXE PANEL PARK BRAKE OUTPUT

SHEET 3 SHEET 3 SHEET 4

1590 RNG/WHT

5

1240 RED/WHT

1

2250 BLK

3

SWITCHED POWER UNSWITCHED POWER GROUND

6

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 8 of 13 Printable Version Click Here (PRINTED APRIL 2014) 699 of 1311

Printed In U.S.A.

7197683

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 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

ACS SJC

LEGEND

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

CAB

CONNECTOR

* DLX CAB HARN 7196753 ONLY (NOT IN STD CAB HARN 7165991)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

PAGE 14 PAGE 15

SHEET #

*

SHEET 3 SHEET 9

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH 1785 RNG/WHT 2 1 3 2060 BLK 5 6 4

C408 CAB-MFR HARN

SHEET 4 SHEET 3

2790 BLK 1370 RED/WHT

2

4235 LGN

3

4275 LGN

5

4550 LGN

24 23

*

C212 POWER SOCKET

1 2

2795 BLK 1375 RED/WHT

2790 BLK

2790 BLK 1370 RED/WHT

*

GND +12V PWR

C209

2010 BLK 1390 RED/WHT 3640 LBL

B A C

GND +12V PWR DOOR SIG

DOME LIGHT

C129 CAB ACCESSORY

1210 RED/WHT SHEET 3

1580 RNG/WHT

16

1580 RNG/WHT

A B C

1865 RNG/WHT 2820 BLK 1510 RNG/WHT

+12V BATT PWR +12V SW PWR

Dealer Copy -- Not for Resale

GND

SHEET 13 SHEET 13

1885 RNG/WHT

2210 BLK

SHEET 13

2885 BLK 2060 BLK SHEET 4

2730 BLK

33

SHEET 13 SHEET 9

2730 BLK

3620 LBL 1400 RED/WHT

SHEET 8 SHEET 3

*

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

3630 LBL

4 5

DOOR SIGNAL DOOR UNSW PWR

6

SHEET 3

1850 RNG/WHT

27 1850 RNG/WHT C482

J1B GWY CTRLR

SHEET 4

11

+5V

24

2370 BRN 3370 LBL

5100 YEL 5140 YEL SHEET 6

5370 YEL

45

2370 BRN OR 3910, LBL

A

GND

SEATBAR SENSOR

46

3370 LBL OR 3920, LBL

B

SIG

44

5370 YEL OR 3900, LBL

C

+5V PWR

* 2845 BLK

1850 RNG/WHT

1

2840 BLK

2

7310 WHT

3

WIPER SWITCH, MOTOR SWITCHED POWER WIPER MOTOR GROUND WASHER SIGNAL

C252

L

SIG

X

GND

WASHER MOTOR

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 9 of 13 Printable Version Click Here (PRINTEDAPRIL 2014)

700 of 1311

Printed In U.S.A.

7197683

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 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 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

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS SJC

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

PARTIAL CONNECTOR

MANUAL CONTROLS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

C409 RIGHT HANDLE J2A AUX CTRLR

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

A

30 31

C103 TAILGATE HARN

7100 WHT

C

T19 TERMINAL (+)

SHEET 3

13

7100 WHT

SHEET 4

BACK UP ALARM

2650 BLK

1520 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

K G A H J E F C D B

SKI CTRL DETENT FLOW TWO SPD PWM (8 VOLT)

T20 TERMINAL (-)

Dealer Copy -- Not for Resale

3 1 2

GND SIG

TILT SPOOL LOCK 7.8 OHM 12V

C422

2680 BRN 4680 LGN

2

7

3 1 2

C410 LEFT HANDLE

J2B AUX CTRLR

C421

2670 BRN 4670 LGN

10 J1A GWY CTRLR

21 17 18 23

GND SIG

LIFT SPOOL LOCK 7.8 OHM 12V

28 22 12 11 SHEET 3

4840 LGN 4830 LGN 4820 LGN 4810 LGN 1530 RNG/WHT

K D C B G F A J H E

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 10 of 13 Printable Version Click Here (PRINTED APRIL 2014)

701 of 1311

SIDE SHIFT

5

J1B GWY CTRLR

Printed In U.S.A.

SKI CTRL

7197683

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS SJC

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 YEL CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW PINK PNK LIGHTS 6000 THROUGH 6999 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

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

LIGHTS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

PAGE 14 PAGE 15

C434-1

2735 BLK 6100 PNK

C408 CAB-MFR HARN

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 4

2765 BLK

28

2765 BLK

2750 BLK 6110 PNK

6000 PNK

25

6000 PNK

6120 PNK 2760 BLK

B A

C435-1

A B C435-2

6130 PNK 2705 BLK

FRC1 FRONT WORK LIGHTS RELAY 1330 RED/WHT

SHEET 3

30 87

2105 BLK 2045 BLK

SHEET 4

85

C103 TAILGATE HARN

6340 PNK

C603

Dealer Copy -- Not forA Resale 6310 PNK 6310 PNK

SHEET 4

5 31 17 28

2610 BLK 6320 PNK

86 6330 PNK 2640 BLK

2620 BLK 6210 PNK

SHEET 7

GND SIG

RIGHT REAR TAIL LIGHT

1 2

SIG GND

LEFT REAR TAIL LIGHT

6320 PNK 3460 LBL 6210 PNK 3440 LBL

SHEET 4

SHEET 3

2 1 C602

SHEET 4

J1A GWY CTRLR

A B

1320 RED/WHT

2045 BLK 2035 BLK

FRC1 REAR LIGHT RELAY 30 87 85

86

T16 TERMINAL (-) GND SIG

RIGHT REAR WORK LIGHT

T15 TERMINAL (+)

6200 PNK

H

T17 TERMINAL (+) SIG

6200 PNK SHEET 4

2630 BLK

GND

LEFT REAR WORK LIGHT

T18 TERMINAL (-)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 11 of 13 Printable Version Click Here (PRINTED APRIL 2014) 702 of 1311

Printed In U.S.A.

7197683

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 LIGHTS 6000 THROUGH 6999 PINK PNK WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

ACS SJC

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

PARTIAL CONNECTOR

HVAC

CONNECTOR

SHEET #

2440 BLK *

*

2 1

C A B

1140 RED/WHT

SHEET 3

21

85

2030 BLK 2005 BLK 1790 RNG/WHT

SHEET 3 SHEET 6 SHEET 3

1500 RNG/WHT

22

SWITCH

Dealer Copy -- Not for Resale

OFF 5 2 1 4 6 3 7410 WHT SW11 AC SWITCH

*

2745 BLK 7015 WHT 2100 BLK

7020 WHT

7021 WHT

C350

B A

1 C

*

7530 WHT 7520 WHT 7510 WHT 2580 BLK

C611

1 2 3 4

14.00 Amps 7.50 Amps 5.00 Amps

7400 WHT

C630

3 2 1

THERMOSTAT

Printable Version Click Here C355 FUEL HARN

A SHEET 13

7024 WHT 2290 BLK

# 7025 WHT 2280 BLK D4

C486

1 2

SIG GND

MAGNET CLUTCH (COMPRESSOR)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 12 of 13 (PRINTED APRIL 2014)

703 of 1311

BLOWER MOTOR

3

2570 BLK 7020 WHT

7023 WHT 7024 WHT

Printed In U.S.A.

High Med Low

34

* AC EVAPORATOR SWITCH

HEATER VALVE

SW10 *BLOWER

3450 LBL 2745 BLK

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

POTENTIOMETER (TEMP CONTROL SWITCH)

D SIG C GND A +12V PWR B E F

21 1500 RNG/WHT

J1A GWY CTRLR

11

BLK DBL WHT

86

SHEET 4

HVAC DUCT FAN

C635

2130 BLK 7430 WHT

C408 CAB-MFR HARN

GND SIG

C483

2560 BLK 7420 WHT 7425 WHT

*

#

C610

7440 WHT

FRC1 HVAC RELAY 30 87

* DLX CAB HARN 7196753 ONLY (NOT IN STD CAB HARN 7165991)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

7197683

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 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

# POWER BOB-TACH CLOSE

SIG GND

POWER BOB-TACH OPEN

SIG GND

E B

4470 LGN OR 7010, WHT 2470 OR 2770, BLK 2770 OR 2751, BLK

SHEET 12

#

ACS SJC

C355 FUEL HARN

C607

1 2

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

LEGEND PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

SHEET #

PAGE 14 PAGE 15

# 4470 LGN

2290 BLK

2480 OR 2775, BLK 4480 LGN OR 7000, WHT

4480 LGN

F

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

4480 LGN

SHEET 4

C606

2 1

* DLX CAB HARN 7196753 ONLY (NOT IN STD CAB HARN 7165991)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

C408 10 CAB-MFR HARN

4470 LGN 2770 BLK

OPTIONS

CONNECTOR

SW5 *POWER

2

1

BOBTACH SWITCH

5

3 4 6

9 1380 RED/WHT 1410 RED/WHT

SHEET 3

26

1410 RED/WHT

1200 RED/WHT

LEFT HANDLE (BLINKER / FLASHER) 5 PIN

6010 PNK

15

6515 PNK

6500 PNK

36

6415 PNK

6400 PNK

29

3500 LBL 6500 PNK 6540 PNK 6400 PNK 3400 LBL

SHEET 8

SHEET 8

D1

EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS SHEET)

E D

*

SW3 HAZARD SWITCH

2780 BLK

30

SHEET 3 SIG

A

4450 LGN

D3 4455 LGN

GND

B

2450 BLK

2455 BLK

1550 RNG/WHT

13

35

4455 LGN

SHEET 4

3 1 4 6

SHEET 4

7210 WHT 1460 RED/WHT

38

SHEET 4 2785 BLK 7210 WHT

B A

J2B AUX CTRLR

26

2460 BRN 4460 LGN

27

2360 BRN 4360 LGN

26

2350 BRN 4350 LGN

J1A GWY CTRLR

B A

GND SIG

2 5

SW6 *BUCKET

J1B GWY CTRLR

1 2

+

*

+

SIG

2 1

GND SIG

2 1

GND SIG

*

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V TRACK 2 SPEED TWO SPEED SOLENOID 5.1 OHM 12 V

ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

C676

3 4

E D F B C A

BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

FRONT HORN

RADIO CONN

C278

RIGHT SPEAKER GND

7820 WHT 7830 WHT

2420 BLK

C670

-

POSITION SWITCH

SHEET 9 SHEET 9

SHEET 9 SHEET 9

HIGH FLOW SOLENOID 7.5 OHM 12 V

C441

25 26

Printed In U.S.A.

2850 BLK

6

2 1

7810 WHT 7800 WHT 1885 RNG/WHT 2885 BLK

6 5 1 2

*

C437

704 of 1311

6700 PNK

SHEET 3

C415

26

1 3 4

C279

LEFT SPEAKER

C126

J2A AUX CTRLR

5

1550 RNG/WHT

2830 BLK

C412

B A

2

SWITCH 6 5 4 1 2 3

2725 BLK

2780 BLK 6440 PNK 6540 PNK

C423

LEFT HANDLE (HORN) 2 PIN

SW2 *BEACON

Dealer Copy -- Not for Resale SHEET 4

BUCKET POSITION SOLENOID 9.8 OHM

6430 PNK

(PINS 3 & 6 INTERNALLY INSULATED)

6410 PNK 6510 PNK

T3 FLASHER CONN

6530 PNK

D2

C103 TAILGATE HARN

*

L

6570 PNK

B C A E D

X

1430 RED/WHT 6010 PNK

C411

1510 RNG/WHT 2210 BLK

PWR GND

C277

1 2 3 4 5 6

PWR GND

AIR RIDE SEAT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV13099 - A3NV18204) (S/N A3NW11249 - A3NW12733) Sheet 13 of 13 Printable Version Click Here (PRINTED APRIL 2014) 7197683

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C209 C212 C252

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN CAB ACCESSORY DOME LIGHT POWER SOCKET WASHER

C277 C278 C279 C308 C350 C355 C404 C405 C406 C408 C409 C410 C411 C412 C415 C418 C419 C420 C421 C422 C423

AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS BU ALARM-MFR HARN AIR FILTER SWITCH FUEL SENDER CAB-MFR HARN CONN (BLK) RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY (FLSHR) LEFT HANDLE 2 WAY (HORN) HIGH FLOW SOLENOID FRONT ROD FRONT BASE HYD LOCK TILT SPOOL LOCK TILT SPOOL LCOK BUCKET POSITION

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 3 2 2

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9 9

C425 C426 C428 C434-1 C434-2 C435-1 C435-2 C437 C438 C441 C446 C449 C450 C479 C480

6 2 2 2 2 6 2 2 2 14 10 10 5 2 2 2 2

13 13 13 7 12 6,12,13 3,10 6 6 3-5,8,9,11,13 10 10 13 13 13 7 7

2 3 3 2

7 10 10 13

C482 C483 C486 C489 C499 C500 C503 C602 C603 C606 C607 C610 C611 C630 C635 C667 C670 C676

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS BRAKE SOLENOID 3 7 CAN (Remote Start Tool, ACD) CAB-MFR HARN CONN (LT GRY) 14 2 LEFT WORKLIGHT 1 LEFT WORKLIGHT 2 2 2 RIGHT WORKLIGHT 1 RIGHT WORKLIGHT 2 2 2 TWO SPEED MAKEUP CAB-MFR HARN CONN (DK GRY) 14 2 TWO SPEED 2 HYDRAULIC FAN 4 LEFT JOYSTICK (CAB HARN) 4 RIGHT JOYSTICK (CAB HARN) 12 LEFT PANEL(BLACK) 12 LEFT PANEL(GRAY) SEATBAR SENSOR TEMP CONTROL SWITCH AC COMPRESSOR MFR ACCESSORY PTOL RH KEY SWITCH RH DLX PANEL LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT POWER BOBTACH OPEN POWER BOBTACH CLOSE HVAC DUCT FAN BLOWER MOTOR THERMOSTAT HEATER VALVE DOOR EXTERIOR BEACON RADIO

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 BRN CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN LBL MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC LIGHT GREEN LGN 4000 THROUGH 4999 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

3 3 2 2 4 6 6 2 2 2 2 2 4 3 6 Dealer 6 6 6

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

NUM OF PINS 8 8 64

3 3 3,6,7,11,12

J1A J1B J2A J2B

GATEWAY CONTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER

34 26 34 26

3,6-8,10-13 3-10,13 7,10,13 3,4,5,7,10,13

SW1 SW2 SW3 SW4 SW5

BRAKE SWITCH BEACON SWITCH HAZARD SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH

6 6 6 6 6

8 13 13 9 13

SW6 SW9 SW10 SW11

BUCKET POSITION SWITCH TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

6 6 5 3

13 8 12 12

1 1 2

4

SHEET

CONN

DESCRIPTION

7 5 3,4,9,13 11 11 11 11 13 9,12,13 13 7 5 5 5,8 8

FC1 FC2 FRC1

9 12 12 3,4 8 8 5,8 11 11 13 13 12 12 12 12 Copy -9 13 13

T1 T2 T3 T6 T8 T13 T14 T15 T16

Not

BATT GROUND BUZZER GROUND FLASHER BATT GROUND BATT GROUND BUZZER POWER PRE HEATER RIGHT REAR WORK LIGHT(+) RIGHT REAR WORK LIGHT(-) T17 for ResaleLEFT REAR WORK LIGHT (+) LEFT REAR WORK LIGHT (-) T18 T19 BACKUP ALARM T20 BACKUP ALARM (GND)

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CAB PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13

SHEET

1 1

8 13 4 4 8 6

1 1 1 1 1 1

11 11 11 11 10 10

1 1

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 1 of 13 (PRINTED APRIL 2014)

Printed In U.S.A. 705 of 1311

7210766 (A)

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

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) FUNCTION PIN FUNCTION HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS B-2 LIFT SPOOL LOCK RETURN UNSW BATT FUEL PULL RELAY B-3 UNSW BATT B-4 SWITCHED POWER OUT RELAY FUEL HOLD LIGHT 1 RELAY B-5 LIFT SPOOL LOCK GLOW PLUG RELAY B-6 TRACTION LOCK HOLD B-7 STARTER RELAY TILT SPOOL LOCK B-8 TRACTION PULL RELAY CAN LO 1 B-9 CAN HI 1 TILT SPOOL LOCK RETURN B-10 B-11 SPARE DIGITAL, ECU SINKS SEAT BAR B-12 FUEL LEVEL B-13 TRACTION PULL RELAY FDBK BICS HYD LOCK HOLD GLOW PLUG RELAY FDBK B-14 CAN HI 2 ENGINE SPEED B-15 GROUND P1 B-16 AIR FILTER SWITCH GROUND P2 B-17 LIGHT 2 RELAY GROUND P3, SENSOR FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) PTOL LED B-19 FAN 2 OUTPUT B-20 PTOL SWITCH CAN LO 2 B-21 SWITCHED POWER OUT RELAY FDBK REMOTE KEY B-22 STATER RELAY FDBK RUN/ENTER B-23 SENSOR SUPPLY 8V START ENGINE B-24 SENSOR SUPPLY 5V B-25 ENGINE OIL PRESS TWO SPEED MAKEUP B-26 SPARE TWO SPEED COIL SPARE LIGHT 2 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP (8 VOLT) HYD OIL FILTER SW1

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 Dealer A-31 A-32 A-33 A-34

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) FUNCTION PIN FUNCTION B-1 FRONT AUX (F) RETURN B-2 REAR AUX (F) RETURN UNSW BATT B-3 UNSW BATT B-4 DIVERTED SOLENOID B-5 REAR AUX (F) B-6 RELIEF SOLENOID B-7 REAR AUX (M) B-8 CAN LO 1 B-9 CAN HI 1 B-10 REAR AUX (M) RETURN B-11 LH PADDLE RIGHT LH PADDLE LEFT B-12 RH RIGHT BUTTON UP B-13 FRONT AUX (F) B-14 B-15 GROUND B-16 GROUND B-17 HANDLE POT GND B-18 FRONT AUX (M) RETURN RH PVM POT SIGNAL B-19 FRONT AUX (M) B-20 B-21 RH TRIGGER LH RIGHT BUTTON DOWN B-22 SWITCHED POWER B-23 HANDLE POT POWER B-24 B-25 HIGH FLOW RETURN B-26 HIGH FLOW LH RIGHT BUTTON RH LEFT UP

Copy -- Not for Resale RH LEFT DOWN

HARNESS PART NUMBER S630, S650, T630, T650 7210764 MAINFRAME A770 7210768 MAINFRAME S750, S770, T750, T770 7210768 MAINFRAME DLX CAB 7210556 7210577 STD CAB DLX FUEL 7184255 7149219 STD FUEL S/R 6733370 7217484 TAILGATE DOM TRK BRAKE ADP 7165061 7159366 WHL 2 SPD ADP

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 2 of 13 (PRINTED APRIL 2014)

Printed In U.S.A. 706 of 1311

7210766 (A)

1240 RED/WHT C408 (BLACK) CAB-MFR HARN CONN 1

POWER

1450 RED/WHT

6

1110 RED/WHT 1130 RED/WHT

2 3

1400 RED/WHT

1450 RED/WHT

1440 RED/WHT

FC1 FUSE CENTER

FUSE 1 25 A 1070 RED

+12V BATTERY

1120 RED/WHT FUSE 2 25 A

1025 RED MEGAFUSE 100.0 Amps

1420 RED/WHT

1160 RED/WHT

J1B GWY CTRLR

1150 RED/WHT

3

1180 RED/WHT

2

SHEET 9 C667 DOOR HARNESS SHEET 8 C500 RH KEY SWITCH SHEET 8 C479 LH PANEL

J2B AUX CTRLR

FUSE 3 OPEN

BATT_CABLE

LEGEND

1010 RED

FUSE 4 OPEN

SHEET 6 STARTER

PARTIAL CONNECTOR

FC2 FUSE CENTER

FUSE 1 25 A

1190 RED

FUSE 2 25 A

1040 RED

CONNECTOR

1165 RED/WHT

SHEET 5 C426 REMOTE RUN, ACD 1410 RED/WHT

1490 RED/WHT

FUSE 3 OPEN FUSE 4 15 A

1290 RED

1460 RED/WHT 1370 RED/WHT

FUSE 5 30 A 1060 RED SHEET 6 FRC1 PRE HEATER RELAY

FUSE 6 30 A

1310 RED

1030 RED SHEET 6 FRC1 STARTER RELAY

FUSE 9 15 A

SHEET 13 C412 LH HANDLE HORN

SHEET #

FUSE 11 25 A

1300 RED

FUSE1 25 A 1760 RNG/WHT

FUSE 2 25 A FUSE 3 15 A

1350 RED/WHT

SHEET 6 FRC1 FUEL SHUTOFF RELAY SHEET 7 FRC1 TRACTION LOCK RELAY

1360 RED/WHT

1320 RED/WHT

SHEET 11Copy -- Not for Resale Dealer FRC1 REAR LIGH RELAY

1140 RED/WHT

SHEET 11 FRC1 FRONT LIGHT RELAY SHEET 12 FRC1 HVAC RELAY

1850 RNG/WHT 1550 RNG/WHT

SHEET 13 C408 CAB-MFR CONN (BKT POSITION)

FUSE 8 25 A

FRC1 SWITCHED POWER RELAY +12V PWR

1765 RNG/WHT 1815 RNG/WHT 30 87

2055 BLK GND

85

86

FUSE 12 15 A

J1A GWY CTRLR

3450 LBL 3380 LBL

21 4

1580 RNG/WHT

1800 RNG/WHT 1790 RNG/WHT

C428 (LT GRAY) CAB-MFR HARN CONN 2

1920 RNG/WHT

6

1920 RNG/WHT

C489 MFR ACCESSORY

1520 RNG/WHT

SHEET 10 C410 LEFT HANDLE SHEET 10 C409 RIGHT HANDLE

22

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)

SHEET 12 FRC1 HVAC RELAY

1840 RNG/WHT 1830 RNG/WHT

SHEET 5 C449 LH JOYSTICK SHEET 5 C450 RH JOYSTICK

1940 RNG/WHT 1930 RNG/WHT

1590 RNG/WHT 1950 RNG/WHT

SHEET 5 C426 REMOTE RUN, ACD

SHEET 6 C110 ALT EXCITATION

1620 RNG/WHT

1775 RNG/WHT 1660 RNG/WHT

2

1560 RNG/WHT 1730 RNG/WHT

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

C428 (LT GRAY) CAB-MFR HARN CONN 2

1660 RNG/WHT

1570 RNG/WHT FUSE 7 25 A

A

1780 RNG/WHT SHEET 9 C408 CAB-MFR CONN (FR WIPER)

1530 RNG/WHT

1795 RNG/WHT

B

1720 RNG/WHT

1750 RNG/WHT

FUSE4 5 A

J2B AUX CTRLR

1785 RNG/WHT 1960 RNG/WHT

SHEET 8 C479 LH PANEL SHEET 8 T13 LH PANEL BUZZER SHEET 8 C499 RH PANEL PTOL SHEET 8 SW1 BRAKE SWITCH SHEET 8 C503 RH DELUXE PANEL SHEET 8 C500 RH PANEL KEY SWITCH SHEET 9 SW4 H/ISO SWITCH SHEET 8

SW9 TRAVEL CONTROL SWITCH WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 3 of 13 Printable Version Click Here

(PRINTED APRIL 2014) 707 of 1311

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES)

FUSE 10 20 A 1330 RED/WHT

1340 RED

SHEET 4

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET 13 C408 CAB-MFR CONN (OPTIONS)

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

FRC1 FUSE RELAY CENTER

1050 RED

1050 RED

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 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

SHEET 8 C503 RH DLX PANEL

Printed In U.S.A.

7210766 (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 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 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

2080 BLK SHEET 5 C449 LH JOYSTICK 2070 BLK SHEET 5 C450 RH JOYSTICK 2920 BLK SHEET 8 C479 LH PANEL 2940 BLK SHEET 8 C499 PTOL 2960 BLK SHEET 8 C500 RH PANEL KEY SWITCH 2250 BLK SHEET 8 C503 RH DELUXE PANEL

2930 BLK SHEET 8 SW1 BRAKE SWITCH 2830 BLK SHEET 13 SW6 BKT POSITION SWITCH 2700 BLK SHEET 8 SW9 TRAVEL CONTROL SWITCH 2785 BLK SHEET 13 C126 HORN 2620 BLK SHEET 11 T16 RH REAR LIGHT 2630 BLK SHEET 11 T18 LH REAR LIGHT 2650 BLK SHEET 10 T20 BU ALARM 2640 BLK SHEET 11 C602 LH REAR LIGHT 2610 BLK SHEET 11 C603 RH REAR LIGHT

2950 BLK

2140 BRN SHEET 6 C107 ENG OIL PRESS SENDER 2150 BRN SHEET 6 C405 AIR FILTER SWITCH

708 of 1311

Printed In U.S.A.

GROUND

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

2950 BLK 16

2510 BLK

J1B GWY CTRLR 15

C428 (LT GRAY) CAB-MFR HARN CONN 2

2900 BLK

2110 BLK

T6 BATT GND

2500 BLK

16

2540 BLK

J2B 15 AUX CTRLR

2550 BLK

1

2765 BLK SHEET 11 C408 CAB-MFR CONN (FR LIGHTS) 2745 BLK SHEET 12 C408 CAB-MFR CONN (HVAC) 2790 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES) 2780 BLK SHEET 13 C408 CAB-MFR CONN (OPTIONS) 2730 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)

2090 BLK

2900 BLK 2455 BLK SHEET 13 C423 BKT POSITION SOLENOID 2710 BLK SHEET 5 C426 REMOTE RUN, ACD

2300 BLK

Dealer Copy -- Not for Resale

2770 BLK SHEET 13 C355 FUEL HARN (PWR BOB/AC) C103 TAILGATE HARN

2600 BLK

C489 MFR ACCESSORY

B

T1 BATT GND

2720 BLK

B

T8 BATT GND

2600 BLK 2390 BLK 2400 BLK SHEET 6 C101 FUEL SHUTOFF SOLENOID 2200 BLK SHEET 7 C425 BRAKE

SHEET 6 FRC1 FUEL PULL RELAY SHEET 7 FRC1 TRACTION LOCK RELAY SHEET 11 FRC1 REAR LIGHT RELAY SHEET 11 FRC1 FRONT LIGHT RELAY SHEET 6 FRC1 GLOW PLUG RELAY

2320 BRN SHEET 7 C112 HYD OIL FILTER SWITCH 2370 BRN SHEET 9 C408 CAB-MFR CONN (SEATBAR SENSOR)

2180 BRN SHEET 6 C355 FUEL HARN (FUEL SENDER)

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

10

2160 BRN SHEET 6 C106 ENGINE SPEED SENSOR

2190 BRN SHEET 7 C105 HYD CHG PRESSURE SENDER

PARTIAL CONNECTOR

C408 (BLACK) CAB-MFR HARN CONN 1

2170 BRN SHEET 6 C104 ENGINE COOLANT SENSOR

2220 BRN SHEET 7 C108 HYD TEMP SENDER

SCHEMATIC INDEX

J1B GWY CTRLR

2230 BRN

17

SHEET 3 FRC1 SWITCHED PWR RELAY SHEET 12 FRC1 HVAC RELAY SHEET 6 FRC1 STARTER RELAY

2025 BLK 2035 BLK 2045 BLK 2115 BLK

2105 BLK

2016 BLK 2055 BLK 2030 BLK 2005 BLK

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 4 of 13 (PRINTED APRIL 2014) 7210766 (A)

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 RED/WHITE RED/WHT 1000 THROUGH 1499 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 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 PURPLE/WHITE PUR/WHT COMMUNICATION 9000 THROUGH 9999

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

8 9

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

CAN BUS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

* DLX CAB HARN 7210556 ONLY (NOT IN STD CAB HARN 7210557)

C408 (BLACK) CAB-MFR HARN CONN 1

J1B GWY CTRLR

CAN LO CAN HI

PARTIAL CONNECTOR

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9230 PUR 9130 PUR/WHT

9230 PUR 9130 PUR/WHT

4 3

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

120 OHM RESISTOR

9630 PUR 9530 PUR/WHT

4 3

C479 LEFT PANEL (BLACK)

4 2

C503 RIGHT DELUXE PANEL

120 OHM RESISTOR

Dealer Copy -- Not for Resale 9260 PUR 9160 PUR/WHT

C426 Remote Run Tool, ACD

14

CAN HI 20 CAN LO

21 SHEET 3 SHEET 3 SHEET 4

9500 PUR/WHT 9600 PUR 3090 LBL 1730 RNG/WHT 1165 RED/WHT 2710 BLK

A B D C E F G

REMOTE RUN KEY

SHEET 3 SHEET 4

SWITCHED POWER UNSWITCHED POWER GROUND

9220 PUR 9120 PUR/WHT

8 9

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1 2 3 4

C450 RIGHT JOYSTICK (SJC/AWS ONLY)

1840 RNG/WHT 2080 BLK 9540 PUR/WHT 9640 PUR

1 2 3 4

C449 LEFT JOYSTICK (SJC/AWS ONLY)

*

J2B AUX CTRLR

SHEET 3 SHEET 4

*

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 5 of 13 Printable Version Click Here (PRINTED APRIL 2014) 709 of 1311

Printed In U.S.A.

7210766 (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 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

1030 RED

SHEET 3

+12V PWR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

FRC1 STARTER RELAY 30 8200 TAN 87

2005 BLK

SHEET 4

85

86

ENGINE

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

C109 S/R ADAPTER

3560 LBL GND

PARTIAL CONNECTOR

STARTER

A B

TAN TAN

S R

8210 TAN

M

B

SHEET 3 1015 RED C110

B ALTERNATOR

S L

G

1020 RED 1800 RNG/WHT

SHEET 3

EXCITATION

2015 BLK FRC1 FUEL PULL RELAY +12V SHEET 3

1350 RED/WHT

PWR

30 87

2025 BLK

SHEET 4

GND

85

86

FRC1 GLOW PLUG RELAY +12V 30 1060 RED PWR 87

SHEET 3

2016 BLK

SHEET 4

6

GND

85

C101 D5

8120 TAN 3410 LBL SHEET 4

2400 BLK

FUEL SHUTOFF SOLENOID

8100 TAN

B

PULL

2800 BLK

C

GND

8800 TAN

A

HOLD

0.33 OHM

8110 TAN 24.5 OHM

T14 PRE HEATER

Dealer Copy -- Not for Resale

8500 TAN

86

8510 TAN

14

3420 LBL

3

8110 TAN

30

3410 LBL

7

8210 TAN

22

3560 LBL C107

J1A GWY CTRLR

SHEET 9

25

SHEET 4

5140 YEL 3140 LBL 2140 BRN

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

Printable Version Click Here

C405

SHEET 4

16

2150 BRN 3150 LBL

B A

GND SIG

AIR FILTER SWITCH (NC)

C106

15 SHEET 4

3160 LBL 2160 BRN

A B

SIG GND

ENGINE SPEED SENSOR (163 OHM)

C104

SHEET 4

18 4

2170 BRN 3170 LBL

710 of 1311

GND SIG

ENGINE COOLANT SENSOR (500-3000 OHM) (8 VOLT)

8800 TAN

J1B GWY CTRLR

Printed In U.S.A.

B A

C355 FUEL HARN

12 SHEET 4

3180 LBL 2180 BRN

C D

3180 LBL 2180 BRN

(PRINTED APRIL 2014)

C406

A B

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 6 of 13

SIG GND

FUEL SENDER (30 - 270 OHM)

7210766 (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 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 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

SHEET 3

FRC1 TRACTION LOCK RELAY +12V 1360 RED/WHT PWR 30 3430 LBL 87 2035 BLK

SHEET 4

GND 85

86

SCHEMATIC INDEX PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

HYDRAULICS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET # C425

4100 LGN SHEET 4

4200 LGN 2200 BLK

B A C

C308

4200 LGN 2200 BLK

A B

BRAKE SOLENOID 9.8 OHM 12 V

WHEEL 2 SPD ADP HARNESS 7159366 TRACK SINGLE SPD BRAKE ADP HARNESS 7165061

4110 LGN

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

C425

B A C

8

PULL HOLD

0.3 OHM 10.9 OHM WHEEL SINGLE SPEED TRACTION LOCK

13 C108

SHEET 4

32

2220 BRN 3220 LBL

B A

GND SIG

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM (8 VOLT)

C112 J1A GWY CTRLR

34 SHEET 4

3320 LBL 2320 BRN

A B

SIG GND

HYDRAULIC OIL FILTER SWITCH (NC)

Dealer Copy -- Not for Resale

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

HYDRAULIC LOCK SOLENOID 9.8 OHM 12 V

C105

SHEET 4

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

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. 711 of 1311

J2B AUX CTRLR

2 1

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 7 of 13 (PRINTED APRIL 2014) 7210766 (A)

LEGEND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 BLACK BLK BATTERY GROUND 2000 THROUGH 2999 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 TAN TAN ENGINE 8000 THROUGH 8999 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

PARTIAL CONNECTOR PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

CAB DISPLAY

CONNECTOR

* DLX CAB HARN 7210556 ONLY (NOT IN STD CAB HARN 7210557)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

T13 BUZZER (+)

1940 RNG/WHT

SHEET 3

C479 LEFT PANEL (BLACK)

T2 BUZZER (-)

SHEET 4 SHEET 3

1960 RNG/WHT

SHEET 3

*

SW9 TRAVEL CONTROL SWITCH (OPTIONAL)

SHEET 4

2700 BLK

SHEET 3 SHEET 13

5 6 4 2 3 1

SHEET 3 SHEET 4

SHEET 13

3610 LBL 1775 RNG/WHT 2930 BLK

C499 Press To Operate Loader (PTOL)

LEFT PANEL BUZZER

7040 WHT

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

SHEET 3 C408 SHEET 4 (BLACK) CAB-MFR HARN CONN 1

BUZZER GROUND

20

3030 LBL

1

3030 LBL

2

SWITCHED POWER

19

2380 BRN

12

2380 BRN

4

LEFT BLINKER INPUT RIGHT BLINKER INPUT

J1A GWY CTRLR

Dealer Copy -- Not for Resale 24

TRAVEL CONTROL INPUT

8130 TAN

2

8130 TAN

22

3040 LBL

14

3040 LBL

6

3610 LBL

12 11 10 9 2 8 7 6 5 4 3 1

DOOR SIGNAL

PTOL OUTPUT PTOL LED

2

START

6 J1B GWY CTRLR

C480 LEFT PANEL (GRAY)

SWITCHED POWER GROUND

C500 RIGHT KEY SWITCH PANEL

PARK BRAKE INPUT

12

3620 LBL

1 3

UNSWITCHED POWER

5

SHEET 9

1930 RNG/WHT 2940 BLK

SHEET 3 SHEET 3 SHEET 4

4 5 1 3

1950 RNG/WHT 1420 RED/WHT 2960 BLK

RUN/ENTER SWITCH

SWITCHED POWER UNSWITCHED POWER GROUND

C503 RIGHT DELUXE PANEL PARK BRAKE OUTPUT

SHEET 3 SHEET 3 SHEET 4

1590 RNG/WHT

5

1240 RED/WHT

1

2250 BLK

3

UNSWITCHED POWER

712 of 1311

GROUND

6

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 8 of 13 Printable Version Click Here (PRINTED APRIL 2014)

Printed In U.S.A.

SWITCHED POWER

7210766 (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 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 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

SHEET 3 C438 SHEET 9 (DK GRAY) CAB-MFR HARN CONN 3

4

4235 LGN

5

4275 LGN

6

4550 LGN

SCHEMATIC INDEX

PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

SHEET 3

7

* DLX CAB HARN 7210556 ONLY (NOT IN STD CAB HARN 7210557)

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

*

C212 POWER SOCKET

1 2

2795 BLK 1375 RED/WHT

C408 (BLACK) CAB-MFR HARN CONN 1

1370 RED/WHT

CAB

CONNECTOR

*

C209

2010 BLK 1390 RED/WHT 3640 LBL

1370 RED/WHT

GND +12V PWR

B A C

GND +12V PWR DOOR SIG

DOME LIGHT

C129 CAB ACCESSORY

SHEET 3

1580 RNG/WHT

5

1210 RED/WHT 1580 RNG/WHT 1865 RNG/WHT 2820 BLK 1510 RNG/WHT 1885 RNG/WHT

SHEET 4

2730 BLK

11

2730 BLK

A B C

+12V BATT PWR +12V SW PWR

Dealer Copy -- Not for Resale

GND

SHEET 13 SHEET 13 2210 BLK

SHEET 13

2885 BLK 2060 BLK

SHEET 13 SHEET 9

*

C428 (LT GRAY) CAB-MFR HARN CONN 2

SHEET 4

2790 BLK

11

2790 BLK 3620 LBL 1400 RED/WHT

2790 BLK SHEET 8 SHEET 3

SHEET 3

1850 RNG/WHT

13 1850 RNG/WHT

SHEET 4

11

+5V

24

2370 BRN 3370 LBL

5100 YEL 5140 YEL SHEET 6

5370 YEL

4 5 3

2370 BRN

3630 LBL

1850 RNG/WHT C482

J1B GWY CTRLR

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

A

GND

3370 LBL

B

SIG

5370 YEL

C

+5V PWR

2

2840 BLK

SEATBAR SENSOR

7310 WHT

* 2845 BLK

4 5 6 1

3

DOOR SIGNAL DOOR UNSW PWR WIPER SWITCH, MOTOR SWITCHED POWER WIPER MOTOR GROUND WASHER SIGNAL

C252

L X

SIG GND

WASHER MOTOR

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 9 of 13 Printable Version Click Here (PRINTEDMARCH 2011)

713 of 1311

Printed In U.S.A.

7210766 (A)

LEGEND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 LIGHTS 6000 THROUGH 6999 PINK PNK WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 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 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

MANUAL CONTROLS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

C409 RIGHT HANDLE

K G A H J E F C D B

J2A AUX CTRLR

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

A

30 31

C103 TAILGATE HARN

7100 WHT

C

T19 TERMINAL (+)

SHEET 3

13

7100 WHT

SHEET 4

BACK UP ALARM

2650 BLK

1520 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

SKI CTRL DETENT FLOW TWO SPD PWM

T20 TERMINAL (-)

Dealer Copy -- Not for Resale 21 17 18 23

C421

2670 BRN 4670 LGN

10 J1A GWY CTRLR

3 1 2

GND SIG

TILT SPOOL LOCK 7.8 OHM 12V

C422

2680 BRN 4680 LGN

2

7

5

J1B GWY CTRLR

3 1 2

C410 LEFT HANDLE

J2B AUX CTRLR

GND SIG

LIFT SPOOL LOCK 7.8 OHM 12V

28 22 12 11 SHEET 3

4840 LGN 4830 LGN 4820 LGN 4810 LGN 1530 RNG/WHT

K D C B G F A J H E

714 of 1311

SIDE SHIFT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 10 of 13 Printable Version Click Here (PRINTED APRIL 2014)

Printed In U.S.A.

SKI CTRL

7210766 (A)

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 BLK BATTERY GROUND 2000 THROUGH 2999 BLACK 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 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

PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

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 4

2765 BLK

9

2765 BLK

2750 BLK 6110 PNK

6000 PNK

8

6000 PNK

6120 PNK 2760 BLK

B A

C435-1

A B C435-2

6130 PNK 2705 BLK

FRC1 FRONT WORK LIGHTS RELAY SHEET 3

SHEET 4

1330 RED/WHT

+12V PWR

87 2115 BLK

GND

85

C103 HARN Dealer Copy -- NotTAILGATE for Resale

C603

SHEET 4

30

6340 PNK

6310 PNK

A

6310 PNK

2610 BLK 6320 PNK

86 6330 PNK 2640 BLK

2620 BLK 6210 PNK

SHEET 4

Printed In U.S.A. 715 of 1311

GND SIG

RIGHT REAR TAIL LIGHT

1 2

SIG GND

LEFT REAR TAIL LIGHT

6320 PNK 3460 LBL 6210 PNK 3440 LBL

SHEET 4

SHEET 3

2 1 C602

SHEET 4 5 31 J1A 17 GWY CTRLR 28

A B

1320 RED/WHT

2045 BLK

FRC1 REAR LIGHT RELAY +12V PWR 30 87 GND

85

86

T16 TERMINAL (-) GND SIG

RIGHT REAR WORK LIGHT

T15 TERMINAL (+)

6200 PNK

H

6200 PNK SHEET 4

6220 PNK 2630 BLK

T17 TERMINAL (+) SIG GND

LEFT REAR WORK LIGHT

T18 TERMINAL (-)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 11 of 13 Printable Version Click Here (PRINTED APRIL 2014) 7210766 (A)

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 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 LIGHTS 6000 THROUGH 6999 PINK PNK WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

HVAC

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

2440 BLK 7440 WHT

* * *

2 1

SHEET 3

SHEET 4 SHEET 3

1140 RED/WHT

+12V PWR

1500 RNG/WHT

85

GND

C A B

7

D SIG C GND A +12V PWR B E F

8

7020 WHT

7021 WHT

Dealer Copy -- Not for Resale

SWITCH OFF 5 2 1 4 6 3

1500 RNG/WHT

7410 WHT SW11 AC SWITCH

*

2745 BLK

2570 BLK 7020 WHT

7023 WHT 7024 WHT C355 FUEL HARN

A SHEET 13

7024 WHT 2290 BLK

# 7025 WHT 2280 BLK D4

C486

1 2

SIG GND

*

7530 WHT 7520 WHT 7510 WHT 2580 BLK

C611

1 2 3 4

14.00 Amps 7.50 Amps 5.00 Amps

BLOWER MOTOR

3 C

7400 WHT

1

MAGNET CLUTCH (COMPRESSOR)

C630

3 2 1

THERMOSTAT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 12 of 13 Printable Version Click Here (PRINTED APRIL 2014)

Printed In U.S.A. 716 of 1311

High Med Low

9

C350

B A

HEATER VALVE

SW10 *BLOWER

* AC EVAPORATOR SWITCH

POTENTIOMETER (TEMP CONTROL SWITCH)

1790 RNG/WHT

2745 BLK

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

C635

2100 BLK 7015 WHT 11

BLK DBL WHT

86

SHEET 4

J1A GWY CTRLR

HVAC DUCT FAN

30 87

2030 BLK

GND SIG

C483

2130 BLK 7430 WHT

C438 (DK GRAY) CAB-MFR HARN CONN 3

#

C610

2560 BLK 7420 WHT 7425 WHT

FRC1 HVAC RELAY

* DLX CAB HARN 7210556 ONLY (NOT IN STD CAB HARN 7210557)

7210766 (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 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 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

# POWER BOB CLOSE

SIG GND

4470 LGN 2470 BLK

POWER BOB OPEN

GND SIG

E B

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

C428 (LT GRAY) CAB-MFR HARN CONN 2

# 4470 LGN

2480 BLK 4480 LGN

F

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

4480 LGN

SHEET 4

C606

2 1

* DLX CAB HARN 7210556 ONLY (NOT IN STD CAB HARN 7210557)

SHEET #

8

4470 LGN 2770 BLK

OPTIONS

CONNECTOR

2290 BLK

SHEET 12

#

2770 BLK

PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

C355 FUEL HARN

C607

1 2

SCHEMATIC INDEX

4480 LGN

SW5 *POWER

2

1

BOBTACH SWITCH

5

3 4 6

7 1380 RED/WHT 1410 RED/WHT

SHEET 3

12

1410 RED/WHT

1200 RED/WHT

LEFT HANDLE (BLINKER / FLASHER) 5 PIN

6010 PNK

10 6400 PNK

6415 PNK

14

1550 RNG/WHT

6515 PNK

6010 PNK

9

D2

6400 PNK 3400 LBL

SHEET 8

*

SW3 HAZARD SWITCH

1550 RNG/WHT

EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS SHEET)

E

6410 PNK

D

(PINS 3 & 6 INTERNALLY INSULATED)

C438 (DK GRAY) CAB-MFR HARN CONN 3

6500 PNK

6510 PNK

BUCKET POSITION SOLENOID 9.8 OHM

A

4450 LGN

D3 4455 LGN

GND

B

2450 BLK

2455 BLK

2

D1

6500 PNK

2780 BLK

SHEET 4

LEFT HANDLE (HORN) 2 PIN

7210 WHT 1460 RED/WHT

3 1 4 6

SHEET 4

13

26

J2B AUX CTRLR

26

2460 BRN 4460 LGN

6530 PNK 6440 PNK 6540 PNK

GND SIG

2360 BRN 4360 LGN

26

2350 BRN 4350 LGN

J1A GWY CTRLR

7210 WHT

GND SIG

J1B GWY CTRLR

2 1

GND SIG

BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

B A

*

C676 RADIO CONN

C279 GND SIG

FRONT HORN

LEFT SPEAKER

+

1 2

7820 WHT 7830 WHT

3 4

* C2771

-

RIGHT SPEAKER

HIGH FLOW SOLENOID 7.5 OHM 12 V

+

SHEET 9 SHEET 9

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V TRACK 2 SPEED TWO SPEED SOLENOID 5.1 OHM 12 V

-

ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

2 1

7810 WHT 7800 WHT 1885 RNG/WHT 2885 BLK

6 5 1 2

SHEET 9 SHEET 9

1510 RNG/WHT 2210 BLK

2 3 4 5 6

AIR RIDE SEAT PWR GND

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV18205 - A3NV21746) (S/N A3NW12734 - A3NW13097) Sheet 13 of 13 Printable Version Click Here (PRINTED APRIL 2014) 7210766 (A)

717 of 1311

D F B C A

POSITION SWITCH

C278

C441

25 26

Printed In U.S.A.

2 1

2420 BLK

SW6 *BUCKET

C126

C437

27

2 5

SHEET 3

B A

6700 PNK

SWITCH 6 5 4 1 2 3

2780 BLK

C415 J2A AUX CTRLR

2725 BLK

2850 BLK

6

1

C408 (BLACK) CAB-MFR HARN CONN 1 SHEET 4 2785 BLK

C412

B A

4455 LGN 2830 BLK

SHEET 4

2 5

1 3 4

* C670E

C423 SIG

SW2 *BEACON

Dealer3500 Copy LBL -- Not for Resale

SHEET 8

3

L

6430 PNK

SHEET 3 C103 TAILGATE HARN

T3 * FLASHER CONN

6570 PNK

B C D E A

X

1430 RED/WHT

C411

C277

AIR RIDE SEAT

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 2 2 6

C278 C279 C308 C350 C355 C404 C405 C406 C408 C409 C410 C411 C412 C415 C418 C419

RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS BU ALARM-MFR HARN AIR FILTER SWITCH FUEL SENDER CAB-MFR HARN CONN (BLK) RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY (FLSHR) LEFT HANDLE 2 WAY (HORN) HIGH FLOW SOLENOID FRONT ROD FRONT BASE

2 2 2 2 6 2 2 2 14 10 10 5 2 2 2 2

13 13 7 12 6,12,13 3,10 6 6 3-5,8,9,11,13 10 10 13 13 13 7 7

C420 C421 C422 C423

HYD LOCK TILT SPOOL LOCK TILT SPOOL LCOK BUCKET POSITION

2 3 3 2

7 10 10 13

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C212 C252

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN CAB ACCESSORY POWER SOCKET WASHER

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9 13

C425 C426 C428 C434-1 C434-2 C435-1 C435-2 C437 C438 C441 C446 C449 C479 C480 C483 C486 C489 C499 C500 C503 C602 C603 C606 C607 C610 C611 C630 C635 C667 C670 C676

C482

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS 3 BRAKE SOLENOID CAN (Remote Start Tool, ACD) 7 14 CAB-MFR HARN CONN (LT GRY) LEFT WORKLIGHT 1 2 2 LEFT WORKLIGHT 2 RIGHT WORKLIGHT 1 2 RIGHT WORKLIGHT 2 2 2 TWO SPEED MAKEUP CAB-MFR HARN CONN (DK GRY) 14 2 TWO SPEED HYDRAULIC FAN 2 4 LEFT JOYSTICK (CAB HARN) LEFT PANEL(BLACK) 12 LEFT PANEL(GRAY) 12 3 SEATBAR SENSOR TEMP CONTROL SWITCH AC COMPRESSOR MFR ACCESSORY PTOL RH KEY SWITCH RH DLX PANEL LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT POWER BOBTACH OPEN POWER BOBTACH CLOSE HVAC DUCT FAN BLOWER MOTOR THERMOSTAT HEATER VALVE DOOR EXTERIOR BEACON RADIO

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 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 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

Printed In U.S.A. 718 of 1311

3 2 2 4 6 6 2 2 2 2 2 Dealer 4 3 6 6 6 6

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

NUM OF PINS 8 8 64

3 3 3,6,7,11,12

J1A J1B J2A J2B

GATEWAY CONTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER

34 26 34 26

3,6-8,10-13 3-10,13 7,10,13 3,4,5,7,10,13

SW1 SW2 SW4 SW5

BRAKE SWITCH BEACON SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH

8 13 9 13 13

SHEET

CONN

DESCRIPTION

7 5 3,4,9,13 11 11 11 11 13 9,12,13 13 7 5 5,8 8 9

FC1 FC2 FRC1

Copy

12 12 3,4 8 8 5,8 11 11 13 13 12 -- Not 12 12 12 9 13 13

for

SHEET

SW6

BUCKET POSITION SWITCH

6 6 6 6 6

SW9 SW10 SW11

TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

6 5 3

8 12 12

T1 T2 T3

BATT GROUND BUZZER GROUND FLASHER

1 1 2

4

BATT GROUND BATT GROUND BUZZER POWER PRE HEATER RIGHT REAR WORK LIGHT(+) RIGHT REAR WORK LIGHT(-) LEFT REAR WORK LIGHT (+) LEFT REAR WORK LIGHT (-)

1 1

8 13 4 4

1 1

8 6

1 1 1 1 1 1

11 11 11 11 10 10 9

T6 T8 T13 T14 Resale T15 T16 T17 T18 T19 T20 T36 T37

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CAB PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13

BACKUP ALARM BACKUP ALARM (GND) DOMELIGHT (-) DOMELIGHT (+)

9

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 1 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) 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 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 SPARE DIGITAL, ECU SINKS TRACTION PULL RELAY FDBK GLOW PLUG RELAY FDBK ENGINE SPEED AIR FILTER SWITCH LIGHT 2 RELAY FAN 2 RELAY PTOL LED PTOL SWITCH SWITCHED POWER OUT RELAY FDBK STATER RELAY FDBK START ENGINE ENGINE OIL PRESS SPARE SPARE LIGHT 2 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP (8 VOLT) HYD OIL FILTER SW1

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 ENGINE COOLANT TEMP (8 VOLT) FAN 2 OUTPUT CAN LO 2 REMOTE KEY RUN/ENTER SENSOR SUPPLY 8V SENSOR SUPPLY 5V TWO SPEED MAKEUP TWO SPEED COIL

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

Dealer

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) FUNCTION PIN FUNCTION FRONT AUX (F) RETURN B-1 B-2 REAR AUX (F) RETURN UNSW BATT B-3 UNSW BATT B-4 DIVERTED SOLENOID B-5 REAR AUX (F) B-6 RELIEF SOLENOID B-7 REAR AUX (M) B-8 CAN LO 1 B-9 CAN HI 1 B-10 REAR AUX (M) RETURN LH PADDLE RIGHT B-11 LH PADDLE LEFT B-12 RH RIGHT BUTTON UP B-13 FRONT AUX (F) B-14 B-15 GROUND B-16 GROUND B-17 HANDLE POT GND B-18 FRONT AUX (M) RETURN RH PVM POT SIGNAL B-19 FRONT AUX (M) B-20 B-21 RH TRIGGER B-22 LH RIGHT BUTTON DOWN SWITCHED POWER B-23 HANDLE POT POWER B-24 B-25 Copy -- Not for Resale B-26 HIGH FLOW RETURN HIGH FLOW LH RIGHT BUTTON RH LEFT UP RH LEFT DOWN

Printable Version Click Here

HARNESS PART NUMBER EXMF 7210764 MAINFRAME LF 7210768 DLX CAB 7234737 7210557 STD CAB DLX FUEL 7184255 STD FUEL 7149219 S/R 6733370 7217484 TAILGATE DOM TRK BRAKE ADP 7165061 WHL 2 SPD ADP 7159366

Printed In U.S.A.

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 2 of 13 (PRINTED JANUARY 2017) 7210766 (C)

719 of 1311

1240 RED/WHT

POWER

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

1440 RED/WHT

FC1 FUSE CENTER

FUSE 1 25 A

1070 RED

+12V BATTERY

MEGAFUSE 100.0 Amps

BATT_CABLE

1120 RED/WHT

FUSE 2 25 A

1025 RED

1420 RED/WHT

1160 RED/WHT

J1B GWY CTRLR

1150 RED/WHT

3

1180 RED/WHT

2

SHEET 9 C667 DOOR HARNESS SHEET 8 C500 RH KEY SWITCH SHEET 8 C479 LH PANEL

J2B AUX CTRLR

FUSE 3 OPEN

1010 RED

SHEET 6 STARTER

PARTIAL CONNECTOR

FC2 FUSE CENTER

FUSE 1 25 A

1190 RED

FUSE 2 25 A

1040 RED

CONNECTOR

1165 RED/WHT

SHEET 5 C426 REMOTE RUN, ACD 1410 RED/WHT

1490 RED/WHT

FUSE 3 OPEN FUSE 4 15 A

1290 RED

1460 RED/WHT 1370 RED/WHT

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET 13 C408 CAB-MFR CONN (OPTIONS) SHEET 13 C412 LH HANDLE HORN

SHEET #

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

FUSE 5 30 A

1060 RED SHEET 6 FRC1 PRE HEATER RELAY

FUSE 6 30 A

1310 RED

1030 RED SHEET 6 FRC1 STARTER RELAY

FUSE 9 15 A FUSE 10 20 A

1340 RED

FUSE 11 25 A

1300 RED

FUSE1 25 A 1760 RNG/WHT

FUSE 2 25 A FUSE 3 15 A

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES)

1350 RED/WHT 1360 RED/WHT

1320 RED/WHT 1330 RED/WHT

1140 RED/WHT

SHEET 6 FRC1 FUEL SHUTOFF RELAY SHEET 7 FRC1 TRACTION LOCK RELAY SHEET 11 FRC1 REAR LIGH RELAY

Dealer Copy -- Not for Resale

SHEET 11 FRC1 FRONT LIGHT RELAY

1850 RNG/WHT 1550 RNG/WHT

1780 RNG/WHT SHEET 9 C408 CAB-MFR CONN (FR WIPER) SHEET 13 C408 CAB-MFR CONN (BKT POSITION)

1570 RNG/WHT

FUSE 8 25 A

FRC1 SWITCHED POWER RELAY +12V PWR

1765 RNG/WHT 30 87

2055 BLK GND

85

86

FUSE 7 25 A

1815 RNG/WHT

FUSE 12 15 A

J1A GWY CTRLR

3450 LBL 3380 LBL

21 4

1730 RNG/WHT 1580 RNG/WHT 1800 RNG/WHT 1790 RNG/WHT

C428 (LT GRAY) CAB-MFR HARN CONN 2

1920 RNG/WHT

6

1920 RNG/WHT

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET) C489 MFR ACCESSORY

C428 (LT GRAY) CAB-MFR HARN CONN 2

1520 RNG/WHT 1560 RNG/WHT

SHEET 10 C410 LEFT HANDLE SHEET 10 C409 RIGHT HANDLE

22

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)

SHEET 12 FRC1 HVAC RELAY

1840 RNG/WHT

SHEET 5 C449 LH JOYSTICK SHEET 5 C450 RH JOYSTICK

1940 RNG/WHT 1930 RNG/WHT

1590 RNG/WHT 1950 RNG/WHT

SHEET 5 C426 REMOTE RUN, ACD

SHEET 6 C110 ALT EXCITATION

1620 RNG/WHT

1775 RNG/WHT 1660 RNG/WHT

2

1830 RNG/WHT

Printed In U.S.A.

A

1660 RNG/WHT 1530 RNG/WHT

1795 RNG/WHT

B

1720 RNG/WHT

SHEET 12 FRC1 HVAC RELAY

1750 RNG/WHT

FUSE4 5 A

J2B AUX CTRLR

1785 RNG/WHT 1960 RNG/WHT

SHEET 8 C479 LH PANEL SHEET 8 T13 LH PANEL BUZZER SHEET 8 C499 RH PANEL PTOL SHEET 8 SW1 BRAKE SWITCH SHEET 8 C503 RH DELUXE PANEL SHEET 8 C500 RH PANEL KEY SWITCH SHEET 9 SW4 H/ISO SWITCH SHEET 8 SW9 TRAVEL CONTROL SWITCH

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 3 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

720 of 1311

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

FRC1 FUSE RELAY CENTER

1050 RED

SHEET 4

COLOR CODE RED RED/WHT RNG/WHT BLK BRN LBL LGN YEL PNK WHT TAN PUR PUR/WHT

LEGEND

FUSE 4 OPEN

1050 RED

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION 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

SHEET 8 C503 RH DLX PANEL

LEGEND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION 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 LIGHTS 6000 THROUGH 6999 PINK OTHER FUNCTIONS 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

2080 BLK SHEET 5 C449 LH JOYSTICK 2070 BLK SHEET 5 C450 RH JOYSTICK 2920 BLK SHEET 8 C479 LH PANEL 2940 BLK SHEET 8 C499 PTOL 2960 BLK SHEET 8 C500 RH PANEL KEY SWITCH 2250 BLK SHEET 8 C503 RH DELUXE PANEL

2930 BLK SHEET 8 SW1 BRAKE SWITCH 2830 BLK SHEET 13 SW6 BKT POSITION SWITCH 2700 BLK SHEET 8 SW9 TRAVEL CONTROL SWITCH 2785 BLK SHEET 13 C126 HORN

SCHEMATIC INDEX COLOR CODE RED RED/WHT RNG/WHT BLK BRN LBL LGN YEL PNK WHT TAN PUR PUR/WHT

2950 BLK

10 16

C428 (LT GRAY) CAB-MFR HARN CONN 2

2900 BLK

2140 BRN SHEET 6 C107 ENG OIL PRESS SENDER 2150 BRN SHEET 6 C405 AIR FILTER SWITCH

Printed In U.S.A. 721 of 1311

2510 BLK

16

2110 BLK

T6 BATT GND

2540 BLK

J2B 15 AUX CTRLR

2550 BLK

2765 BLK SHEET 11 C408 CAB-MFR CONN (FR LIGHTS) 2745 BLK SHEET 12 C408 CAB-MFR CONN (HVAC) 2790 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES) 2780 BLK SHEET 13 C408 CAB-MFR CONN (OPTIONS) 2730 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)

2090 BLK

2900 BLK 2455 BLK SHEET 13 C423 BKT POSITION SOLENOID 2710 BLK SHEET 5 C426 REMOTE RUN, ACD

2300 BLK

Dealer Copy -- Not for Resale

2770 BLK SHEET 13 C355 FUEL HARN (PWR BOB/AC) C103 TAILGATE HARN

2600 BLK

C489 MFR ACCESSORY

B

B

2600 BLK

SHEET 6 FRC1 FUEL PULL RELAY SHEET 7 FRC1 TRACTION LOCK RELAY SHEET 11 FRC1 REAR LIGHT RELAY

J1B GWY CTRLR

2230 BRN

17

T8 BATT GND

T1 BATT GND

2720 BLK

2400 BLK SHEET 6 C101 FUEL SHUTOFF SOLENOID 2200 BLK SHEET 7 C425 BRAKE

2320 BRN SHEET 7 C112 HYD OIL FILTER SWITCH 2370 BRN SHEET 9 C408 CAB-MFR CONN (SEATBAR SENSOR)

2180 BRN SHEET 6 C355 FUEL HARN (FUEL SENDER)

SHEET #

2500 BLK

1

2160 BRN SHEET 6 C106 ENGINE SPEED SENSOR

2190 BRN SHEET 7 C105 HYD CHG PRESSURE SENDER

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

2950 BLK

J1B GWY CTRLR 15

2170 BRN SHEET 6 C104 ENGINE COOLANT SENSOR

2220 BRN SHEET 7 C108 HYD TEMP SENDER

GROUND

CONNECTOR

C408 (BLACK) CAB-MFR HARN CONN 1

2620 BLK

SHEET 11 T16 RH REAR LIGHT 2630 BLK SHEET 11 T18 LH REAR LIGHT 2650 BLK SHEET 10 T20 BU ALARM 2640 BLK SHEET 11 C602 LH REAR LIGHT 2610 BLK SHEET 11 C603 RH REAR LIGHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

2025 BLK 2035 BLK 2045 BLK

SHEET 11 FRC1 FRONT LIGHT RELAY

2115 BLK

SHEET 6 FRC1 GLOW PLUG RELAY

2016 BLK

SHEET 3 FRC1 SWITCHED PWR RELAY

2055 BLK

SHEET 12 FRC1 HVAC RELAY SHEET 6 FRC1 STARTER RELAY

2390 BLK

2030 BLK 2005 BLK

2105 BLK

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 4 of 13 (PRINTED JANUARY 2017) 7210766 (C)

LEGEND SCHEMATIC INDEX

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

8 9

CAN BUS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

* DLX CAB HARN 7234737 ONLY (NOT IN STD CAB HARN 7210557)

C408 (BLACK) CAB-MFR HARN CONN 1

J1B GWY CTRLR

CAN LO CAN HI

PARTIAL CONNECTOR PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9230 PUR 9130 PUR/WHT

9230 PUR 9130 PUR/WHT

4 3

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

120 OHM RESISTOR

14 20 CAN LO 21

SHEET 3 SHEET 3 SHEET 4

9500 PUR/WHT 9600 PUR 3090 LBL 1730 RNG/WHT 1165 RED/WHT 2710 BLK

A B D C E F G

9260 PUR 9160 PUR/WHT

C479 LEFT PANEL (BLACK)

4 2

C503 RIGHT DELUXE PANEL

Dealer Copy -- Not for Resale REMOTE RUN KEY

SHEET 3 SHEET 4

SWITCHED POWER UNSWITCHED POWER GROUND

9220 PUR 9120 PUR/WHT

8 9

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1 2 3 4

C450 RIGHT JOYSTICK (SJC/AWS ONLY)

1840 RNG/WHT 2080 BLK 9540 PUR/WHT 9640 PUR

1 2 3 4

C449 LEFT JOYSTICK (SJC/AWS ONLY)

*

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 5 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

722 of 1311

*

J2B AUX CTRLR

SHEET 3 SHEET 4

Printed In U.S.A.

4 3

120 OHM RESISTOR

C426 Remote Run Tool, ACD CAN HI

9630 PUR 9530 PUR/WHT

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 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

1030 RED

SHEET 3

2005 BLK

SHEET 4

+12V PWR

GND

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

FRC1 STARTER RELAY 30 8200 TAN 87 85

86

PARTIAL CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

C109 S/R ADAPTER

3560 LBL

ENGINE

CONNECTOR

STARTER

A B

TAN TAN

8210 TAN

S R

M

B

SHEET 3 1015 RED C110

B ALTERNATOR

S L

G

1020 RED 1800 RNG/WHT

SHEET 3

EXCITATION

2015 BLK FRC1 FUEL PULL RELAY +12V SHEET 3

1350 RED/WHT

PWR

30 87

2025 BLK

SHEET 4

GND

85

86

FRC1 GLOW PLUG RELAY +12V 1060 RED PWR 30 87

SHEET 3

2016 BLK

SHEET 4

6

GND

85

C101 D5

8120 TAN 3410 LBL SHEET 4

8110 TAN

2400 BLK

FUEL SHUTOFF SOLENOID

8100 TAN

B

PULL

2800 BLK

C

GND

8800 TAN

A

HOLD

0.33 OHM

24.5 OHM

T14 PRE HEATER

8500 TAN

Dealer Copy -- Not for Resale

86

8510 TAN

14

3420 LBL

3

8110 TAN

30

3410 LBL

7

8210 TAN

22

3560 LBL C107

SHEET 9

J1A GWY CTRLR 25

SHEET 4

5140 YEL 3140 LBL 2140 BRN

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

C405

SHEET 4

16

2150 BRN 3150 LBL

B A

GND SIG

AIR FILTER SWITCH (NC)

C106

15 SHEET 4

3160 LBL 2160 BRN

A B

SIG GND

C104

SHEET 4

18 4

2170 BRN 3170 LBL

SIG

C355 FUEL HARN

12

Printed In U.S.A.

GND

ENGINE COOLANT SENSOR (500-3000 OHM) (8 VOLT)

8800 TAN

J1B GWY CTRLR

723 of 1311

B A

ENGINE SPEED SENSOR (163 OHM)

SHEET 4

3180 LBL 2180 BRN

C D

3180 LBL 2180 BRN

Printable Version Click Here

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 6 of 13 (PRINTED JANUARY 2017)

C406

A B

SIG GND

FUEL SENDER (30 - 270 OHM)

7210766 (C)

LEGEND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR COLOR CODE GROUP DESCRIPTION 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 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 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

SHEET 3

FRC1 TRACTION LOCK RELAY +12V 1360 RED/WHT PWR 30 3430 LBL 87 2035 BLK

SHEET 4

GND 85

86

SCHEMATIC INDEX PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

HYDRAULICS

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET # C425

4100 LGN SHEET 4

4200 LGN 2200 BLK

B A C

C308

4200 LGN 2200 BLK

A B

BRAKE SOLENOID 9.8 OHM 12 V

WHEEL 2 SPD ADP HARNESS 7159366 TRACK SINGLE SPD BRAKE ADP HARNESS 7165061

4110 LGN

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

C425

B A C

8

PULL HOLD

0.3 OHM 10.9 OHM WHEEL SINGLE SPEED TRACTION LOCK

13 C108

SHEET 4

32

2220 BRN 3220 LBL

B A

GND SIG

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM (8 VOLT)

C112 J1A GWY CTRLR

34 SHEET 4

3320 LBL 2320 BRN

A B

SIG GND

HYDRAULIC OIL FILTER SWITCH (NC)

Dealer Copy -- Not for Resale

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

HYDRAULIC LOCK SOLENOID 9.8 OHM 12 V

C105

SHEET 4

2190 BRN 3190 LBL 5190 YEL

B C A

GND SIG +8V PWR

4200 LGN

19 13

HYDRAULIC CHARGE PRESSURE 0.5-7.5V

Printable Version Click Here

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

Printed 724 of 1311

In U.S.A.

J2B AUX CTRLR

2 1

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 7 of 13 (PRINTED JANUARY 2017) 7210766 (C)

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 YEL CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW LIGHTS PINK PNK 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

1940 RNG/WHT

SHEET 3

1960 RNG/WHT

SHEET 3

*

SW9 TRAVEL CONTROL SWITCH (OPTIONAL)

SHEET 3 SHEET 4

SHEET 3 SHEET 13

5 6 4 2 3 1

SHEET 13

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

SHEET #

C499 Press To Operate Loader (PTOL)

SHEET 3 SHEET 4

C408 (BLACK) CAB-MFR HARN CONN 1

GROUND UNSWITCHED POWER SWITCHED POWER LEFT BLINKER INPUT

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 KEY SWITCH PANEL

24

TRAVEL CONTROL INPUT

8130 TAN

2

8130 TAN

PARK BRAKE INPUT

2

START

6

Dealer Copy -- Not for Resale J1B GWY CTRLR

C480 LEFT PANEL (GRAY)

12 11 10 9 2 8 7 6 5 4 3 1

1 3

20

22

3040 LBL

14

3040 LBL

6 3630 LBL

1930 RNG/WHT 2940 BLK

RIGHT BLINKER INPUT

12

3610 LBL

725 of 1311

* DLX CAB HARN 7234737 ONLY (NOT IN STD CAB HARN 7210557)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

BUZZER

5

SHEET 9

Printed In U.S.A.

CAB DISPLAY

CONNECTOR

C479 LEFT PANEL (BLACK)

SHEET 4

2700 BLK

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

LEFT PANEL BUZZER T2 BUZZER (-)

SHEET 4

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

T13 BUZZER (+)

7040 WHT

SHEET 3

SCHEMATIC INDEX

DOOR SIGNAL

SHEET 3 SHEET 3 SHEET 4

1950 RNG/WHT 1420 RED/WHT 2960 BLK

4 5 1 3

RUN/ENTER SWITCH SWITCHED POWER UNSWITCHED POWER GROUND

C503 RIGHT DELUXE PANEL PARK BRAKE OUTPUT

SHEET 3 SHEET 3 SHEET 4

1590 RNG/WHT

5

1240 RED/WHT

1

2250 BLK

3 6

SWITCHED POWER UNSWITCHED POWER GROUND

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 8 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

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 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

SHEET 3 C438 SHEET 9 (DK GRAY) CAB-MFR HARN CONN 3

4

4235 LGN

5

4275 LGN

6

4550 LGN

SCHEMATIC INDEX PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

SHEET 3

7

SHEET #

*

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH 1 1785 RNG/WHT 2 3 6 2060 BLK 5 4

*

C212 POWER SOCKET

1370 RED/WHT

5

1580 RNG/WHT 1865 RNG/WHT 2820 BLK 1510 RNG/WHT 1885 RNG/WHT

SHEET 4

2730 BLK

11

2730 BLK

A B C

11

*

Dealer Copy -- Not for Resale

1850 RNG/WHT

13

SHEET 13 SHEET 13 2210 BLK

SHEET 13 SHEET 13 SHEET 9

*

SHEET 4

11 +5V

24

3370 LBL 5100 YEL 5140 YEL SHEET 6

Printed In U.S.A.

726 of 1311

2370 BRN

5370 YEL

4

1850 RNG/WHT

1850 RNG/WHT

2370 BRN

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

2790 BLK 3630 LBL 1400 RED/WHT

2790 BLK

C482 J1B GWY CTRLR

T38 DOME LIGHT (-)

GND

SHEET 8 SHEET 3 SHEET 3

DOME LIGHT

+12V BATT PWR +12V SW PWR

C428 (LT GRAY) CAB-MFR HARN CONN 2

2790 BLK

T37 DOME LIGHT (+)

2010 BLK

2885 BLK 2060 BLK

SHEET 4

GND +12V PWR

*

1390 RED/WHT

1210 RED/WHT 1580 RNG/WHT

1 2

2795 BLK 1375 RED/WHT

C129 CAB ACCESSORY

SHEET 3

* DLX CAB HARN 7234737 ONLY (NOT IN STD CAB HARN 7210557)

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

C408 (BLACK) CAB-MFR HARN CONN 1

1370 RED/WHT

CAB

CONNECTOR

A

5

3370 LBL

B

SIG

3

5370 YEL

C

+5V PWR

2

2840 BLK

SEATBAR GND SENSOR

7310 WHT

* 2845 BLK

C252

L X

SIG GND

WASHER MOTOR

4 5 6 1

3

DOOR SIGNAL DOOR UNSW PWR WIPER SWITCH, MOTOR SWITCHED POWER WIPER MOTOR GROUND WASHER SIGNAL

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 9 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

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 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 PINK PNK LIGHTS 6000 THROUGH 6999 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN TAN 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

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

PARTIAL CONNECTOR

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

MANUAL CONTROLS C409 RIGHT HANDLE

J2A AUX CTRLR

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

A

30 31

C103 TAILGATE HARN

7100 WHT

C

T19 TERMINAL (+)

13

7100 WHT

SHEET 4

SHEET 3

BACK UP ALARM

2650 BLK T20 TERMINAL (-)

1520 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

K G A H J E F C D B

SKI CTRL DETENT FLOW TWO SPD PWM

Dealer Copy -- Not for Resale 21 17 18 23

C421 J1A GWY CTRLR

2670 BRN 4670 LGN

10

3 1 2

GND SIG

TILT SPOOL LOCK 7.8 OHM 12V

C422

2680 BRN 4680 LGN

2

7

5

J1B GWY CTRLR

Printed In U.S.A.

3 1 2

C410 LEFT HANDLE

J2B AUX CTRLR

GND SIG

LIFT SPOOL LOCK 7.8 OHM 12V

28 22 12 11 SHEET 3

4840 LGN 4830 LGN 4820 LGN 4810 LGN 1530 RNG/WHT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 10 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

727 of 1311

K D C B G F A J H E

SKI CTRL SIDE SHIFT

LEGEND SCHEMATIC INDEX

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 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

PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

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 4

2765 BLK

9

2765 BLK

2750 BLK 6110 PNK

6000 PNK

8

6000 PNK

6120 PNK 2760 BLK

B A

C435-1

A B C435-2

6130 PNK 2705 BLK

FRC1 FRONT WORK LIGHTS RELAY SHEET 3 SHEET 4

1330 RED/WHT

+12V PWR

30 87

2115 BLK

GND

85

C103 TAILGATE HARN

C603

Dealer Copy -- Not for Resale 6340 PNK

6310 PNK

A

6310 PNK

SHEET 4

SHEET 4

Printed In U.S.A. 728 of 1311

2 1

GND SIG

RIGHT REAR TAIL LIGHT

C602

6330 PNK 2640 BLK

1 2

SIG GND

LEFT REAR TAIL LIGHT

6320 PNK 3460 LBL 6210 PNK 3440 LBL

SHEET 4

SHEET 3

2610 BLK 6320 PNK

86

SHEET 4 5 31 J1A 17 GWY CTRLR 28

A B

1320 RED/WHT

2045 BLK

FRC1 REAR LIGHT RELAY +12V PWR 30 87 GND

85

86

2620 BLK 6210 PNK

T16 TERMINAL (-) GND SIG

RIGHT REAR WORK LIGHT

T15 TERMINAL (+)

6200 PNK

H

6200 PNK SHEET 4

6220 PNK 2630 BLK

T17 TERMINAL (+) SIG GND T18 TERMINAL (-)

LEFT REAR WORK LIGHT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 11 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

HVAC

LEGEND SCHEMATIC INDEX

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 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 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN TAN COMMUNICATION 9000 THROUGH 9999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

PARTIAL CONNECTOR

* DLX CAB HARN 7234737 ONLY (NOT IN STD CAB HARN 7210557)

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

2440 BLK 7440 WHT

* * *

2 1

SHEET 3 SHEET 4 SHEET 3

1140 RED/WHT

+12V PWR

30

1500 RNG/WHT

87 2030 BLK

85

GND

C A B

11

2745 BLK

8

7020 WHT

SWITCH OFF 5 2 1 4 6 3

1500 RNG/WHT

7410 WHT SW11 AC SWITCH

*

2745 BLK

3

2570 BLK 7020 WHT

7023 WHT 7024 WHT

A SHEET 13

7024 WHT 2290 BLK

# 7025 WHT 2280 BLK D4

C486

1 2

SIG GND

C

MAGNET CLUTCH (COMPRESSOR)

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

7400 WHT

C630

3 2 1

Printable Version Click Here THERMOSTAT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 12 of 13 (PRINTED JANUARY 2017) 7210766 (C)

729 of 1311

BLOWER MOTOR

1

9

C350

C355 FUEL HARN

HEATER VALVE

SW10 *BLOWER

Copy -- Not for Resale

1790 RNG/WHT

7021 WHT

Printed In U.S.A.

POTENTIOMETER (TEMP CONTROL SWITCH)

WHT

D SIG C GND A +12V PWR B E F

* B A

BLK DBL

C635

2100 BLK 7015 WHT

J1A GWY CTRLR

HVAC DUCT FAN

86

SHEET 4

AC EVAPORATOR SWITCH

7

GND SIG

C483

2130 BLK 7430 WHT

C438 (DK GRAY) Dealer CAB-MFR HARN CONN 3

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

C610

2560 BLK 7420 WHT 7425 WHT

FRC1 HVAC RELAY

#

SHEET #

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 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 WHITE WHT OTHER FUNCTIONS 7000 THROUGH 7999 TAN TAN ENGINE 8000 THROUGH 8999 PURPLE PUR COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

# POWER BOB CLOSE

SIG GND

4470 LGN 2470 BLK

POWER BOB OPEN

GND SIG

E B

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

C428 (LT GRAY) CAB-MFR HARN CONN 2

# 4470 LGN 4480 LGN

SHEET 4

C606

2 1

2480 BLK 4480 LGN

F

* DLX CAB HARN 7234737 ONLY (NOT IN STD CAB HARN 7210557)

SHEET #

8

4470 LGN 2770 BLK

OPTIONS

CONNECTOR

2290 BLK

SHEET 12

#

2770 BLK

PARTIAL CONNECTOR

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13

OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CAB MANUAL CONTROLS LIGHTS HVAC OPTIONS

C355 FUEL HARN

C607

1 2

SCHEMATIC INDEX

4480 LGN

SW5 *POWER

2

1

BOBTACH SWITCH

5

3 4 6

7

DLX FUEL HARN 7184255 ONLY (NOT IN STD FUEL HARN 7149219)

1380 RED/WHT 1410 RED/WHT

SHEET 3

12

1410 RED/WHT

1200 RED/WHT

LEFT HANDLE (BLINKER / FLASHER) 5 PIN

6010 PNK

10 6400 PNK

6415 PNK

14

1550 RNG/WHT

6515 PNK

6010 PNK

9

1550 RNG/WHT

D2

6400 PNK 3400 LBL

SHEET 8

C103 TAILGATE HARN EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS SHEET)

E

*

D

(PINS 3 & 6 INTERNALLY INSULATED)

C438 (DK GRAY) CAB-MFR HARN CONN 3

6410 PNK 6500 PNK

6510 PNK

3500 LBL 6500 PNK

Dealer Copy -- NotD1for Resale

SHEET 8

3

C423

BUCKET POSITION SOLENOID 9.8 OHM

SIG

A

4450 LGN

GND

B

2450 BLK

D3 4455 LGN

2455 BLK

2

2830 BLK SHEET 4 2780 BLK

SHEET 4

B A

7210 WHT 1460 RED/WHT

3 1 4 6

SHEET 4

13

26

J2B AUX CTRLR

26

2460 BRN 4460 LGN

GND SIG

2360 BRN 4360 LGN

26

2350 BRN 4350 LGN

J1A GWY CTRLR

SHEET 2785 4 BLK

7210 WHT

J1B GWY CTRLR

6530 PNK 6440 PNK 6540 PNK

GND SIG

2 1

GND SIG

C670

2420 BLK

BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS SHEET)

B A

*

C676 RADIO CONN

C279 GND SIG

FRONT HORN

LEFT SPEAKER

+

1 2

7820 WHT 7830 WHT

3 4

*

-

RIGHT SPEAKER

HIGH FLOW SOLENOID 7.5 OHM 12 V

+

SHEET 9 SHEET 9

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V TRACK 2 SPEED TWO SPEED SOLENOID 5.1 OHM 12 V

-

ADAPTER (SEE ADDITIONAL OPTIONS SHEET)

2 1

7810 WHT 7800 WHT 1885 RNG/WHT 2885 BLK

6 5 1 2

SHEET 9 SHEET 9

1510 RNG/WHT 2210 BLK

C277

1 2 3 4 5 6

AIR RIDE SEAT PWR GND

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV21747 - A3NV25155) (S/N A3NW13098 - A3NW13766) (S/N 1MLS11001 AND ABOVE) Sheet 13 of 13 Printable Version Click Here (PRINTED JANUARY 2017) 7210766 (C)

730 of 1311

E D F B C A

POSITION SWITCH

C278

C441

25 26

Printed In U.S.A.

2 1

6700 PNK 2850 BLK

6

SW6 *BUCKET

C126

C437

27

SWITCH 6 5 4 1 2 3

2725 BLK

*

SHEET 3 B A

SW2 *BEACON

2780 BLK

C415 J2A AUX CTRLR

2 5

2 5

1 3 4

1

C408 (BLACK) CAB-MFR HARN CONN 1

C412 LEFT HANDLE (HORN) 2 PIN

4455 LGN

L

T3 FLASHER CONN

6430 PNK SW3 HAZARD SWITCH

SHEET 3

*

6570 PNK

B C D E A

X

1430 RED/WHT

C411

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C212 C252 C253

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN CAB ACCESSORY POWER SOCKET WASHER ADAPTER INTMD WASHER PUMP

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 2 2 2

C277 C278 C279 C308 C350 C355 C404 C405 C406 C408 C409 C410 C411 C412 C415 C418 C419

AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS BU ALARM-MFR HARN AIR FILTER SWITCH FUEL SENDER CAB-MFR HARN CONN (BLK) RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY (FLSHR) LEFT HANDLE 2 WAY (HORN) HIGH FLOW SOLENOID FRONT ROD FRONT BASE

6 2 2 2 2 6 2 2 2 14 10 10 5 2 2 2 2

13 13 13 7 12 6,12,13 3,10 6 6 3-5,8,9,11,13 10 10 13 13 13 7 7

C420 C421 C422

HYD LOCK TILT SPOOL LOCK TILT SPOOL LCOK

2 3 3

7 10 10

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9 9

C423 C425 C426 C428 C434-1 C434-2 C435-1 C435-2 C437 C438 C441 C446 C449 C479 C480 C482 C483 C486 C489 C499 C500 C503 C602 C603 C606 C607 C610 C611 C630 C635 C667 C670 C676

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 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 LIGHTS 6000 THROUGH 6999 PINK PNK 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

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS 2 BUCKET POSITION 3 BRAKE SOLENOID 7 CAN (Remote Start Tool, ACD) 14 CAB-MFR HARN CONN (LT GRY) 2 LEFT WORKLIGHT 1 LEFT WORKLIGHT 2 2 RIGHT WORKLIGHT 1 2 RIGHT WORKLIGHT 2 2 TWO SPEED MAKEUP 2 CAB-MFR HARN CONN (DK GRY) 14 TWO SPEED 2 HYDRAULIC FAN 2 4 LEFT JOYSTICK (CAB HARN) 12 LEFT PANEL(BLACK) 12 LEFT PANEL(GRAY) SEATBAR SENSOR TEMP CONTROL SWITCH AC COMPRESSOR MFR ACCESSORY PTOL RH KEY SWITCH RH DLX PANEL LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT POWER BOBTACH Dealer OPEN POWER BOBTACH CLOSE HVAC DUCT FAN BLOWER MOTOR THERMOSTAT HEATER VALVE DOOR EXTERIOR BEACON RADIO

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CAB PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13

3 3 2 2 4 6 6 2 2 Copy 2-2 2 4 3 6 6 6 6

Not

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

NUM OF PINS 8 8 64

3 3 3,6,7,11,12

J1A J1B J2A J2B

GATEWAY CONTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER

34 26 34 26

3,6-8,10-13 3-10,13 7,10,13 3,4,5,7,10,13

SW1 SW2 SW4 SW5 SW6

BRAKE SWITCH BEACON SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH BUCKET POSITION SWITCH

6 6 6 6 6

8 13 9 13 13

SW9 SW10 SW11

TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

6 5 3

8 12 12

T1 T2 T3 T6 T8 T13 T14 T15 T16

BATT GROUND BUZZER GROUND FLASHER BATT GROUND BATT GROUND BUZZER POWER PRE HEATER RIGHT REAR WORK LIGHT(+) RIGHT REAR WORK LIGHT(-) LEFT REAR WORK LIGHT (+) LEFT REAR WORK LIGHT (-) BACKUP ALARM BACKUP ALARM (GND) DOMELIGHT (+) DOMELIGHT (-)

1 1 2

4 8 13 4 4 8 6 11 11 11 11 10 10 9 9

SHEET

CONN

DESCRIPTION

13 7 5 3,4,9,13 11 11 11 11 13 9,12,13 13 7 5 5,8 8

FC1 FC2 FRC1

9 12 12 3,4 8 8 5,8 11 11 13 for Resale 13 12 12 12 12 9 13 13

T17 T18 T19 T20 T37 T38

SHEET

1 1 1 1 1 1 1 1 1 1 1 1

LEGEND PARTIAL CONNECTOR

CONNECTOR

WIRE BREAK (TWO WIRE BREAKS JOIN ONE WIRE)

SHEET #

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 1 OF 13 (PRINTED JANUARY 2017)

Printed In U.S.A. 731 of 1311

7254943 (0)

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

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) FUNCTION PIN FUNCTION HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS B-2 LIFT SPOOL LOCK RETURN UNSW BATT FUEL PULL RELAY B-3 UNSW BATT SWITCHED POWER OUT RELAY B-4 FUEL HOLD B-5 LIGHT 1 RELAY LIFT SPOOL LOCK GLOW PLUG RELAY B-6 TRACTION LOCK HOLD STARTER RELAY B-7 TILT SPOOL LOCK B-8 TRACTION PULL RELAY CAN LO 1 B-9 CAN HI 1 TILT SPOOL LOCK RETURN B-10 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR B-12 FUEL LEVEL TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD GLOW PLUG RELAY FDBK B-14 CAN HI 2 B-15 ENGINE SPEED GROUND P1 B-16 AIR FILTER SWITCH GROUND P2 LIGHT 2 RELAY B-17 GROUND P3, SENSOR HYD FAN RETURN B-18 ENGINE COOLANT TEMP (8 VOLT) B-19 PTOL LED HYD FAN OUTPUT PTOL SWITCH B-20 CAN LO 2 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY B-22 STATER RELAY FDBK RUN/ENTER B-23 SENSOR SUPPLY 8V START ENGINE B-24 SENSOR SUPPLY 5V B-25 ENGINE OIL PRESS TWO SPEED MAKEUP B-26 TWO SPEED MAKE UP GROUND TWO SPEED COIL TWO SPEED GROUND LIGHT 2 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP (8 VOLT) HYD OIL FILTER SW1

Printed In U.S.A.

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN B-1 A-2 B-2 UNSW BATT A-3 B-3 UNSW BATT A-4 B-4 A-5 B-5 A-6 B-6 A-7 B-7 A-8 B-8 CAN LO 1 A-9 B-9 CAN HI 1 A-10 B-10 A-11 LH PADDLE RIGHT B-11 A-12 LH PADDLE LEFT B-12 A-13 B-13 RH RIGHT BUTTON UP FRONT AUX (F) A-14 B-14 A-15 B-15 GROUND A-16 B-16 GROUND A-17 B-17 HANDLE POT GND A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL A-19 B-19 FRONT AUX (M) A-20 B-20 A-21 B-21 RH TRIGGER A-22 B-22 LH RIGHT BUTTON DOWN SWITCHED POWER A-23 B-23 HANDLE POT POWER A-24 B-24 Dealer Copy -- Not for Resale A-25 B-25 A-26 B-26 HIGH FLOW RETURN HIGH FLOW A-27 A-28 A-29 A-30 RH LEFT UP A-31 RH LEFT DOWN A-32 A-33 A-34 HARNESS PART NUMBER EXMF 7265252 MAINFRAME LF 7210768 EXMF 7265252 MAINFRAME LF 7210768 DLX CAB 7253409 7210557 STD CAB DLX FUEL 7266824 STD FUEL 7149219 6733370 S/R (STARTER) TAILGATE DOM 7217484 TRK BRAKE ADP 7234968 7159366 WHL 2 SPD ADP 7214626 TRK 2 SPD (1PC) TRK 2 SPD 7243409

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 2 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

732 of 1311

1240 RED/WHT

POWER

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

1420 RED/WHT 1440 RED/WHT

FC1 FUSE CENTER

FUSE 1 25 A

1070 RED

+12V BATTERY

FUSE 2 25 A

1025 RED MEGAFUSE 100.0 Amps

BATT_CABLE

1120 RED/WHT

1160 RED/WHT

J1B GWY CTRLR

1150 RED/WHT

3

1180 RED/WHT

2

SHEET 8 C503 RH DLX PANEL SHEET 9 C667 DOOR HARNESS SHEET 8 C500 RH KEY SWITCH SHEET 8 C479 LH PANEL

J2B AUX CTRLR

FUSE 3 OPEN

1010 RED

FUSE 4 OPEN

SHEET 6 STARTER

FC2 FUSE CENTER

FUSE 1 25 A

1190 RED

FUSE 2 25 A

1040 RED

1165 RED/WHT

SHEET 5 C426 REMOTE RUN, ACD 1410 RED/WHT

1490 RED/WHT

FUSE 3 OPEN FUSE 4 15 A

1290 RED

SHEET 13 C408 CAB-MFR CONN (OPTIONS)

1460 RED/WHT 1370 RED/WHT

SHEET 13 C412 LH HANDLE HORN

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES)

FRC1 FUSE RELAY CENTER

1050 RED

FUSE 5 30 A

1060 RED SHEET 6 FRC1 PRE HEATER RELAY

FUSE 6 30 A

1310 RED

1350 RED/WHT

SHEET 6 FRC1 FUEL SHUTOFF RELAY SHEET 7 FRC1 TRACTION LOCK RELAY

1360 RED/WHT

1030 RED

SHEET 6 FRC1 STARTER RELAY

FUSE 9 15 A

1320 RED/WHT

FUSE 10 20 A 1330 RED/WHT

1340 RED

FUSE 11 25 A

1300 RED

FUSE1 25 A 1760 RNG/WHT

FUSE 2 25 A FUSE 3 15 A

SHEET 11 FRC1 REAR LIGH RELAY

Dealer Copy -- Not for Resale

1140 RED/WHT

SHEET 11 FRC1 FRONT LIGHT RELAY

1850 RNG/WHT 1550 RNG/WHT

SHEET 9 C408 CAB-MFR CONN (FR WIPER) SHEET 13 C408 CAB-MFR CONN (BKT POSITION)

FUSE 8 25 A

1050 RED

+12V PWR

1765 RNG/WHT 1815 RNG/WHT 30 87

SHEET 4

2055 BLK GND

85

86

FUSE 12 15 A

J1A GWY CTRLR

3450 LBL 3380 LBL

21 4

1730 RNG/WHT 1580 RNG/WHT 1800 RNG/WHT 1790 RNG/WHT

C428 (LT GRAY) CAB-MFR HARN CONN 2

1920 RNG/WHT

6

1920 RNG/WHT

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS DWG) C489 MFR ACCESSORY

C428 (LT GRAY) CAB-MFR HARN CONN 2

1660 RNG/WHT 1570 RNG/WHT

FRC1 SWITCHED POWER RELAY

A

1780 RNG/WHT

1520 RNG/WHT 1560 RNG/WHT

SHEET 10 C410 LEFT HANDLE SHEET 10 C409 RIGHT HANDLE

SHEET 9 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)

SHEET 12 FRC1 HVAC RELAY

1840 RNG/WHT 1830 RNG/WHT

SHEET 5 C449 LH JOYSTICK SHEET 5 C450 RH JOYSTICK

1940 RNG/WHT 1930 RNG/WHT

1590 RNG/WHT 1950 RNG/WHT

22

SHEET 5 C426 REMOTE RUN, ACD

SHEET 6 C110 ALT EXCITATION

1620 RNG/WHT

1775 RNG/WHT 1660 RNG/WHT

2 1530 RNG/WHT

1795 RNG/WHT

1720 RNG/WHT

SHEET 12 FRC1 HVAC RELAY

1750 RNG/WHT

FUSE4 5 A

FUSE 7 25 A

B

J2B AUX CTRLR

1785 RNG/WHT 1960 RNG/WHT

SHEET 8 C479 LH PANEL SHEET 8 T13 LH PANEL BUZZER SHEET 8 C499 RH PANEL PTOL SHEET 8 SW1 BRAKE SWITCH SHEET 8 C503 RH DELUXE PANEL SHEET 8 C500 RH PANEL KEY SWITCH SHEET 9 SW4 H/ISO SWITCH SHEET 8 SW9 TRAVEL CONTROL SWITCH

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 3 OF 13 Printed In U.S.A. 733 of 1311

(PRINTED JANUARY 2017) 7254943 (0)

2080 BLK SHEET 5 C449 LH JOYSTICK 2070 BLK SHEET 5 C450 RH JOYSTICK 2920 BLK SHEET 8 C479 LH PANEL 2940 BLK SHEET 8 C499 PTOL 2960 BLK SHEET 8 C500 RH PANEL KEY SWITCH 2250 BLK SHEET 8 C503 RH DELUXE PANEL 2930 BLK

SHEET 8 SW1 BRAKE SWITCH 2830 BLK SHEET 13 SW6 BKT POSITION SWITCH 2700 BLK SHEET 8 SW9 TRAVEL CONTROL SWITCH 2785 BLK SHEET 13 C126 HORN 2620 BLK SHEET 11 T16 RH REAR LIGHT 2630 BLK SHEET 11 T18 LH REAR LIGHT 2650 BLK SHEET 10 T20 BU ALARM 2640 BLK SHEET 11 C602 LH REAR LIGHT 2610 BLK SHEET 11 C603 RH REAR LIGHT

2950 BLK

10

C428 (LT GRAY) CAB-MFR HARN CONN 2

2900 BLK

2140 BRN

SHEET 6 C107 ENG OIL PRESS SENDER 2150 BRN SHEET 6 C405 AIR FILTER SWITCH

Printed In U.S.A. 734 of 1311

2510 BLK

15

2500 BLK

16 J2B AUX CTRLR

15

2110 BLK

2900 BLK

C103 TAILGATE HARN

C489 MFR ACCESSORY

B

2300 BLK

B

2600 BLK

SHEET 6 FRC1 FUEL PULL RELAY SHEET 7 FRC1 TRACTION LOCK RELAY SHEET 11 FRC1 REAR LIGHT RELAY

J1B GWY CTRLR

17

T8 BATT GND

T1 BATT GND

2720 BLK

2400 BLK SHEET 6 C101 FUEL SHUTOFF SOLENOID Dealer Copy 2200 BLK SHEET 7 C425 BRAKE

2230 BRN

2765 BLK SHEET 11 C408 CAB-MFR CONN (FR LIGHTS) 2745 BLK SHEET 12 C408 CAB-MFR CONN (HVAC) 2790 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES) 2780 BLK SHEET 13 C408 CAB-MFR CONN (OPTIONS) 2730 BLK SHEET 9 C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)

2090 BLK

2550 BLK

2770 BLK SHEET 13 C355 FUEL HARN (PWR BOB/AC)

2600 BLK

T6 BATT GND

2540 BLK

2455 BLK SHEET 13 C423 BKT POSITION SOLENOID 2710 BLK SHEET 5 C426 REMOTE RUN, ACD

2320 BRN SHEET 7 C112 HYD OIL FILTER SWITCH 2370 BRN SHEET 9 C408 CAB-MFR CONN (SEATBAR SENSOR)

2180 BRN SHEET 6 C355 FUEL HARN (FUEL SENDER)

16

1

2160 BRN SHEET 6 C106 ENGINE SPEED SENSOR

2190 BRN SHEET 7 C105 HYD CHG PRESSURE SENDER

2950 BLK

J1B GWY CTRLR

2170 BRN SHEET 6 C104 ENGINE COOLANT SENSOR

2220 BRN SHEET 7 C108 HYD TEMP SENDER

GROUND

C408 (BLACK) CAB-MFR HARN CONN 1

2390 BLK

-- Not for Resale

2025 BLK 2035 BLK 2045 BLK

SHEET 11 FRC1 FRONT LIGHT RELAY SHEET 6 FRC1 GLOW PLUG RELAY

2115 BLK

SHEET 3 FRC1 SWITCHED PWR RELAY

2055 BLK

SHEET 12 FRC1 HVAC RELAY SHEET 6 FRC1 STARTER RELAY

2016 BLK

2030 BLK 2005 BLK

2105 BLK

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 4 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

CAN BUS C408 (BLACK) CAB-MFR HARN CONN 1

J1B GWY CTRLR

CAN LO CAN HI

8 9

* DLX CAB HARN 7253409 ONLY (NOT IN STD CAB HARN 7210557)

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9230 PUR 9130 PUR/WHT

9230 PUR 9130 PUR/WHT

4 3

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

120 OHM RESISTOR

9500 PUR/WHT 9600 PUR 3090 LBL

14

21

1730 RNG/WHT 1165 RED/WHT 2710 BLK

SHEET 3 SHEET 3 SHEET 4

A B D C E F G

9260 PUR 9160 PUR/WHT

REMOTE RUN KEY

SHEET 3 SHEET 4

SWITCHED POWER UNSWITCHED POWER GROUND

4 3

C479 LEFT PANEL (BLACK)

4 2

C503 RIGHT DELUXE PANEL

120 OHM RESISTOR

C426 Remote Run Tool, ACD CAN HI 20 CAN LO

9630 PUR 9530 PUR/WHT

9220 PUR 9120 PUR/WHT

8 9

J2B AUXDealer CTRLR

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1 2 3 4

C450 RIGHT JOYSTICK (SJC/AWS ONLY)

1840 RNG/WHT 2080 BLK 9540 PUR/WHT 9640 PUR

1 2 3 4

C449 LEFT JOYSTICK (SJC/AWS ONLY)

*

Copy -- Not for Resale SHEET 3 SHEET 4

*

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 5 OF 13 Printed In U.S.A.

(PRINTED JANUARY 2017) 7254943 (0)

735 of 1311

1030 RED

SHEET 3

2005 BLK

SHEET 4

+12V PWR

GND

FRC1 STARTER RELAY 30 8200 TAN 87 85

86

C109 S/R ADAPTER

3560 LBL

STARTER

A B

TAN TAN

8210 TAN

S R

M

B

SHEET 3 1015 RED C110

B

S L

G

ALTERNATOR

1020 RED 1800 RNG/WHT

SHEET 3

EXCITATION

2015 BLK FRC1 FUEL PULL RELAY +12V SHEET 3

1350 RED/WHT

PWR

30 87

2025 BLK

SHEET 4

GND

85

86

FRC1 GLOW PLUG RELAY +12V 30 PWR 1060 RED 87

SHEET 3

2016 BLK

SHEET 4

GND

85

6

8510 TAN

14

3420 LBL

3

8110 TAN

30

3410 LBL

7

8210 TAN

22

3560 LBL

C101 D5

8120 TAN 3410 LBL SHEET 4

8110 TAN

2400 BLK

FUEL SHUTOFF SOLENOID

8100 TAN

B

PULL

2800 BLK

C

GND

8800 TAN

A

HOLD

T14 PRE HEATER

0.33 OHM

24.5 OHM

ENGINE

8500 TAN

86

Dealer Copy -- Not for Resale

C107 J1A GWY CTRLR

SHEET 9

25

SHEET 4

5140 YEL 3140 LBL 2140 BRN

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

C405

SHEET 4

16

2150 BRN 3150 LBL

B A

GND SIG

AIR FILTER SWITCH (NC)

C106

15 SHEET 4

3160 LBL 2160 BRN

A B

SIG GND

C104

SHEET 4

18 4

2170 BRN 3170 LBL

GND SIG

Printable Version Click Here C355 FUEL HARN

12 SHEET 4

Printed In U.S.A.

ENGINE COOLANT SENSOR (500-3000 OHM) (8 VOLT)

8800 TAN

J1B GWY CTRLR

736 of 1311

B A

ENGINE SPEED SENSOR (163 OHM)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930)

3180 LBL 2180 BRN

C D

3180 LBL 2180 BRN

Sheet 6 OF 13 C406

A B

SIG GND

FUEL SENDER (30 - 270 OHM)

(PRINTED JANUARY 2017) 7254943 (0)

SHEET 3

FRC1 TRACTION LOCK +12V RELAY 1360 RED/WHT PWR 30 3430 LBL 87 2035 BLK

SHEET 4

GND 85

86

HYDRAULICS 4100 LGN SHEET 4

4200 LGN 2200 BLK

C425

B A C

C308

4200 LGN 2200 BLK

A B

BRAKE SOLENOID 9.8 OHM 12 V

WHEEL 2 SPD ADP HARNESS 7159366 TRACK SINGLE SPD BRAKE ADP HARNESS 7165061

4110 LGN

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS DWG)

C425

B A C

8

PULL HOLD

0.3 OHM 10.9 OHM WHEEL SINGLE SPEED TRACTION LOCK

13 C108

SHEET 4

32

2220 BRN 3220 LBL

B A

GND SIG

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM (8 VOLT)

C112 J1A GWY CTRLR

34 SHEET 4

3320 LBL 2320 BRN

A B

SIG GND

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

HYDRAULICDealer LOCK SOLENOID 9.8 OHM 12 V

Copy -- Not for Resale

C105

SHEET 4

2190 BRN 3190 LBL 5190 YEL

B C A

GND SIG +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

2 1

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

19 13 J2B AUX CTRLR

Printed In U.S.A.

Sheet 7 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

737 of 1311

1940 RNG/WHT

SHEET 3

CAB DISPLAY

T13 BUZZER (+) LEFT PANEL BUZZER

7040 WHT

C479 LEFT PANEL (BLACK)

T2 BUZZER (-)

SHEET 4 1960 RNG/WHT

SHEET 3

SHEET 3

*

SW9 TRAVEL CONTROL SWITCH (OPTIONAL)

SHEET 4

2700 BLK

SHEET 3 SHEET 4

SHEET 3 SHEET 13

5 6 4 2 3 1

SHEET 13

3610 LBL 1775 RNG/WHT 2930 BLK

3 1 4

* DLX CAB HARN 7253409 ONLY (NOT IN STD CAB HARN 7210557)

7040 WHT

10

2920 BLK

2

1440 RED/WHT

1

1620 RNG/WHT

5

SWITCHED POWER

3400 LBL

11

LEFT BLINKER INPUT

3500 LBL

8

3650 LBL

7

3600 LBL

9 6

SW1 BRAKE SWITCH 2

C499 Press To Operate Loader (PTOL)

SHEET 3 SHEET 4

C408 (BLACK) CAB-MFR HARN CONN 1

BUZZER GROUND

20

UNSWITCHED POWER

19

3030 LBL

1

3030 LBL

2

2380 BRN

12

2380 BRN

4

24

TRAVEL CONTROL INPUT

8130 TAN

2

8130 TAN

PARK BRAKE INPUT J1B GWY CTRLR

22

C480 LEFT PANEL (GRAY)

3610 LBL

DOOR SIGNAL

PTOL OUTPUT PTOL LED

2

START

6 3040 LBL

14

3040 LBL

6 12 11 10 9 2 8 7 6 5 4 3 1

SWITCHED POWER GROUND

C500 RIGHT KEY SWITCH PANEL

RIGHT BLINKER INPUT

12

3630 LBL

1 3

J1A GWY CTRLR

5

SHEET 9

1930 RNG/WHT 2940 BLK

Dealer Copy -- Not for Resale

SHEET 3 SHEET 3 SHEET 4

4 5 1 3

1950 RNG/WHT 1420 RED/WHT 2960 BLK

RUN/ENTER SWITCH SWITCHED POWER UNSWITCHED POWER GROUND

C503 RIGHT DELUXE PANEL PARK BRAKE OUTPUT

SHEET 3 SHEET 3 SHEET 4

1590 RNG/WHT

5

1240 RED/WHT

1

2250 BLK

3 6

SWITCHED POWER UNSWITCHED POWER GROUND

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Printed In U.S.A.

Sheet 8 OF 13 (PRINTED JANUARY 2017)

738 of 1311

*

SHEET 3 C438 SHEET 9 (DK GRAY) CAB-MFR HARN CONN 3

4

4235 LGN

5

4275 LGN

6

4550 LGN

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH 1785 RNG/WHT 2 1 3 5 6 2060 BLK 4

CAB * DLX CAB HARN 7253409 ONLY (NOT IN STD CAB HARN 7210557) *

C212 POWER SOCKET

C408 (BLACK) CAB-MFR HARN CONN 1

SHEET 3

1370 RED/WHT

7

1370 RED/WHT

1210 RED/WHT 1580 RNG/WHT

5

1580 RNG/WHT 1865 RNG/WHT 2820 BLK 1510 RNG/WHT 1885 RNG/WHT

SHEET 4

2730 BLK

11

2730 BLK

A B C

11

*

1850 RNG/WHT

SHEET 13 SHEET 13 2210 BLK

SHEET 13 SHEET 13

Copy --SHEET Not for 9 Resale

*

SHEET 4

11 +5V

24

5100 YEL 5140 YEL SHEET 6

13 1850 RNG/WHT

1850 RNG/WHT

2370 BRN

4

2370 BRN

A

SEATBAR GND SENSOR

3370 LBL

5

3370 LBL

B

SIG

3

5370 YEL

C

+5V PWR

5370 YEL

2840 BLK 7310 WHT

HARNESS WASHER PUMP 7253378

* 2845 BLK

Printed In U.S.A.

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

2790 BLK 3630 LBL 1400 RED/WHT

2790 BLK

C482 J1B GWY CTRLR

T38 DOME LIGHT (-)

GND

SHEET 8 SHEET 3 SHEET 3

DOME LIGHT

+12V BATT PWR +12V SW PWR

C428 (LT GRAY) CAB-MFR HARN CONN 2

2790 BLK

T37 DOME LIGHT (+)

2010 BLK

2885 BLK 2060Dealer BLK

SHEET 4

GND +12V PWR

*

1390 RED/WHT C129 CAB ACCESSORY

SHEET 3

1 2

2795 BLK 1375 RED/WHT

C253

C252

A

7310 WHT

1

B

2845 BLK

2

2 3

DOOR SIGNAL DOOR UNSW PWR WIPER SWITCH, MOTOR SWITCHED POWER WIPER MOTOR GROUND WASHER SIGNAL

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

PWR WASHER MOTOR GND

4 5 6 1

Sheet 9 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

739 of 1311

MANUAL CONTROLS

C409 RIGHT HANDLE

J2A AUX CTRLR

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTIONS SHEET)

A

30 31

C103 TAILGATE HARN

7100 WHT

C

T19 TERMINAL (+)

13

7100 WHT

SHEET 4

SHEET 3

BACK UP ALARM

2650 BLK

1520 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

K G A H J E F C D B

SKI CTRL DETENT FLOW TWO SPD PWM

T20 TERMINAL (-)

21 17 18 23 C421

2670 BRN 4670 LGN

10 J1A GWY CTRLR

3 1 2

GND SIG

TILT SPOOL LOCK 7.8 OHM 12V

Dealer Copy -- Not for Resale

C422

2680 BRN 4680 LGN

2

7

5

J1B GWY CTRLR

3 1 2

C410 LEFT HANDLE

J2B AUX CTRLR

GND SIG

LIFT SPOOL LOCK 7.8 OHM 12V

28 22 12 11 SHEET 3

4840 LGN 4830 LGN 4820 LGN 4810 LGN 1530 RNG/WHT

K D C B G F A J H E

Sheet 10 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

740 of 1311

SIDE SHIFT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Printed In U.S.A.

SKI CTRL

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 4

LIGHTS

2765 BLK

9

2765 BLK

2750 BLK 6110 PNK

6000 PNK

8

6000 PNK

6120 PNK 2760 BLK

B A

C435-1

A B C435-2

6130 PNK 2705 BLK

FRC1 FRONT WORK LIGHTS RELAY SHEET 3 SHEET 4

1330 RED/WHT

+12V PWR

30 87

2115 BLK

GND

85

C103 TAILGATE HARN

6340 PNK

6310 PNK

A

6310 PNK

C603

SHEET 4

6320 PNK 3460 LBL 6210 PNK 3440 LBL

SHEET 4

1320 RED/WHT

2045 BLK

2 1

GND SIG

RIGHT REAR TAIL LIGHT

C602

6330 PNK 2640 BLK

1 2

SIG

LEFT REAR TAIL LIGHT

GND

Dealer Copy -- Not for Resale

SHEET 4

SHEET 3

2610 BLK 6320 PNK

86

SHEET 4 5 31 J1A 17 GWY CTRLR 28

A B

FRC1 REAR LIGHT RELAY +12V PWR 30 87 GND

85

86

2620 BLK 6210 PNK

T16 TERMINAL (-) GND SIG

RIGHT REAR WORK LIGHT

T15 TERMINAL (+)

6200 PNK

H

6200 PNK SHEET 4

6220 PNK 2630 BLK

T17 TERMINAL (+) SIG GND

LEFT REAR WORK LIGHT

T18 TERMINAL (-)

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Printed In U.S.A.

Sheet 11 OF 13 (PRINTED JANUARY 2017)

741 of 1311

7254943 (0)

HVAC

2440 BLK 7440 WHT

2560 BLK*

* DLX CAB HARN 7253409 ONLY (NOT IN STD CAB HARN 7210557) #

SHEET 3 SHEET 4 SHEET 3

1140 RED/WHT

FRC1 HVAC RELAY 30 85

GND

1500 RNG/WHT

AC EVAPORATOR SWITCH

*

7

C A B

1790 RNG/WHT

2745 BLK

7020 WHT

7021 WHT

8

SW10 *BLOWER SWITCH OFF 5 2 1 4 6 3

1500 RNG/WHT

7410 WHT SW11 AC SWITCH

*

2745 BLK

2570 BLK 7020 WHT

7023 WHT 7024 WHT

SHEET 13

7024 WHT 2290 BLK

# 7025 WHT 2280 BLK D4

C486

1 2

SIG GND

HEATER VALVE

3

C

*

7530 WHT 7520 WHT 7510 WHT 2580 BLK

C611

1 2 3 4

14.00 Amps 7.50 Amps 5.00 Amps

7400 WHT

MAGNET CLUTCH (COMPRESSOR)

C630

3 2 1

THERMOSTAT

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Sheet 12 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

742 of 1311

BLOWER MOTOR

1

Printable Version Click Here

Printed In U.S.A.

High Med Low

9

C350

A

POTENTIOMETER (TEMP CONTROL SWITCH)

D SIG C GND A +12V PWR B E F

2130 BLK 7430 WHT

Dealer Copy -- Not for Resale

C355 FUEL HARN

BLK DBL WHT

C635

* B A

HVAC DUCT FAN

C483

2100 BLK 7015 WHT 11

GND SIG

86

SHEET 4

J1A GWY CTRLR

2 1

C438 (DK GRAY) CAB-MFR HARN CONN 3

87 2030 BLK

C610

7420 WHT 7425 WHT

DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

+12V PWR

*

# POWER BOB CLOSE

SIG GND

1 2

4470 LGN 2470 BLK

POWER BOB OPEN

GND SIG

2770 BLK

E B

8

4470 LGN 2770 BLK

4480 LGN

SHEET 4

C606

2 1

2480 BLK 4480 LGN

F

* DLX CAB HARN 7253409 ONLY (NOT IN STD CAB HARN 7210557)

4470 LGN

2290 BLK

SHEET 12

#

C428 (LT GRAY) CAB-MFR HARN CONN 2

C355 FUEL HARN

C607

OPTIONS

4480 LGN

SW5 *POWER

2

1

BOBTACH SWITCH

5

3 4 6

7

#

DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

1380 RED/WHT 1410 RED/WHT

SHEET 3

12

1410 RED/WHT

1200 RED/WHT

LEFT HANDLE (BLINKER / FLASHER) 5 PIN

6010 PNK

10 6400 PNK

6415 PNK

14

1550 RNG/WHT

6515 PNK

9

1550 RNG/WHT

D2

6400 PNK 3400 LBL

SHEET 8

C103 TAILGATE HARN

*

EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS DWG)

E

6410 PNK

D

(PINS 3 & 6 INTERNALLY INSULATED)

C438 (DK GRAY) CAB-MFR HARN CONN 3

6500 PNK

6510 PNK

SHEET 8

3

BUCKET POSITION SOLENOID 9.8 OHM

SIG

A

4450 LGN

D3 4455 LGN

GND

B

2450 BLK

2455 BLK

2 SHEET 4 2780 BLK

B A

7210 WHT 1460 RED/WHT

4

6

SHEET 4

13

26

J2B AUX CTRLR

26

2460 BRN 4460 LGN

GND SIG

2360 BRN 4360 LGN

J1A GWY CTRLR

GND SIG

2350 BRN 4350 LGN 25 26 J1B GWY CTRLR

2 1

GND SIG

6

6530 PNK 6440 PNK 6540 PNK

5

2420 BLK

E D F B C A

BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

SHEET 2785 4 BLK

B A

*

C676 RADIO CONN

C279 GND SIG

FRONT HORN

LEFT SPEAKER

+

1 2

7820 WHT 7830 WHT

3 4

*

C278

RIGHT SPEAKER

HIGH FLOW SOLENOID 7.5 OHM 12 V

+

SHEET 9 SHEET 9

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V TRACK 2 SPEED TWO SPEED SOLENOID 5.1 OHM 12 V

-

ADAPTER (SEE ADDITIONAL OPTIONS DWG)

2 1

7810 WHT 7800 WHT 1885 RNG/WHT 2885 BLK

6 5 1 2

SHEET 9 SHEET 9

1510 RNG/WHT 2210 BLK

C277

1 2 3 4 5 6

AIR RIDE SEAT PWR GND

WIRING SCHEMATIC (STANDARD MACHINE) S650 (S/N A3NV25156 - A3NV25639) (S/N A3NW13767 - A3NW13930) Printable Version Click Here

Sheet 13 OF 13 (PRINTED JANUARY 2017) 7254943 (0)

743 of 1311

C670

POSITION SWITCH

C126

7210 WHT

C441

26

Printed In U.S.A.

2 1

6700 PNK 2850 BLK

2780 BLK

C437

27

D1

SHEET 3 B A

SWITCH 6 5 4 1 2 3

2725 BLK

3

C415 J2A AUX CTRLR

5

1

C408 (BLACK) CAB-MFR HARN CONN 1

C412

2

1 3 4

SW6 Dealer Copy -- Not for Resale 1 *BUCKET 2

2830 BLK

SHEET 4

LEFT HANDLE (HORN) 2 PIN

4455 LGN

SW2 *BEACON

*

3500 LBL 6500 PNK

C423

L

T3 FLASHER CONN

6430 PNK SW3 HAZARD SWITCH

SHEET 3

*

6570 PNK

B C D E A

X

1430 RED/WHT 6010 PNK

C411

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 - HYDRAULICS

8

SH08 - CAB DISPLAY

9

SH09 - CAB

10

SH10 - MANUAL CONTROLS

11

SH11 - LIGHTS

12

SH12 - HVAC

13

SH13 - OPTIONS 1

14

SH14 - OPTIONS 2

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

2000 THROUGH 2999

BROWN

BRN

MONITORING

3000 THROUGH 3999

LIGHT BLUE

LBL

HYDRAULIC

4000 THROUGH 4999

LIGHT GREEN

LGN

HARNESS PART NUMBER EXMF MAN

7305441

LF MAN MFR

7304757

CONTROLLER SUPPLY (5V, 8V)

5000 THROUGH 5999

YELLOW

YEL

DLX CAB

7304511

LIGHTS

6000 THROUGH 6999

PINK

PNK

STD CAB

7210557

OTHER FUNCTIONS

7000 THROUGH 7999

WHITE

WHT

STD FUEL

7149219

S/R (STARTER)

6733370

ENGINE

8000 THROUGH 8999

TAN

TAN

TAILGATE DOM

7217484

WHL 2 SPD ADP

7159366

(1 PC) TRK 2 SPD

7243409

SUSP JSTK

7163706

COMMUNICATION CAN LO COMMUNICATION CAN HI

90XX, 92XX, 94XX, 96XX, 98XX 91XX, 93XX, 95XX, 97XX, 99XX

PURPLE

LEGEND CONNECTOR 1

PARTIAL CONNECTOR 1

1

1

1

WIRE BREAK SHT1/E2

PUR

PURPLE/WHITE

1

SHT1/F2

PUR/WHT

WIRE BREAK WIRE BREAK

SHT1/E2 SHT1/F2

Dealer Copy -- Not for Resale

Wiring Schematic Standard Machine

S630 S650

COPYRIGHT

Click Here for Interactive PDF 102712

0 REV

744 of 1311

DESCRIPTION

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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.

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 1 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 1 /Printable 14

UNSWITCHED BATT POWER 1240 RED/WHT 1400 RED/WHT

C408 1450 RED/WHT

6

6

1450 RED/WHT

SP7

1420 RED/WHT 1440 RED/WHT

FC1 FUSE CENTER 1070 RED

1

HW11

1

1120 RED/WHT

SHT8/E3 SHT8/G8

2 GWY CTRLR

1130 RED/WHT

3

SP2

4

1160 RED/WHT

SP36

1150 RED/WHT

3 AUX CTRLR

1180 RED/WHT

1 T4

T5

SHT9/D3

J1B

3

MEGAFUSE 100.0 Amps

2 FUSE 2 25 A

1025 RED

+12V BATTERY

1110 RED/WHT

FUSE 1 25 A

SHT8/E3

2 J2B

FUSE 3 25 A 7

8 FUSE 4 25 A 6

FC1

FC1

1010 RED

SHT6/G1

5

FC2 FUSE CENTER FUSE 1 25 A

1190 RED

1 FUSE 2 25 A

1040 RED

SP26

2

3

4

1165 RED/WHT

SHT5/C8

SP24

1490 RED/WHT

1410 RED/WHT 1460 RED/WHT

Dealer 1370 Copy -- Not for Resale RED/WHT

FUSE 4 15 A

1290 RED

5

6

FC2

SHT13/G7 SHT13/B7 SHT9/F8

FC2

FUSE RELAY CENTER

BUS BAR

FUSE 5 30 A

1310 RED

5A

5B FUSE 6 30 A

6A

6B

BUS BAR

FUSE 9 15 A

1340 RED

1300 RED

9A

9B FUSE 10 20 A

10A

10B FUSE 11 25 A

11A

11B

FRC1

1350 RED/WHT

SHT6/D1

1360 RED/WHT

SHT7/H8

1320 RED/WHT

SHT11/B8

1330 RED/WHT

SHT11/D8

1140 RED/WHT

SHT12/F8

FRC1 1030 RED

SHT6/H8

1050 RED

SHT3/E8

1060 RED

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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

745 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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.

SHT6/E1

TOLERANCES:

ECN

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 2 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 2 /Printable 14

SWITCHED POWER

1720 RNG/WHT

FUSE RELAY CENTER

BUS BAR

FUSE 1 25 A

1760 RNG/WHT

1A FUSE 2 25 A

B

A

A

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)

SP52 1780 RNG/WHT

C489 MFR ACCESSORY

1850 RNG/WHT

2B

2A BUS BAR

1750 RNG/WHT

1B

B

SHT9/D8

1575 RNG/WHT

FUSE 3 15 A

SHT14/G4

1550 RNG/WHT

3B

3A

SHT13/F7

BUS BAR

1620 RNG/WHT

C428 MFR HARN CONN 2 (LT GRAY)

FUSE 4 5 A

1660 RNG/WHT

4B

4A

1940 RNG/WHT

2

2

1930 RNG/WHT 1775 RNG/WHT

1660 RNG/WHT

SP42

1590 RNG/WHT 1950 RNG/WHT 1785 RNG/WHT 1960 RNG/WHT 1565 RNG/WHT

FRC1 SWITCHED POWER RELAY - A

1520 RNG/WHT 1570 RNG/WHT

SP11

SHT4/B8

2055 BLK

G4

G5

30 87 86

85

FRC1

G1

1765 RNG/WHT

1795 RNG/WHT

SP25

G2 FRC1 1815 RNG/WHT

FUSE 7Copy 25 A Dealer -- Not 7B for Resale

7A BUS BAR

SHT2/B1

1050 RED

FUSE 8 25 A

FUSE 12 15 A 12A

SHT9/H6 SHT8/E8 SHT14/E4

SHT5/C8

SHT9/F8

1800 RNG/WHT

12B

SHT8/F3

22 AUX CTRLR

1580 RNG/WHT

8B

8A

SHT8/D8 SHT8/E3

SHT10/D3

J2B

1730 RNG/WHT

SHT8/H8 SHT8/H3

SHT10/G3

1530 RNG/WHT 1560 RNG/WHT

SHT8/G8

SHT6/G4

FRC1

FRC1

1790 RNG/WHT

SHT12/E8

GWY 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

6

6

1830 RNG/WHT 1920 RNG/WHT

SHT5/E3

SP37 1840 RNG/WHT

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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

746 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

SHT5/D3

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 3 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 3 /Printable 14

GROUND SHT6/E7 SHT6/G7 SHT5/D3

SHT6/F7

2080 BLK

SHT6/B7 SHT5/E3 SHT8/G8 SHT8/G3 SHT8/E3 SHT8/D3

2070 BLK

SHT6/B7

2920 BLK

C408 MFR HARN CONN 1 (BLACK)

SP4

2940 BLK

SHT7/D7

2950 BLK

SHT7/F7 2950 BLK

10 10

SHT7/F7 SHT9/C8

2960 BLK 2250 BLK

GWY CTRLR

SP3

2510 BLK

16

2110 BLK

1

2140 BRN 2150 BRN 2160 BRN

GWY CTRLR

2170 BRN 2180 BRN

SP12

2230 BRN

17

SENSOR GND

2190 BRN

J1B

2220 BRN 2320 BRN 2370 BRN

T6

BATTERY GROUND

2500 BLK

15 J1B

2540 BLK

16 SHT14/D4 SHT14/H4 SHT8/E8 SHT13/D5 SHT8/F8 SHT13/B7 SHT13/D6 SHT5/B8 SHT13/H6 SHT11/C4 SHT10/F8 SHT11/C4

2860 BLK

AUX CTRLR

2930 BLK

2090 BLK

2900 BLK

1

SP47

SHT11/B4 SHT7/H4 SHT6/C7

2900 BLK

1

SP27

2455 BLK

2300 BLK

2710 BLK 2770 BLK

C489 MFR ACCESSORY B

2620 BLK

2650 BLK

2720 BLK

B

Dealer Copy -- Not for Resale

C103 TAILGATE HARN 2600 BLK

2640 BLK

B

2600 BLK

B

SP6

2390 BLK

1

T1

SHT6/D1 SHT12/E8 SHT7/H5 SHT11/B8 SHT3/D8 SHT11/D8 SHT14/G4 SHT14/F5

T10 ENGINE GROUND

BATTERY GROUND

2610 BLK 2630 BLK 2200 BLK

AUX CTRLR

2400 BLK

747 of 1311

REV

DESCRIPTION

SP58 2195 BRN

2995 BRN

17

SENSOR GND

J2B

2016 BLK 2025 BLK 2030 BLK

SP1

2105 BLK

2035 BLK 2045 BLK 2055 BLK 2115 BLK 2505 BLK 2155 BLK

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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

2185 BRN

2005 BLK

Wiring Schematic Standard Machine 0

1

2015 BLK

SHT6/G4

SHT14/E7

SHT6/E1

2790 BLK

SHT9/D8

2785 BLK

BATTERY GROUND

2780 BLK

SHT13/D8

T8

1

2765 BLK

SHT11/H8

SHT10/G3 SHT6/G8

2745 BLK

SHT12/D8

SP51 SHT11/E4

2730 BLK

SHT9/E8

C428 MFR HARN CONN 2 (LT GRAY)

2830 BLK 2700 BLK

SP28

2550 BLK

15 J2B

2915 BLK

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 4 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 4 /Printable 14

CAN BUS * DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557) RE016 120 OHM 0.5 W RESISTOR R3-1

GWY CTRLR

TP-09

CAN LO

8

CAN HI

9

9200 PUR

TP-09

TP-10

9100 PUR/WHT

C408 MFR HARN CONN 1 (BLACK) TP-10

9270 PUR

9170 PUR/WHT

R3-2

SP31

TP-16

9230 PUR

SP30

TP-16

9130 PUR/WHT

4

4

3

3

TP-01 9230 PUR

SP18

TP-01

9130 PUR/WHT

TP-11

TP-03

SP17

TP-03

9240 PUR

SP39

9140 PUR/WHT

TP-05

SP38

9250 PUR

TP-05

9150 PUR/WHT

SP35 TP-07

SP34

TP-07

9650 PUR

TP-08 9630 PUR

9550 PUR/WHT

TP-04

TP-02

RE019 120 OHM 0.5 W RESISTOR R1-1

C479 LEFT PANEL (BLACK) TP-08

9530 PUR/WHT

4

CAN LO

3

CAN HI

R1-2

TP-06

C479

C503 RH DLX PANEL TP-06

9260 PUR 9160 PUR/WHT

4

CAN LO

2

CAN HI

C503

*

9220 PUR

8

CAN LO

9

CAN HI

1830 RNG/WHT

SHT3/C1

2070 BLK

SHT4/G8

9120 PUR/WHT

C460 RIGHT JOYSTICK

C450 RIGHT JOYSTICK CONN

AUX CTRLR TP-11

9560 PUR/WHT TP-04

J2B

9660 PUR

1

1

2

2

3

3

4

4

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1

1

2

2

3

3

4

4

RIGHT JOYSTICK

+12V PWR GND CAN HI CAN LO

C426 Remote Run Tool, ACD CAN HI

CAN LO

14

TP-17

TP-17

9500 PUR/WHT

C449 LEFT JOYSTICK CONN 1840 RNG/WHT

SHT3/B1

9600 PUR

20

*

A CAN HICopy -- Not for Resale Dealer

A

B

B

CAN LO

2080 BLK

SHT4/H8

9540 PUR/WHT TP-02 9640 PUR

1

1

2

2

3

3

4

4

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

REMOTE RUN KEY

21

3090 LBL

SP93

3085 LBL

D

D

REMOTE RUN KEY

E

E

SWITCHED POWER

F

F

UNSWITCHED POWER

G

G

GROUND

J1B AUX CTRLR REMOTE RUN KEY

24

3095 LBL

J2A 1730 RNG/WHT

SHT3/D1

1165 RED/WHT

SHT2/E1

2710 BLK

SHT4/E8

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 5 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 5 /Printable 14

1030 RED

SHT2/B1

J4

8210 TAN

J2 FRC1

30

87 85

86

STARTER

T7

FRC1 STARTER RELAY - M C109 STARTER CONNECTOR J1

8200 TAN

J5

A

A

B

B

1 1

R

T21

S

T9 1

B

ENGINE

8220 TAN 3560 LBL

FRC1

2005 BLK

SHT4/C8

SHT2/E6 C110 1015 RED

GWY CTRLR SHT3/D1 STARTER RELAY SIGNAL

7

STARTER RELAY FEEDBACK

22

L

T11

3560 LBL GND

2150 BRN

SHT4/H3

3150 LBL

16

S

1

2015 BLK

SHT4/D3

AIR FILTER SENDER SIGNAL

1020 RED

1800 RNG/WHT

ALTERNATOR

1

GND

B

AIR FILTER SWITCH (NC)

A

T12

SIG

C405 ENGINE SPEED SENDER SIGNAL

3160 LBL

15

2160 BRN

SHT4/H3

A

ENGINE SPEED SENSOR (163 OHMS)

B C106

5140 YEL

SHT9/B8 ENGINE OIL PRESS SENDER SIGNAL

3140 LBL

25

2140 BRN

SHT4/H3

B C

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

A

FRC1 GLOW PLUG RELAY - F

C107

GLOW PLUG RELAY FEEDBACK

14

GLOW PLUG RELAY SIGNAL

6

1

8500 TAN

T14

3420 LBL 8510 TAN

SHT2/B1

2016 BLK

F5

F2 FRC1

1060 RED

F4

F1

SHT4/C8

Dealer Copy -- Not for Resale FRC1

FRC1 FUEL PULL RELAY - E

FUEL RELAY FEEDBACK

30

FUEL RELAY SIGNAL

3

3410 LBL 8110 TAN

E5

SHT2/D1

2025 BLK

E2

FRC1

J1A

1350 RED/WHT

E1

E4

SHT4/C8

FRC1 C101 FUEL SHUTOFF SOLENOID 8100 TAN

2400 BLK

SHT4/C8 FUEL SHUTOFF SOLENOID HOLD

D1

8120 TAN

2800 BLK

8800 TAN

4

B

B

C

C

A

A

PULL

0.33 OHM

GND HOLD

24.5 OHM

C355 FUEL HARN FUEL SENDER SIGNAL

3180 LBL

12

2180 BRN

SHT4/G3

ENGINE COOLANT SENSOR SIGNAL

C

C

D

D

3180 LBL

2180 BRN

3170 LBL

18

Wiring Schematic Standard Machine

B

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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

749 of 1311

SEE SHEET 1

REV

DESCRIPTION

ENGINE COOLANT SENSOR (500 - 3000 OHM) (8 VOLT)

C104

J1B

0

FUEL SENDER (30 - 270 OHM)

B C406 A

2170 BRN

SHT4/G3

A

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 6 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 6 /Printable 14

FRC1 TRACTION LOCK RELAY - D

HYDRAULICS

C425 +12V PWR

1360 RED/WHT

SHT2/C1

4100 LGN

D1

D5

30

87 85

86

D4 D2

GND

2035 BLK

SHT4/C8

2200 BLK

SHT4/D8

B

B

A

A

C

C

FRC1

FRC1

4200 LGN

2200 BLK

C308 BRAKE SOLENOID 9.8 OHM 12 V

A

B C308

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS DWG)

WHEEL 2 SPD ADP HARNESS 7159366

GWY CTRLR TRACTION LOCK RELAY SIGNAL TRACTION LOCK RELAY FEEDBACK

4110 LGN

8

3430 LBL

13

C425 GND

2220 BRN

SHT4/G3

SIG

3220 LBL

32

HYD FILTER DIFF PRESS

34 SHT4/G3

HYDRAULIC FAN GROUND

18

SIG

2320 BRN

GND

4010 LGN

SIG

2910 BRN

GND

A

A

C

C

PULL

0.3 OHMS 10.9 OHMS

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM (8 VOLT)

HOLD

A

C108 3320 LBL

B

B T

HYD TEMP SIGNAL

B

WHEEL SINGLE SPEED TRACTION LOCK

A HYDRAULIC OIL FILTER SWITCH (NC)

B C112 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

Dealer Copy -- Not for Resale

C420 SHT4/G3

2190 BRN

GND

3190 LBL

SIG

5190 YEL

+8 PWR

B C

P

HYDRAULIC CHARGE PRESSURE 0.5-7.5V

A

C105

19

13

1

23

6

HYDRAULIC FAN SIGNAL

HYD LOCK SOLENOID SIGNAL

HYD CHARGE PRESS SENDER SIGNAL

HYD CHARGE PRESS SENDER POWER

TRACTION SOLENOID OUTPUT

J1B

4200 LGN

4330 LGN

AUX CTRLR

FRONT ROD SOLENOID GROUND

2330 BRN

18

1

2

GND

SIG

FRONT ROD SOLENOID (MALE) 3.3 OHM PWM

C418 4340 LGN

GWY CTRLR

2340 BRN

1 19

13

FRONT ROD SOLENOID SIGNAL

FRONT BASE SOLENOID SIGNAL

J2A

2

GND

SIG

FRONT BASE SOLENOID (FEMALE) 3.3 OHM PWM

C419

J2B

FRONT BASE SOLENOID GROUND

1

AUX CTRLR

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 7 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 7 /Printable 14

CAB DISPLAY

T13 LEFT PANEL BUZZER 1940 RNG/WHT

SHT3/F1

1 7040 WHT

1

C499 PTOL CONN

T2 C479 LEFT PANEL (BLACK)

1930 RNG/WHT

SHT3/F1

2940 BLK

SHT4/G8

10 2920 BLK

SHT4/G8

2

1440 RED/WHT

SHT2/G1

1

1620 RNG/WHT

SHT3/F1

5

3400 LBL

SHT13/F5

11

3500 LBL

SHT13/F5

8

GWY CTRLR

BUZZER GROUND

3

SWITCHED POWER GROUND

C408 MFR HARN CONN 1 (BLACK)

PTOL SWITCH

20

PTOL LED

19

UNSWITCHED POWER

1

3030 LBL 2380 BRN

1

3030 LBL

1

2380 BRN

12 12

SWITCHED POWER

2

PTOL OUTPUT

4

PTOL LED

C499 C500 RH KEY SWITCH CONNECTOR

LEFT BLINKER INPUT RIGHT BLINKER INPUT

START ENGINE

8130 TAN

24

2

8130 TAN

2

2

START

4

RUN/ENTER SWITCH

J1A SW9 TRAVEL CONTROL SWITCH(OPTIONAL) SHT4/E8

2700 BLK

3

2

RUN/ENTER 3650 LBL

7

3040 LBL

22

3040 LBL

14 14

J1B

TRAVEL CONTROL INPUT

1950 RNG/WHT

SHT3/F1

6 1 5

4

SW9 SHT3/E1

SW9

1420 RED/WHT

SHT2/G1 3600 LBL

9

1960 RNG/WHT

2960 BLK

SHT4/G8

2930 BLK

2

1

5

6

C479

3 C500

Dealer Copy -- Not for Resale

SHT3/F1

C480 LEFT PANEL CONN (GRAY)

SW1 3630 LBL

SHT9/D3

12

3610 LBL

2

GROUND

SHT5/G1

4 3 SW1

UNSWITCHED POWER

C503 RH DLX PANEL 1590 RNG/WHT

SHT3/F1

1775 RNG/WHT

1

SWITCHED POWER

PARK BRAKE INPUT

SW1 BRAKE SWITCH SHT4/F8

5

1240 RED/WHT

SHT2/H1

2250 BLK

SHT4/G8

5 1 3

SWITCHED POWER UNSWITCHED POWER GROUND

6

DOOR SIGNAL

C503

SHT5/F1

PARK BRAKE OUTPUT

C480

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 8 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 8 /Printable 14

*

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH

1785 RNG/WHT

SHT3/E1

2

CAB

1

*

6 2060 BLK

SHT9/E3

5 SW4

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

4 3 SW4

C438 MFR HARN CONN 3 (DK GRAY) HAND CONTROL LIGHT

4

4

FOOT CONTROL LIGHT

5

5

FOOT CONTROL SIGNAL

6

6

4235 LGN

4275 LGN

*

C212 POWER SOCKET

4550 LGN

GND

2795 BLK

1

+12V PWR

1375 RED/WHT

2 C212

C408 MFR HARN CONN 1 (BLACK) 1370 RED/WHT

SHT2/D1

7

7

DOME LIGHT SP45

1370 RED/WHT

*

1390 RED/WHT

C129 CAB ACCESSORY 1210 RED/WHT 1580 RNG/WHT

SHT3/D1

5

5

SP8

1580 RNG/WHT

1865 RNG/WHT 2820 BLK

A

A

+12V BATT PWR

B

B

+12V SW PWR

C

C

GND

1510 RNG/WHT

2730 BLK

11 11

SP44

2730 BLK

2060 BLK

SHT9/H6 SHT13/C2

2885Resale BLK Dealer Copy -- Not for

11 11

*

SHT13/B3

C428 MFR HARN CONN 2 (LT GRAY) SHT4/E3

*

1 T38

SHT13/B3

2210 BLK

2790 BLK

2010 BLK

SHT13/C2

1885 RNG/WHT

SHT4/F3

SP41

1 T37

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

2790 BLK 3630 LBL

SHT8/D8

1400 RED/WHT

SHT2/G1 2840 BLK 1850 RNG/WHT

SHT3/F1

13 13

2370 BRN

SHT4/G3

4

4

5

5

1850 RNG/WHT

2370 BRN

GWY CTRLR SEATBAR SENSOR SIGNAL

11

3370 LBL

3370 LBL

GND

A

SIG

B

+5V PWR 5V CTRLR POWER

24

5100 YEL

SP13

5370 YEL

3

3

7310 WHT

SEATBAR SENSOR

C482

* A 2845 BLK

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

CHG NOTICE DWN

SHEET

DOOR SIGNAL

5

DOOR UNSW PWR

2

2

WIPER MOTOR GROUND

1

1

WIPER SWITCH, MOTOR SWITCHED POWER

3

3

WASHER SIGNAL

C

5140 YEL

Wiring Schematic Standard Machine

4

5

5370 YEL

J1B SHT6/F7

4

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.

HARNESS WASHER PUMP 7253378 C253

C252 A

B

7310 WHT PWR

TOLERANCES:

WASHER MOTOR

2845 BLK

B

GND

ECN

102712

1

2

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO. Sheet 9 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 9 /Printable 14

MANUAL CONTROLS RIGHT HANDLE AUX CTRLR RIGHT HANDLE LEFT ROCKER DOWN RIGHT HANDLE LEFT ROCKER UP

1520 RNG/WHT

SHT3/E1

4930 LGN

31

4940 LGN

30

2195 BRN

SHT4/C3

4320 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

13

A J H

D

4300 LGN

B

4910 LGN

F

4920 LGN

BACK UP ALARM

LEFT POSITION SWITCH

C

E

PADDLE

RIGHT POSITION SWITCH TRIGGER

HANDLE LOCK (ACS ONLY)

K

T20

G C409

GWY CTRLR TILT SPOOL LOCK SOLENOID GROUND

J2B

23

18

21

TILT (ACS/AHC ONLY)

AUX CTRLR 2670 BRN

10

4670 LGN

GND

SIG

3 TILT SPOOL LOCK 7.8 OHM 12V 1

LEFT HANDLE

Dealer Copy -- Not for Resale

LIFT (ACS/AHC ONLY)

C421

H LIFT SPOOL LOCK SOLENOID GROUND

2680 BRN

2

GND

3

4680 LGN

SIG

1

J1B

5

D 1530 RNG/WHT

SHT3/E1 LEFT HANDLE RIGHT ROCKER DOWN

22

LEFT HANDLE RIGHT ROCKER UP

28

LEFT HANDLE PADDEL RIGHT

11

LEFT HANDLE PADDEL LEFT

12

4830 LGN 4840 LGN 4810 LGN 4820 LGN

FLOAT (ACS/AHC ONLY)

A B

RIGHT POSTION SWITCH

C F

PADDLE

G C410

LIFT SPOOL LOCK SOLENOID SIGNAL

7

C422

TILT SPOOL LOCK SOLENOID SIGNAL

E LIFT SPOOL LOCK 7.8 OHM 12V

J1A

HANDLE LOCK (ACS ONLY)

J2A

LEFT POSITION SWITCH

TRIGGER

GWY CTRLR

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO.Sheet 10 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 10Printable / 14

LIGHTS

C434-1 6100 PNK SIG

A 37 WATT

C408 MFR HARN CONN 1 (BLACK) 2765 BLK

SHT4/E3

9

9

GND

2735 BLK 2765 BLK

SP14

2750 BLK GND

LEFT FRONT WORKLIGHT

B B 50 WATT

6110 PNK

SIG

A

C434-2

C435-1 6000 PNK

8

SP15

6000 PNK

8

6120 PNK

A

SIG

37 WATT

GND

2760 BLK 6130 PNK

B

RIGHT FRONT WORK LIGHT

A

SIG

50 WATT

GND

2705 BLK

B

C435-2

FRC1 FRONT WORK LIGHTS RELAY - B 1330 RED/WHT

SHT2/C1

2115 BLK

SHT4/B8

B1

Dealer Copy -- Not SHT4/D8 for Resale 6340 PNK

B4

B2

A

A

2 RIGHT REAR TAIL LIGHT

C103 TAILGATE HARN 6310 PNK

GND

SP49

6310 PNK

6320 PNK

SIG

1

C603

6320 PNK

B5

FRC1

SP10

2610 BLK

FRC1 6330 PNK

SIG

1 LEFT REAR TAIL LIGHT

GWY CTRLR 5

MRKR LIGHT PWR RELAY FEEDBACK

31

REAR LIGHT RELAY SIGNAL

17

REAR LIGHT RELAY FEEDBACK

28

SHT4/C8

GND

2

C602 3460 LBL

6210 PNK

T16 TERMINAL (-) 2620 BLK

SHT4/E8

3440 LBL

GND

1320 RED/WHT

2045 BLK

C1

C2

87

30

85 86

FRC1

1 RIGHT REAR WORK LIGHT

FRC1 REAR LIGHT RELAY - C

J1A

SHT2/C1

2640 BLK

SHT4/D8

MRKR LIGHT PWR RELAY SIGNAL

6210 PNK

SIG

1

T15 TERMINAL (+)

6200 PNK

C4

H

H

SP96

6200 PNK

T17 TERMINAL (+)

6220 PNK

SIG

1 LEFT REAR WORK LIGHT

C5 FRC1

GND

2630 BLK

SHT4/D8

1

T18 TERMINAL (-)

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO.Sheet 11 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 11Printable / 14

2440 BLK

HVAC

* GND

2 HVAC DUCT FAN

M 7440 WHT

SIG

1

C610

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557) * DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

*

*

2560 BLK

C

7420 WHT

POTENTIOMETER (TEMP CONTROL SWITCH)

A

7425 WHT

B C483

* 7425 WHT

D

2130 BLK

SP48

HEATER VALVE

C

7430 WHT

A C635

BLOWER MOTOR

FRC1 HVAC RELAY-B 1140 RED/WHT

SHT2/C1

H4

2030 BLK

SHT4/C8

H5

30

87 85

86

C438 MFR HARN CONN 3 (DK GRAY)

H1

1500 RNG/WHT

7

* 1500 RNG/WHT

7

3

FRC1

* 7530 WHT

HIGH

1 MED

7520 WHT

2

7510 WHT

3

LOW

7400 WHT

M

SW10 7410 WHT

1790 RNG/WHT

SHT3/D1

5

2 1 4

SW10

H2

FRC1

SW10 BLOWER SWITCH

4 C611

Dealer Copy -- Not for Resale 2580 BLK

SP16

2100 BLK

GWY CTRLR AC SIGNAL MONITOR

11

7021 WHT

SP40

7020 WHT

9

7020 WHT

9

2570 BLK

J1A

7015 WHT

*

THERMOSTAT

*

1 2 3

C630

B A

SW11 AC SWITCH

C355 FUEL HARN

7023 WHT 7024 WHT

A

A

7024 WHT

7025 WHT

SIG

1

D4

AC EVAPORATOR SWITCH

SW11

2745 BLK

C

8

1

8

3

2745 BLK

SHT4/F3

C350

MAGNET CLUTCH (COMPRESSOR)

2290 BLK 2280 BLK

GND

2

C486

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO.Sheet 12 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 12Printable / 14

#

C428 MFR HARN CONN 2 (LT GRAY)

C355 FUEL HARN 4470 LGN

1 SIG POWER BOB CLOSE

E

4470 LGN

E

8

OPTIONS 1

4470 LGN

8

4480 LGN

2 GND

2470 BLK

SP33

2770 BLK

B

B

F

F

2770 BLK

*

SHT4/E8

C607

#

1 SIG POWER BOB OPEN

2

4480 LGN

4480 LGN

7

SW5 POWER BOBTACH SWITCH

1380 RED/WHT

7

DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

*

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

1

2

3

SW5

GND 2480 BLK

#

SW5

C606 6010 PNK

LEFT HANDLE LIFT (ACS/AHC ONLY)

6010 PNK

10 10

1405 RED/WHT

LEFT HANDLE (FLASHER) 5 WAY (SEE ADDITIONAL OPTIONS DWG)

1410 RED/WHT

SHT2/E1

SHT14/D6

1430 RED/WHT

1410 RED/WHT

12 12

X

SP43

FLOAT (ACS/AHC ONLY)

9

D5

6400 PNK

14 14

1550 RNG/WHT

SHT3/F1

T3

3400 LBL

SHT8/G8 6400 PNK

SHT8/F8

D2

6500 PNK

6500 PNK

C411

EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS DWG)

E

E

D

D

3

SW3

2

4455 LGN

2

SHT4/E8

2830 BLK

1

1

SP46

2850 BLK

2

Dealer Copy -- Not for Resale

2725 BLK

*

2905 BLK

SHT14/F6

2970 BLK

SHT14/F4

5

6 SW6

2780 BLK

SW3 (PINS 3 & 6 INTERNALLY INSULATED)

6570 PNK

4

SHT4/E8

C423

SHT4/E3

4 6

SW6 BUCKET POSITION SWITCH

3 2455 BLK

SW2

3

*

2450 BLK

B GND

SW2

5

4455 LGN

4450 LGN

A SIG

3

SP21

6

1

2

D3

BUCKET POSITION SOLENOID 9.8 OHM

6410 PNK

C103 TAILGATE HARN

6510 PNK

6515 PNK

1

2

SW3 HAZARD SWITCH

C438 MFR HARN CONN 3 (DK GRAY)

6415 PNK

D A

TRIGGER

6530 PNK

*

PADDLE

B

*

SW2 BEACON SWITCH

3500 LBL

RIGHT POSTION SWITCH

LEFT POSITION SWITCH

6430 PNK

1550 RNG/WHT

9

6700 PNK 2810 BLK

SHT14/D5

2420 BLK

SW6

6540 PNK

2780 BLK

1

6440 PNK

LEFT HANDLE LIFT (ACS/AHC ONLY)

LEFT HANDLE (HORN) 2 WAY (SEE ADDITIONAL OPTIONS DWG)

LEFT SPEAKER GWY CTRLR HANDLE LOCK (ACS ONLY)

TWO SPEED MAKEUP GROUND TWO SPEED GROUND

FLOAT (ACS/AHC ONLY)

*

1 2360 BRN

27

2

26 4360 LGN

J1A

1

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V

2

TWO SPEED MAKEUP

PADDLE

TWO SPEED SIGNAL

2350 BRN

GND

4350 LGN

SIG

25 26

*

TRIGGER

A B

C408 MFR HARN CONN 1 SHT2/E1 (BLACK)

1460 RED/WHT 7210 WHT

13 13

1

2 TWO SPEED SOLENOID 5.1 OHM 12 V

TRACK 2 SPEED (SEE ADDITIONAL OPTIONS DWG)

A

1 C278 SHT9/E3

HIGH FLOW SOLENOID GROUND

26 J2A

GND

SIG

HORN 2785 BLK

B

B

B

_

C412 SHT4/E8

SHT9/D3

2460 BRN

SIG

A

GND

4

LEFT SPEAKER (-)

E

D

D

B

B

F

F

C

C

A

A

C670 BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

*

1 2 3

SHT9/E3

7810 WHT 7800 WHT 1885 RNG/WHT

AUX CTRLR

C126 HORN CONNECTOR

7210 WHT

7830 WHT

3

LEFT SPEAKER (+)

E

1510 RNG/WHT

PWR

4

RIGHT SPEAKER

C441

J1B LEFT POSITION SWITCH

2

* 7820 WHT

C676 RADIO CONN

C279

C437 RIGHT POSTION SWITCH

T3 FLASHER

L

1200 RED/WHT HANDLE LOCK (ACS ONLY)

SP22

*

+

HIGH FLOW SOLENOID SIGNAL

26

4460 LGN

A

2885 BLK

6

RIGHT SPEAKER (-)

5

RIGHT SPEAKER (+)

SHT9/E3

2210 BLK

GND

L010 AIR RIDE SEAT PWR

GND

5 6

C277

1 2 C676

HIGH FLOW SOLENOID 7.5 OHM 12 V

C415

J2B

Wiring Schematic Standard Machine

S630 S650

PROPRIETARY NOTICE

WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

102712

MSE

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

102712

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO.Sheet 13 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7305440 Version Click Here

SHT 13Printable / 14

AUX CTRLR

RIDE CONTROL SW AUTO

3700 LBL

23

10 10

3700 LBL

1

2

SW7

RIDE CONTROL RELAY SIGNAL

OPTIONS 1

*

SW7 RIDE CONTROL

C438 MFR HARN CONN 3 (DK GRAY)

2915 BLK

*

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

SHT4/F8

SW7

3480 LBL

7

RIDE CONTROL RELAY - RC1

RIDE CONTROL COIL SIGNAL

SP9

3415 LBL

21

3425 LBL

3435 LBL

1

3445 LBL

1

RIDE CONTROL COIL 2040 BLK

2

2020 BLK

SP32 2155 BLK

3475 LBL

16

29

SHT4/B8

*

SW13 REVERSING FAN 3475 LBL

3

2905 BLK

27

5 4 SW13

2

SHT13/D3

1565 RNG/WHT

SHT3/E1

SW13

REVERSING FAN COIL

J2A REVERSING FAN SIGNAL

2970 BLK

6

C443 REVERSING FAN RETURN SIGNAL

2

1

3470 LBL

11 11

2175 BRN

SHT4/B8

2

SHT13/E3 REVERSING FAN AUTO SIGNAL

2505 BLK

SHT3/F1

C440

12 12

3470 LBL

1575 RNG/WHT

RC1

RC1

C438 MFR HARN CONN 3 (DK GRAY) REVERSING FAN MANUAL SIGNAL

86

85 RIDE CONTROL COIL

C439

30

87

3485 LBL

25

1 C442

RIDE CONTROL PRESSURE SENSOR SIGNAL RIDE CONTROL SENSOR +5V SUPPLY

2185 BRN

SHT4/C3

3455 LBL

10

5105 YEL

24

A C

Dealer Copy -- Not for Resale

RIDE CONTROL PRESSURE SENSOR

B

J2B

SW8 *SIDELIGHT 1405 RED/WHT

SHT13/G3

2

C672 SIDELIGHT CONN 6710 PNK

1 SHT13/D3

6 SW8

Wiring Schematic Standard Machine

S630 S650

COPYRIGHT 102712

0

757 of 1311

REV

DESCRIPTION

MSE

CHG NOTICE DWN

SHEET

C

ORIGINALLY CREATED AND REVISED IN THE YEARS AS IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY RESERVES ALL RIGHTS.

2860 BLK

1

1

2

2

SHT4/F8

SW8

PROPRIETARY NOTICE WARNING S/N A3NT18589 through A3NT19199 A3NV25640 A3NV26199 S/N A3NW13931 A3NU13060 through through A3NU13299 A3NW14199

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.

2810 BLK

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

102712

DATE UNLESS OTHERWISE SPECIFIED X ± 13

DRAWN MAT

Printed On December 2018 7305440_0 SCHEM ELEC MAN DWG. NO.Sheet 14 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

MSE

7305440

Printable Version Click Here

SHT 14 / 14

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 - HYDRAULICS

8

SH08 - CAB DISPLAY

9

SH09 - CAB

10

SH10 - MANUAL CONTROLS

11

SH11 - LIGHTS

12

SH12 - HVAC

13

SH13 - OPTIONS 1

14

SH14 - OPTIONS 2

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

2000 THROUGH 2999

BROWN

BRN

MONITORING

3000 THROUGH 3999

LIGHT BLUE

LBL

HYDRAULIC

4000 THROUGH 4999

LIGHT GREEN

LGN

HARNESS PART NUMBER EXMF MAN

7322221

LF MAN MFR

7322218

CONTROLLER SUPPLY (5V, 8V)

5000 THROUGH 5999

YELLOW

YEL

DLX CAB

7304511

LIGHTS

6000 THROUGH 6999

PINK

PNK

STD CAB

7210557

OTHER FUNCTIONS

7000 THROUGH 7999

WHITE

WHT

STD FUEL

7149219

S/R (STARTER)

6733370

ENGINE

8000 THROUGH 8999

TAN

TAN

TAILGATE DOM

7217484

WHL 2 SPD ADP

7159366

(1 PC) TRK 2 SPD

7243409

SUSP JSTK

7163706

COMMUNICATION CAN LO COMMUNICATION CAN HI

90XX, 92XX, 94XX, 96XX, 98XX 91XX, 93XX, 95XX, 97XX, 99XX

PURPLE

LEGEND CONNECTOR 1

PARTIAL CONNECTOR 1

1

1

1

WIRE BREAK SHT1/E2

PUR

PURPLE/WHITE

1

SHT1/F2

PUR/WHT

WIRE BREAK WIRE BREAK

SHT1/E2 SHT1/F2

Dealer Copy -- Not for Resale

Wiring Schematic Standard Machine

S630 S650

COPYRIGHT

Click Here for Interactive PDF 108481

0 REV

758 of 1311

DESCRIPTION

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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.

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 1 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 1 /Printable 14

UNSWITCHED BATT POWER 1240 RED/WHT 1400 RED/WHT

C408 1450 RED/WHT

6

6

1450 RED/WHT

SP7

1420 RED/WHT 1440 RED/WHT

FC1 FUSE CENTER 1070 RED

1

3

MEGAFUSE 1

HW11

100.0 Amps

2

1120 RED/WHT

SHT8/E3 SHT8/G8

2 GWY CTRLR

1130 RED/WHT

3

SP2

4

1160 RED/WHT

SP36

1150 RED/WHT

3 AUX CTRLR

1180 RED/WHT

1 T4

T5

SHT9/D3

J1B

FUSE 2 25 A

1025 RED

+12V BATTERY

1110 RED/WHT

FUSE 1 25 A

SHT8/E3

2 J2B

FUSE 3 25 A 7

8 FUSE 4 25 A 6

FC1

FC1

1010 RED

SHT6/G1

5

FC2 FUSE CENTER FUSE 1 25 A

1190 RED

1

2 FUSE 2 25 A

1040 RED

3

4

1165 RED/WHT

SHT5/C8

SP24

1490 RED/WHT

1410 RED/WHT 1460 RED/WHT

Dealer 1370 Copy -- Not for Resale RED/WHT

SP26

FUSE 4 15 A

1290 RED

5

6

1325 RED

FC2

SHT9/F8

FC2

FUSE 5 30 A BUS BAR

1055 RED

1310 RED

5A

5B FUSE 6 30 A

6A

6B

BUS BAR

FUSE 9 15 A

1340 RED

1300 RED

9A

9B FUSE 10 20 A

10A

10B FUSE 11 25 A

11A FRC1

11B

1350 RED/WHT

SHT6/D1

1360 RED/WHT

SHT7/H8

1320 RED/WHT

SHT11/B8

1330 RED/WHT

SHT11/D8

1140 RED/WHT

SHT12/F8

FRC1 1030 RED

SHT6/H8

1050 RED

SP60

SHT3/E8

1060 RED

SHT6/E1

1205 RED

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

CHG NOTICE DWN

SHEET

SHT13/B7

FUSE RELAY CENTER SP1

Wiring Schematic Standard Machine

SHT13/G7

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:

SHT3/D8

ECN

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 2 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 2 /Printable 14

SWITCHED POWER

1720 RNG/WHT

FUSE RELAY CENTER FUSE 1 25 A BUS BAR

1750 RNG/WHT

1B

1A FUSE 2 25 A

BUS BAR

2A

B

A

A

C404 BU ALARM-MFR HARN (SEE ADDITIONAL OPTION DWG)

SP52 1780 RNG/WHT

1760 RNG/WHT

B

C489 MFR ACCESSORY

1850 RNG/WHT

2B

SHT9/D8

1575 RNG/WHT

FUSE 3 15 A 3A

SHT14/G4

1550 RNG/WHT

3B

SHT13/F7

BUS BAR

1620 RNG/WHT

FUSE 4 5 A

1660 RNG/WHT

4B

4A

1940 RNG/WHT

C428 MFR HARN CONN 2 (LT GRAY) 2

2

1930 RNG/WHT 1775 RNG/WHT

1660 RNG/WHT

SP42

1590 RNG/WHT 1950 RNG/WHT 1785 RNG/WHT 1960 RNG/WHT 1565 RNG/WHT

SWITCHED POWER RELAY-RC2

1520 RNG/WHT 1570 RNG/WHT

SHT2/B1

1050 RED

30 3390 LBL

87

86

85

1765 RNG/WHT

1560 RNG/WHT

2055 BLK

SHT4/B8

1795 RNG/WHT

7A

FUSE 7Copy 25 A Dealer -- Not 7B for Resale

1820 RNG/WHT

SWITCHED POWER RELAY-RC1

1815 RNG/WHT

FUSE 8 25 A

30 SP100

3385 LBL

SHT8/E8 SHT14/E4

22 AUX CTRLR

SHT5/C8

87

86

85

RC1

1580 RNG/WHT

8B

8A FUSE 12 15 A 12A

SHT9/F8

1800 RNG/WHT

12B

FRC1 1205 RED

SHT8/F3 SHT9/H6

SHT10/D3

J2B

1730 RNG/WHT

SHT8/D8 SHT8/E3

SHT10/G3

1530 RNG/WHT

SP25

SHT8/H8 SHT8/H3

RC2

RC2

SHT2/B1

SP11

SHT8/G8

SHT6/G4

FRC1

1820 RNG/WHT 2065 BLK

SHT4/C8

RC1 1790 RNG/WHT

SHT12/E8

GWY CTRLR 3450

LBL

3380 LBL

21

SWITCHED POWER RELAY FEEDBACK

4

SWITCHED POWER RELAY SIGNAL

J1A 1830 RNG/WHT

C428 MFR HARN CONN 2 (LT GRAY) 1920 RNG/WHT

6

6

1920 RNG/WHT

SP37 1840 RNG/WHT

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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:

SHT5/E3

ECN

108481

SHT5/D3

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 3 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 3 /Printable 14

GROUND SHT6/E7 SHT6/G7 SHT5/D3

SHT6/F7

2080 BLK

SHT6/B7 SHT5/E3 SHT8/G8 SHT8/G3 SHT8/E3 SHT8/D3

2070 BLK

SHT6/B7

2920 BLK

C408 MFR HARN CONN 1 (BLACK)

SP4

2940 BLK

SHT7/D7

2950 BLK

SHT7/F7 2950 BLK

10 10

SHT7/F7 SHT9/C8

2960 BLK 2250 BLK

GWY CTRLR

SP3

2510 BLK

16

2110 BLK

1

2140 BRN 2150 BRN 2160 BRN

GWY CTRLR

2170 BRN 2180 BRN

SP12

2230 BRN

17

SENSOR GND

2190 BRN

J1B

2220 BRN 2320 BRN 2370 BRN

T6

BATTERY GROUND

2500 BLK

15 J1B

2540 BLK

16 SHT14/D4 SHT14/H4 SHT8/E8 SHT13/D5 SHT8/F8 SHT13/B7 SHT13/D6 SHT5/B8 SHT13/H6 SHT11/C4 SHT10/F8 SHT11/C4

2860 BLK

AUX CTRLR

2930 BLK

2090 BLK

2900 BLK

1

SP47

SHT11/B4 SHT7/H4 SHT6/C7

2900 BLK

1

SHT6/G8 SHT6/E1 SHT6/D1 SHT12/E8 SHT7/H5 SHT11/B8 SHT3/E6 SHT11/D8 SHT14/G4 SHT14/F4

SP27

2455 BLK

2300 BLK

2710 BLK 2770 BLK

C489 MFR ACCESSORY B

2620 BLK

2650 BLK

2720 BLK

B

Dealer Copy -- Not for Resale

C103 TAILGATE HARN 2600 BLK

2640 BLK

B

2600 BLK

B

SP6

2390 BLK

1

T1

T10 ENGINE GROUND

BATTERY GROUND

2630 BLK 2200 BLK

AUX CTRLR

2400 BLK 2065 BLK

SHT10/G3

761 of 1311

REV

DESCRIPTION

2185 BRN

SP58 2195 BRN

2005 BLK

2995 BRN

17

SENSOR GND

J2B

2016 BLK 2025 BLK 2030 BLK

SP55

2105 BLK

2035 BLK 2045 BLK 2055 BLK 2115 BLK 2505 BLK 2155 BLK

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

2015 BLK

SHT6/G4

2610 BLK

Wiring Schematic Standard Machine 0

2790 BLK

SHT9/D8

2785 BLK

BATTERY GROUND

2780 BLK

SHT13/D8

T8

1

2765 BLK

SHT11/H8

SHT14/E7 SHT3/C1

2745 BLK

SHT12/D8

SP51 SHT11/E4

2730 BLK

SHT9/E8

C428 MFR HARN CONN 2 (LT GRAY)

2830 BLK 2700 BLK

SP28

2550 BLK

15 J2B

2915 BLK

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 4 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 4 /Printable 14

CAN BUS * DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

GWY CTRLR

C408 MFR HARN CONN 1 (BLACK)

Z3 120 OHM 0.5 W RESISTOR CAN LO

8

CAN HI

9

9200 PUR

9270 PUR

9100 PUR/WHT

9170 PUR/WHT

SP31 SP30

9230 PUR

9130 PUR/WHT

4

4

3

3

SP18 9230 PUR

9130 PUR/WHT

9240 PUR

SP17

SP39

9140 PUR/WHT

SP35

9250 PUR

SP38

9150 PUR/WHT

SP34

C479 LEFT PANEL (BLACK)

Z1 120 OHM 0.5 W RESISTOR 9650 PUR

9630 PUR

9550 PUR/WHT

4

9530 PUR/WHT

3

CAN LO

CAN HI

C479

C503 RH DLX PANEL 9260 PUR 9160 PUR/WHT

4

CAN LO

2

CAN HI

C503

*

9220 PUR

8

CAN LO

9

CAN HI

1830 RNG/WHT

SHT3/B1

2070 BLK

SHT4/G8

9120 PUR/WHT

C460 RIGHT JOYSTICK

C450 RIGHT JOYSTICK CONN

AUX CTRLR

9560 PUR/WHT

J2B

9660 PUR

1

1

2

2

3

3

4

4

1830 RNG/WHT 2070 BLK 9560 PUR/WHT 9660 PUR

1

1

2

2

3

3

4

4

RIGHT JOYSTICK

+12V PWR GND CAN HI CAN LO

C426 Remote Run Tool, ACD CAN HI

CAN LO

9500 PUR/WHT

14

C449 LEFT JOYSTICK CONN 1840 RNG/WHT

SHT3/B1

9600 PUR

20

*

A CAN HICopy -- Not for Resale Dealer

A

B

B

CAN LO

2080 BLK

SHT4/H8

9540 PUR/WHT 9640 PUR

1

1

2

2

3

3

4

4

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

REMOTE RUN KEY

21

3090 LBL

SP93

3085 LBL

D

D

REMOTE RUN KEY

E

E

SWITCHED POWER

F

F

UNSWITCHED POWER

G

G

GROUND

J1B AUX CTRLR REMOTE RUN KEY

24

3095 LBL

J2A 1730 RNG/WHT

SHT3/D1

1165 RED/WHT

SHT2/E1

2710 BLK

SHT4/E8

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

762 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 5 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 5 /Printable 14

1030 RED

SHT2/B1

J4

8210 TAN

J2 FRC1

30

87 85

86

STARTER

T7

FRC1 STARTER RELAY - M C109 STARTER CONNECTOR J1

8200 TAN

J5

A

A

B

B

1 1

R

T21

S

T9 1

B

ENGINE

8220 TAN 3560 LBL

FRC1

2005 BLK

SHT4/C8

SHT2/E6 C110 1015 RED

GWY CTRLR SHT3/D1 STARTER RELAY SIGNAL

7

STARTER RELAY FEEDBACK

22

L

T11

3560 LBL GND

2150 BRN

SHT4/H3

3150 LBL

16

S

1

2015 BLK

SHT4/D3

AIR FILTER SENDER SIGNAL

1020 RED

1800 RNG/WHT

ALTERNATOR

1

GND

B

AIR FILTER SWITCH (NC)

A

T12

SIG

C405 ENGINE SPEED SENDER SIGNAL

3160 LBL

15

2160 BRN

SHT4/H3

A

ENGINE SPEED SENSOR (163 OHMS)

B C106

5140 YEL

SHT9/B8 ENGINE OIL PRESS SENDER SIGNAL

3140 LBL

25

2140 BRN

SHT4/H3

B C

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

A

FRC1 GLOW PLUG RELAY - F

C107

GLOW PLUG RELAY FEEDBACK

14

GLOW PLUG RELAY SIGNAL

6

1

8500 TAN

T14

3420 LBL 8510 TAN

F2 FRC1

1060 RED

F4

F1

SHT2/B1

2016 BLK

F5

SHT4/C8

Dealer Copy -- Not for Resale FRC1

FRC1 FUEL PULL RELAY - E

FUEL RELAY FEEDBACK

30

FUEL RELAY SIGNAL

3

3410 LBL 8110 TAN

SHT2/D1

2025 BLK

E2

E5

SHT4/C8

FRC1

FRC1

J1A

1350 RED/WHT

E1

E4

C101 FUEL SHUTOFF SOLENOID 8100 TAN

2400 BLK

SHT4/C8 FUEL SHUTOFF SOLENOID HOLD

D1

8120 TAN

2800 BLK

8800 TAN

4

B

B

C

C

A

A

PULL

0.33 OHM

GND HOLD

24.5 OHM

C355 FUEL HARN FUEL SENDER SIGNAL

3180 LBL

12

2180 BRN

SHT4/G3

ENGINE COOLANT SENSOR SIGNAL

C

C

D

D

3180 LBL

2180 BRN

3170 LBL

18

Wiring Schematic Standard Machine

B

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

763 of 1311

SEE SHEET 1

REV

DESCRIPTION

ENGINE COOLANT SENSOR (500 - 3000 OHM) (8 VOLT)

C104

J1B

0

FUEL SENDER (30 - 270 OHM)

B C406 A

2170 BRN

SHT4/G3

A

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 6 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 6 /Printable 14

FRC1 TRACTION LOCK RELAY - D

HYDRAULICS

C425 +12V PWR

1360 RED/WHT

SHT2/C1

4100 LGN

D1

D5

30

87 85

86

D4 D2

GND

2035 BLK

SHT4/C8

2200 BLK

SHT4/D8

B

B

A

A

C

C

FRC1

FRC1

4200 LGN

2200 BLK

C308 BRAKE SOLENOID 9.8 OHM 12 V

A

B C308

TRACK 2 SPEED ADAPTER (SEE ADDITIONAL OPTIONS DWG)

WHEEL 2 SPD ADP HARNESS 7159366

GWY CTRLR TRACTION LOCK RELAY SIGNAL TRACTION LOCK RELAY FEEDBACK

4110 LGN

8

3430 LBL

13

C425 GND

2220 BRN

SHT4/G3

3220 LBL

32

SIG

HYD FILTER DIFF PRESS

34 SHT4/G3

HYDRAULIC FAN GROUND

18

SIG

2320 BRN

GND

4010 LGN

SIG

2910 BRN

GND

A

A

C

C

PULL

0.3 OHMS 10.9 OHMS

HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM (8 VOLT)

HOLD

A

C108 3320 LBL

B

B T

HYD TEMP SIGNAL

B

WHEEL SINGLE SPEED TRACTION LOCK

A HYDRAULIC OIL FILTER SWITCH (NC)

B C112 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

Dealer Copy -- Not for Resale

C420 GND

2190 BRN

SHT4/G3

SHT9/B8

3190 LBL

SIG

5190 YEL

+5V PWR

A P

C

HYDRAULIC CHARGE PRESSURE 0.5-4.5V

B C105

19

13

1

6

HYDRAULIC FAN SIGNAL

HYD LOCK SOLENOID SIGNAL

HYD CHARGE PRESS SENDER SIGNAL

TRACTION SOLENOID OUTPUT

J1B

4200 LGN

4330 LGN

AUX CTRLR

FRONT ROD SOLENOID GROUND

2330 BRN

18

1

2

GND

SIG

FRONT ROD SOLENOID (MALE) 3.3 OHM PWM

C418 4340 LGN

GWY CTRLR

2340 BRN

1 19

13

FRONT ROD SOLENOID SIGNAL

FRONT BASE SOLENOID SIGNAL

J2A

2

GND

SIG

FRONT BASE SOLENOID (FEMALE) 3.3 OHM PWM

C419

J2B

FRONT BASE SOLENOID GROUND

1

AUX CTRLR

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

764 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 7 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 7 /Printable 14

CAB DISPLAY

T13 LEFT PANEL BUZZER 1940 RNG/WHT

SHT3/F1

1 7040 WHT

1

C499 PTOL CONN

T2 C479 LEFT PANEL (BLACK)

1930 RNG/WHT

SHT3/F1

2940 BLK

SHT4/G8

10 2920 BLK

SHT4/G8

2

1440 RED/WHT

SHT2/G1

1

1620 RNG/WHT

SHT3/F1

5

3400 LBL

SHT13/F5

11

3500 LBL

SHT13/F5

8

GWY CTRLR

BUZZER GROUND

3

SWITCHED POWER GROUND

C408 MFR HARN CONN 1 (BLACK)

PTOL SWITCH

20

PTOL LED

19

UNSWITCHED POWER

1

3030 LBL 2380 BRN

1

3030 LBL

1

2380 BRN

12 12

SWITCHED POWER

2

PTOL OUTPUT

4

PTOL LED

C499 C500 RH KEY SWITCH CONNECTOR

LEFT BLINKER INPUT RIGHT BLINKER INPUT

START ENGINE

8130 TAN

24

2

8130 TAN

2

2

START

4

RUN/ENTER SWITCH

J1A SW9 TRAVEL CONTROL SWITCH(OPTIONAL) SHT4/E8

2700 BLK

3

2

RUN/ENTER 3650 LBL

7

3040 LBL

22

3040 LBL

14 14

J1B

TRAVEL CONTROL INPUT

1950 RNG/WHT

SHT3/F1

6 1 5

4

SW9 SHT3/E1

SW9

1420 RED/WHT

SHT2/G1 3600 LBL

9

1960 RNG/WHT

2960 BLK

SHT4/G8

2930 BLK

2

1

5

6

C479

3 C500

Dealer Copy -- Not for Resale

SHT3/F1

C480 LEFT PANEL CONN (GRAY)

SW1 3630 LBL

SHT9/D3

12

3610 LBL

2

GROUND

SHT5/G1

4 3 SW1

UNSWITCHED POWER

C503 RH DLX PANEL 1590 RNG/WHT

SHT3/F1

1775 RNG/WHT

1

SWITCHED POWER

PARK BRAKE INPUT

SW1 BRAKE SWITCH SHT4/F8

5

1240 RED/WHT

SHT2/H1

2250 BLK

SHT4/G8

5 1 3

SWITCHED POWER UNSWITCHED POWER GROUND

6

DOOR SIGNAL

C503

SHT5/F1

PARK BRAKE OUTPUT

C480

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

765 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 8 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 8 /Printable 14

*

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH

1785 RNG/WHT

SHT3/E1

2

CAB

1

*

6 2060 BLK

SHT9/E3

5 SW4

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

4 3 SW4

C438 MFR HARN CONN 3 (DK GRAY) HAND CONTROL LIGHT

4

4

FOOT CONTROL LIGHT

5

5

FOOT CONTROL SIGNAL

6

6

4235 LGN

4275 LGN

*

C212 POWER SOCKET

4550 LGN

GND

2795 BLK

1

+12V PWR

1375 RED/WHT

2 C212

C408 MFR HARN CONN 1 (BLACK) 1370 RED/WHT

SHT2/D1

7

7

DOME LIGHT SP45

1370 RED/WHT

*

1390 RED/WHT

C129 CAB ACCESSORY 1210 RED/WHT 1580 RNG/WHT

SHT3/D1

5

5

SP8

1580 RNG/WHT

1865 RNG/WHT 2820 BLK

A

A

+12V BATT PWR

B

B

+12V SW PWR

C

C

GND

1510 RNG/WHT

2730 BLK

11 11

SP44

2730 BLK

2060 BLK

SHT9/H6 SHT13/C2

2885Resale BLK Dealer Copy -- Not for

11 11

*

SHT13/B3

C428 MFR HARN CONN 2 (LT GRAY) SHT4/E3

*

1 T38

SHT13/B3

2210 BLK

2790 BLK

2010 BLK

SHT13/C2

1885 RNG/WHT

SHT4/F3

SP41

1 T37

C667 DOOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

2790 BLK 3630 LBL

SHT8/D8

1400 RED/WHT

SHT2/G1 2840 BLK 1850 RNG/WHT

SHT3/F1

13 13

2370 BRN

SHT4/G3

4

4

5

5

1850 RNG/WHT

2370 BRN

GWY CTRLR SEATBAR SENSOR SIGNAL

11

3370 LBL

3370 LBL

GND

A

SIG

B

+5V PWR 5V CTRLR POWER

24

5100 YEL

SP13

5370 YEL

3

3

7310 WHT

SEATBAR SENSOR

SHT7/D7

C482

* A 2845 BLK

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

766 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

CHG NOTICE DWN

SHEET

DOOR UNSW PWR

2

2

WIPER MOTOR GROUND

1

1

WIPER SWITCH, MOTOR SWITCHED POWER

3

3

WASHER SIGNAL

HARNESS WASHER PUMP 7253378 C253

C252 A

7310 WHT PWR

1 WASHER MOTOR

5190 YEL

S630 S650

DOOR SIGNAL

5

C

5140 YEL

Wiring Schematic Standard Machine

4

5

5370 YEL

J1B SHT6/F7

4

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.

B

2845 BLK

B

TOLERANCES:

GND

ECN

108481

2

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO. Sheet 9 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 9 /Printable 14

MANUAL CONTROLS RIGHT HANDLE AUX CTRLR RIGHT HANDLE LEFT ROCKER DOWN RIGHT HANDLE LEFT ROCKER UP

1520 RNG/WHT

SHT3/E1

4930 LGN

31

4940 LGN

30

2195 BRN

SHT4/C3

4320 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

13

A J H

D

4300 LGN

B

4910 LGN

F

4920 LGN

BACK UP ALARM

LEFT POSITION SWITCH

C

E

PADDLE

RIGHT POSITION SWITCH TRIGGER

HANDLE LOCK (ACS ONLY)

K

T20

G C409

GWY CTRLR TILT SPOOL LOCK SOLENOID GROUND

J2B

23

18

21

TILT (ACS/AHC ONLY)

AUX CTRLR 2670 BRN

10

4670 LGN

GND

SIG

3 TILT SPOOL LOCK 7.8 OHM 12V 1

LEFT HANDLE

Dealer Copy -- Not for Resale

LIFT (ACS/AHC ONLY)

C421

H LIFT SPOOL LOCK SOLENOID GROUND

2680 BRN

2

GND

3

4680 LGN

SIG

E LIFT SPOOL LOCK 7.8 OHM 12V

J1A 1

J1B

5

LEFT HANDLE RIGHT ROCKER DOWN

22

LEFT HANDLE RIGHT ROCKER UP

28

LEFT HANDLE PADDEL RIGHT

11

LEFT HANDLE PADDEL LEFT

12

4830 LGN 4840 LGN 4810 LGN 4820 LGN

FLOAT (ACS/AHC ONLY)

A B

RIGHT POSTION SWITCH

C F

PADDLE

G C410

LIFT SPOOL LOCK SOLENOID SIGNAL

7

D 1530 RNG/WHT

SHT3/E1

C422

TILT SPOOL LOCK SOLENOID SIGNAL

HANDLE LOCK (ACS ONLY)

J2A

LEFT POSITION SWITCH

TRIGGER

GWY CTRLR

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

767 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO.Sheet 10 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 10Printable / 14

LIGHTS

C434-1 6100 PNK SIG

A 37 WATT

C408 MFR HARN CONN 1 (BLACK) 2765 BLK

SHT4/E3

9

9

GND

2735 BLK 2765 BLK

SP14

2750 BLK GND

LEFT FRONT WORKLIGHT

B B 50 WATT

6110 PNK

SIG

A

C434-2

C435-1 6000 PNK

8

SP15

6000 PNK

8

6120 PNK

A

SIG

37 WATT

GND

2760 BLK 6130 PNK

B

RIGHT FRONT WORK LIGHT

A

SIG

50 WATT

GND

2705 BLK

B

C435-2

FRC1 FRONT WORK LIGHTS RELAY - B 1330 RED/WHT

SHT2/C1

2115 BLK

SHT4/B8

B1

Dealer Copy -- Not SHT4/D8 for Resale 6340 PNK

B4

B2

A

A

SP49

6310 PNK

6320 PNK

2

SIG

1

C603

6320 PNK

B5

FRC1

6310 PNK

GND

RIGHT REAR TAIL LIGHT

C103 TAILGATE HARN

SP10

2610 BLK

FRC1 6330 PNK

SIG

1 LEFT REAR TAIL LIGHT

GWY CTRLR 5

MRKR LIGHT PWR RELAY FEEDBACK

31

REAR LIGHT RELAY SIGNAL

17

REAR LIGHT RELAY FEEDBACK

28

SHT4/C8

GND

2

C602 3460 LBL

6210 PNK

T16 TERMINAL (-) 2620 BLK

SHT4/E8

3440 LBL

GND

1320 RED/WHT

2045 BLK

C1

C2

87

30

85 86

FRC1

1 RIGHT REAR WORK LIGHT

FRC1 REAR LIGHT RELAY - C

J1A

SHT2/C1

2640 BLK

SHT4/D8

MRKR LIGHT PWR RELAY SIGNAL

6210 PNK

SIG

1

T15 TERMINAL (+)

6200 PNK

C4

H

H

SP96

6200 PNK

T17 TERMINAL (+)

6220 PNK

SIG

1 LEFT REAR WORK LIGHT

C5 FRC1

GND

2630 BLK

SHT4/D8

1

T18 TERMINAL (-)

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

768 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO.Sheet 11 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 11Printable / 14

2440 BLK

HVAC

* GND

2 HVAC DUCT FAN

M 7440 WHT

SIG

1

C610

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557) * DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

*

*

2560 BLK

C

7420 WHT

POTENTIOMETER (TEMP CONTROL SWITCH)

A

7425 WHT

B C483

* 7425 WHT

D

2130 BLK

SP48

HEATER VALVE

C

7430 WHT

A C635

BLOWER MOTOR

FRC1 HVAC RELAY-B 1140 RED/WHT

SHT2/C1

H4

2030 BLK

SHT4/C8

H5

30

87 85

86

C438 MFR HARN CONN 3 (DK GRAY)

H1

1500 RNG/WHT

7

* 1500 RNG/WHT

7

3

FRC1

* 7530 WHT

HIGH

1 MED

7520 WHT

2

7510 WHT

3

LOW

7400 WHT

M

SW10 7410 WHT

1790 RNG/WHT

SHT3/C1

5

2 1 4

SW10

H2

FRC1

SW10 BLOWER SWITCH

4 C611

Dealer Copy -- Not for Resale 2580 BLK

SP16

2100 BLK

GWY CTRLR AC SIGNAL MONITOR

11

7021 WHT

SP40

7020 WHT

9

7020 WHT

9

2570 BLK

J1A

7015 WHT

*

THERMOSTAT

*

1 2 3

C630

B A

SW11 AC SWITCH

C355 FUEL HARN

7023 WHT 7024 WHT

A

A

7024 WHT

7025 WHT

SIG

1

D4

AC EVAPORATOR SWITCH

SW11

2745 BLK

C

8

1

8

3

2745 BLK

SHT4/F3

C350

MAGNET CLUTCH (COMPRESSOR)

2290 BLK 2280 BLK

GND

2

C486

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

769 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO.Sheet 12 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 12Printable / 14

#

C428 MFR HARN CONN 2 (LT GRAY)

C355 FUEL HARN 4470 LGN

1 SIG POWER BOB CLOSE

E

4470 LGN

E

8

OPTIONS 1

4470 LGN

8

4480 LGN

2 GND

2470 BLK

SP33

2770 BLK

B

B

F

F

2770 BLK

*

SHT4/E8

C607

#

1 SIG POWER BOB OPEN

2

4480 LGN

4480 LGN

7

SW5 POWER BOBTACH SWITCH

1380 RED/WHT

7

DLX FUEL HARN 7266824 ONLY (NOT IN STD FUEL HARN 7149219)

*

DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

1

2

3

SW5

GND 2480 BLK

#

SW5

C606 6010 PNK

LEFT HANDLE LIFT (ACS/AHC ONLY)

6010 PNK

10 10

1405 RED/WHT

LEFT HANDLE (FLASHER) 5 WAY (SEE ADDITIONAL OPTIONS DWG)

1410 RED/WHT

SHT2/E1

SHT14/D6

1430 RED/WHT

1410 RED/WHT

12 12

X

SP43

FLOAT (ACS/AHC ONLY)

9

D5

6400 PNK

14 14

1550 RNG/WHT

SHT3/F1

T3

3400 LBL

SHT8/G8 6400 PNK

SHT8/F8

D2

6500 PNK

6500 PNK

C411

EURO TAIL LIGHTS (SEE ADDITIONAL OPTIONS DWG)

E

E

D

D

3

SW3

2

4455 LGN

2

SHT4/E8

2830 BLK

1

1

SP46

2850 BLK

2

Dealer Copy -- Not for Resale

2725 BLK

*

2905 BLK

SHT14/F6

2970 BLK

SHT14/F4

5

6 SW6

2780 BLK

SW3 (PINS 3 & 6 INTERNALLY INSULATED)

6570 PNK

4

SHT4/E8

C423

SHT4/E3

4 6

SW6 BUCKET POSITION SWITCH

3 2455 BLK

SW2

3

*

2450 BLK

B GND

SW2

5

4455 LGN

4450 LGN

A SIG

3

SP21

6

1

2

D3

BUCKET POSITION SOLENOID 9.8 OHM

6410 PNK

C103 TAILGATE HARN

6510 PNK

6515 PNK

1

2

SW3 HAZARD SWITCH

C438 MFR HARN CONN 3 (DK GRAY)

6415 PNK

D A

TRIGGER

6530 PNK

*

PADDLE

B

*

SW2 BEACON SWITCH

3500 LBL

RIGHT POSTION SWITCH

LEFT POSITION SWITCH

6430 PNK

1550 RNG/WHT

9

T3 FLASHER

L

1200 RED/WHT HANDLE LOCK (ACS ONLY)

SP22

*

6700 PNK 2810 BLK

SHT14/D5

2420 BLK

SW6

6540 PNK

2780 BLK

1

6440 PNK

LEFT HANDLE

E

E

D

D

B

B

F

F

C670 BEACON/FLASHER EXTERIOR HARNESS (SEE ADDITIONAL OPTIONS DWG)

LIFT (ACS/AHC ONLY)

LEFT HANDLE (HORN) 2 WAY (SEE ADDITIONAL OPTIONS DWG)

LEFT SPEAKER GWY CTRLR HANDLE LOCK (ACS ONLY)

TWO SPEED MAKEUP GROUND TWO SPEED GROUND

FLOAT (ACS/AHC ONLY)

*

1 2360 BRN

27

2

26 4360 LGN

J1A

1

TWO SPEED MAKEUP SOLENOID 8.8 OHM 12V

2

TWO SPEED MAKEUP

PADDLE

TWO SPEED SIGNAL

2350 BRN

GND

4350 LGN

SIG

25 26

*

A B

C408 MFR HARN CONN 1 SHT2/E1 (BLACK)

1460 RED/WHT 7210 WHT

13 13

TRACK 2 SPEED (SEE ADDITIONAL OPTIONS DWG)

7210 WHT

A

1 C278 SHT9/E3

HIGH FLOW SOLENOID GROUND

C126 HORN CONNECTOR

26 J2A

GND

+

C412

SIG

HORN SHT4/E8

2785 BLK

B

B

SHT9/D3

2460 BRN

B

SIG

A

GND

LEFT SPEAKER (+)

4

LEFT SPEAKER (-)

HIGH FLOW SOLENOID SIGNAL

26

4460 LGN

A

* SHT9/E3

SHT9/E3

7810 WHT 7800 WHT 1885 RNG/WHT

AUX CTRLR

_

TRIGGER

1

2 TWO SPEED SOLENOID 5.1 OHM 12 V

7830 WHT

3

RIGHT SPEAKER

C441

J1B LEFT POSITION SWITCH

2

7820 WHT

C676 RADIO CONN

C279

C437 RIGHT POSTION SWITCH

*

2885 BLK

6

RIGHT SPEAKER (-)

5

RIGHT SPEAKER (+)

1510 RNG/WHT PWR

2210 BLK

L010 HEATED SEAT 4

GND

PWR

GND

5 C277

SEE OPTION PAGES FOR HARNESSES

1 2 C676

HIGH FLOW SOLENOID 7.5 OHM 12 V

C415

J2B

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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

770 of 1311

0

SEE SHEET 1

REV

DESCRIPTION

108481

MMM

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

108481

Printed On December 2018 7322217_0 SCHEM ELEC MAN DWG. NO.Sheet 13 of 14 csf

WEST FARGO, NORTH DAKOTA, USA TITLE

UNLESS OTHERWISE SPECIFIED X ± 13

MAT

7322217 Version Click Here

SHT 13Printable / 14

AUX CTRLR

RIDE CONTROL SW AUTO

3700 LBL

23

10 10

3700 LBL

1

7

RIDE CONTROL COIL SIGNAL

21

3480 LBL

1

3435 LBL

3425 LBL 3445 LBL

1

RIDE CONTROL COIL

RIDE CONTROL COIL 2

2040 BLK

2020 BLK

SP32

C439

REVERSING FAN MANUAL SIGNAL

16

29

2505 BLK

SHT4/B8

FRC1

SHT4/B8

*

3

2905 BLK

1

3470 LBL

2970 BLK

2

SHT13/D3

6 1565 RNG/WHT

5 4 SW13

2

SHT3/E1

SW13

REVERSING FAN COIL

J2A REVERSING FAN SIGNAL

G2

SHT3/F1

SW13 REVERSING FAN 3475 LBL

11 11

2175 BRN

27

G5

1575 RNG/WHT

2155 BLK

C443 REVERSING FAN RETURN SIGNAL

G1

2

SHT13/E3 REVERSING FAN AUTO SIGNAL

G4

C440

12 12

3470 LBL

SHT4/F8

SW7

FRC1

C438 MFR HARN CONN 3 (DK GRAY) 3475 LBL

* DLX CAB HARN 7304511 ONLY (NOT IN STD CAB HARN 7210557)

RIDE CONTROL RELAY - G FUSE RELAY CENTER

SP9

3415 LBL

2915 BLK

2

SW7

RIDE CONTROL RELAY SIGNAL

OPTIONS 1

*

SW7 RIDE CONTROL

C438 MFR HARN CONN 3 (DK GRAY)

3485 LBL

25

1 C442

RIDE CONTROL PRESSURE SENSOR SIGNAL RIDE CONTROL SENSOR +5V SUPPLY

2185 BRN

SHT4/C3

3455 LBL

10

5105 YEL

24

A C

Dealer Copy -- Not for Resale

RIDE CONTROL PRESSURE SENSOR

B

J2B

SW8 *SIDELIGHT 1405 RED/WHT

SHT13/G3

2

C672 SIDELIGHT CONN 6710 PNK

1 SHT13/D3

6 SW8

Wiring Schematic Standard Machine

S630 S650

WARNING S/N A3NT19200 & Above A3NV26200 S/N A3NW14200 A3NU13300 && Above Above

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 108481

0 REV

771 of 1311

DESCRIPTION

MMM

CHG NOTICE DWN

SHEET

C

ORIGINALLY CREATED AND REVISED IN THE YEARS AS IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY RESERVES ALL RIGHTS.

2810 BLK

2860 BLK

1

1

2

2

SHT4/F8

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

108481

DATE UNLESS OTHERWISE SPECIFIED X ± 13

DRAWN MAT

Printed On December 2018 7322217_0 SCHEM ELEC MAN Sheet 14 of 14 DWG. NO. csf

WEST FARGO, NORTH DAKOTA, USA TITLE

MMM

7322217 Version Click Here

SHT Printable 14 / 14

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C209 C212 C250 C251 C252 C277 C278 C279 C308 C350 C355 C362 C404 C405 C406 C408 C409 C410 C411 C412 C413 C414 C415 C416 C417 C418 C419 C420

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN ACCESSORY DOME LIGHT POWER SOCKET DOOR SENSOR WIPER WASHER AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS REAR AUX SOLENOID BACKUP ALARM AIR FILTER SWITCH FUEL SENDER CAB CONNECTOR RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY HANDLE(HORN) REAR ROD REAR BASE HIGH FLOW SOLENOID DIVERTER SOLENOID REAR AUX RELIEF FRONT ROD FRONT BASE HYD LOCK

NUM OF SHEET PINS 3 6 8 4,10,11,13 2 6 3 7 2 6 3 6 2 7 2 6 2 6 2 7 2 13 3 9 3 9 2 9 2 9 5 9 2 9 6 9 2 9 2 9 7 2 2 12 6 6,12,13 8 7 2 3,10 2 6 2 6 48 3-5, 8-13 10 10 10 10 5 10,13 2 10,13 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7

CONN C421 C422 C423 C425 C426 C434-1 C434-2 C435-1 C435-2 C437 C441 C446 C449 C450 C459 C460 C479 C480 C482 C483 C486 C489 C492 C493 C497 C499 C500 C503 C602 C603 C606 C607 C611 C630 C635 C667 C670 C676

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

Printed In U.S.A. 772 of 1311

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION SHEET CONN PINS TILT SPOOL LOCK 3 10 J1A LIFT SPOOL LOCK 3 10 J1B BUCKET POSITION 2 13 J2A BRAKE SOLENOID 3 7 J2B CAN (Remote Start Tool, ACD) 7 5 J1-ACS LEFT WORKLIGHT 1 2 11 J2-ACS LEFT WORKLIGHT 2 2 11 J3-ACS RIGHT WORKLIGHT 1 2 11 J5 RIGHT WORKLIGHT 2 2 11 TWO SPEED MAKEUP 2 7 TWO SPEED 2 7 FC1 HYDRAULIC FAN 2 7 FC2 LEFT JOYSTICK 4 5,15 FRC1 RIGHT JOYSTICK 4 5,15 LEFT JOYSTICK 4 15 4 RIGHT JOYSTICK 15 T1 LEFT PANEL(BLACK) 12 5,8 T2 LEFT PANEL(GRAY) 12 8 T3 SEATBAR SENSOR 3 9 T6 TEMP CONTROL SWITCH 3 12 T8 AC COMPRESSOR 2 12 T13 2 3,4 ACCESSORY T14 8 3,5,9,14,15 ACS/SJC/AWS 1 T15 4 3,4,14,15 T16 ACS/SJC/AWS 2 3 13 SJC HORN/BLINKER T17 4 8 PTOL T18 6 8 RH KEY SWITCH T19 RH DLX PANEL 6 5,8 T20 Dealer Copy 2 11 LEFT REAR TAIL LIGHT 2 11 RIGHT REAR TAIL LIGHT 2 13 POWER BOBTACH OPEN SW1 2 13 POWER BOBTACH CLOSE SW2 4 12 BLOWER MOTOR SW3 3 12 THERMOSTAT SW4 HEATER VALVE 6 12 SW5 6 9 DOOR KIT SW6 6 13 EXTERIOR BEACON SW8 6 9 RADIO SW9 SW10 SW11

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

DESCRIPTION GATEWAY COTROLLER GATEWAY CONTOLLER AUX CONTROLLER AUX CONTROLLER ACS CONTROLLER ACS CONTROLLER ACS CONTROLLER DRIVE CONTROLLER

NUM OF PINS 34 26 34 26 8 10 10 50

SHEET

CONN C428 C429 C467 C468 C469 C470 C471 C472

FUSE CENTER 1 FUSE CENTER 2 FUSE RELAY CENTER

3 3 3,6,7,11,12

BATT GROUND BUZZER GROUND FLASHER

4 8 13 4 4

BATT GROUND BATT GROUND BUZZER POWER PRE HEATER RIGHT REAR WORK LIGHT(+) RIGHT REAR WORK LIGHT(-) LEFT REAR WORK LIGHT (+) LEFT REAR WORK LIGHT (-) BACKUP ALARM BACKUP ALARM (GND)

8 6

CONN

11 11 11 11 10 10

C536 C537 C428 C429 C453 C454 C474

BRAKE SWITCH BEACON SWITCH HAZARD SWITCH HAND/FOOT, H/ISO SWITCH POWER BOBTACH SWITCH BUCKET POSITION SWITCH FRONT WIPER SWITCH TRAVEL CONTROL SWITCH BLOWER SWITCH AC SWITCH

9 13 13 9 13 13 9 8 12 12

C501 C544 C545 C546 C547 C542 C543 C707

-- Not for Resale

SCHEMATIC INDEX PAGE 1,2 OVERVIEW POWER PAGE 3 GROUND PAGE 4 CAN BUS PAGE 5 ENGINE PAGE 6 HYDRAULICS PAGE 7 CAB DISPLAY PAGE 8 CABIN PAGE 9 MANUAL CONTROLS PAGE 10 LIGHTS PAGE 11 HVAC PAGE 12 OPTIONS PAGE 13 ACS CONTROL PAGE 14 SJC CONTROL PAGE 15

CONNECTOR ASSIGNMENTS (ACS) NUM OF DESCRIPTION PINS TILT ACTUATOR 8 LIFT ACTUATOR 8 LIFT PEDAL LOCK 3 TILT PEDAL LOCK 3 TILT HANDLE 3 TILT PEDAL 3 LIFT PEDAL 3 LIFT HANDLE 3

CONNECTOR ASSIGNMENTS (SJC) NUM OF DESCRIPTION PINS 4 RIGHT SWASHPLATE 4 LEFT SWASHPLATE 8 TILT ACTUATOR 8 LIFT ACTUATOR 4 RIGHT QUAD A DRIVE 4 LEFT QUAD DIRVE 1 BRAKE LIGHT A22 PUMP HARNESS LEFT FORWARD DRIVE LEFT REVERSE DRIVE RIGHT FORWARD DRIVE RIGHT REVERSE DRIVE LEFT SWASHPLATE RIGHT SWASHPLATE OBW STOP BRAKE LIGHT

8 2 2 2 2 3 3 3

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 1 of 15 (PRINTED DECEMBER 2011) 7171253

SHEET 14 14 14 14 14 14 14 14

SHEET 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15

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 B C D E F G H

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) FUNCTION PIN FUNCTION HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS LIFT SPOOL LOCK RETURN B-2 UNSW BATT FUEL PULL RELAY B-3 UNSW BATT SWITCHED POWER OUT RELAY B-4 FUEL HOLD B-5 LIGHT 1 RELAY LIFT SPOOL LOCK GLOW PLUG RELAY B-6 TRACTION LOCK HOLD STARTER RELAY B-7 TILT SPOOL LOCK TRACTION PULL RELAY B-8 CAN LO 1 FAN 1 RELAY B-9 CAN HI 1 B-10 TILT SPOOL LOCK RETURN SPOOL LOCK SENSOR 2 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD B-14 GLOW PLUG RELAY FDBK CAN HI 2 B-15 ENGINE SPEED GROUND P1 AIR FILTER SWITCH B-16 GROUND P2 LIGHT 2 RELAY B-17 GROUND P3, SENSOR FAN 2 RELAY B-18 ENGINE COOLANT TEMP B-19 PTOL LED FAN 2 OUTPUT B-20 PTOL SWITCH CAN LO 2 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY STATER RELAY FDBK B-22 RUN/ENTER HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V B-24 START ENGINE SENSOR SUPPLY 5V B-25 ENGINE OIL PRESS TWO SPEED MAKEUP SPARE B-26 TWO SPEED COIL SPARE LIGHT 2 RELAY FDBK FAN 1 RELAY FDBK FUEL PULL RELAY FDBK LIGHT 1 RELAY FDBK HYD OIL TEMP SPARE ANALOG HYD OIL FILTER SW1

CONNECTOR J1-ACS FUNCTION +5V TO SENSORS SWITCHED POWER HAND/FOOT INPUT CAN HIGH CAN LOW 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

PIN A B C D E F G H J K

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-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 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID B-5 HORN RELAY REAR AUX (F) B-6 RELIEF SOLENOID OUTPUT SPARE B-7 REAR AUX (M) B-8 CAN LO 1 B-9 CAN HI 1 B-10 REAR AUX (M) RETURN LH PADDLE RIGHT B-11 LH PADDLE LEFT B-12 RH RIGHT BUTTON UP B-13 FRONT AUX (F) B-14 DIGITAL INPUT SPARE CAN HI 2 B-15 GROUND B-16 GROUND B-17 HANDLE POT GND FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL B-19 FRONT AUX (M) B-20 LH FLOAT BUTTON CAN LO 2 HYDRAULIC DETENT B-21 RH TRIGGER LH RIGHT BUTTON DOWN B-22 SWITCHED POWER RH CENTER BUTTON B-23 HANDLE POT POWER B-24 DIGITAL INPUT SPARE B-25 BUCKET POSITION (SPARE) HIGH FLOW RETURN B-26 HIGH FLOW BUCKET POSITION(SPARE) RETURN LH RIGHT BUTTON RH RIGHT BUTTON DOWN RH LEFT UP RH LEFT DOWN

Dealer Copy -- Not for Resale DIGITAL INPUT SPARE

HARNESS PART NUMBER MAINFRAME 7175625 STD CAB 7165991 DLX CAB 7176098 DLX FUEL 7175293 STD FUEL 7149219 DOOR 7155024 S/R 6733370 7175271 TAILGATE DOM 7175287 TAILGATE EUR 2 SPD ADP 7159366 ACS 7164144 SJC WHEEL SJC TRACK

7159325 7210503 7159458 7210504

HARNESS PART NUMBER A22 PUMP 7169309 7163706 SUSP JSTK BACKUP ALARM 7175017 BRAKE ADAPTER 7165061

S630, S650, S750, S770 T630, T650, T750, T770

WITH SPEED SENSORS WITHOUT SPEED SENSORS WITH SPEED SENSORS WITHOUT SPEED SENSORS

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

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

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 2 of 15 Printable Version Click Here (PRINTED DECEMBER 2011) Printed In U.S.A. 773 of 1311

7171253

POWER 1270 RED

BATTERY BATT_CABLE

1280 RED MEGAFUSE 100.0 Amps 1025 RED

1070 RED

FC1 FUSE 3 25 A FC1 FUSE 4 25 A

1170 RED/WHT

1235 RED/WHT

C493 1

1120 RED/WHT

FC2 FUSE 4 15 A FC2 FUSE 2 25 A

1040 RED

1190 RED

FC2 FUSE 1 25 A

1310 RED

FRC 1 FUSE 6 30 A

1370 RED/WHT

1490 RED/WHT

1165 RED/WHT

1010 RED 1360 RED/WHT

FRC1 FUSE 5 30 A 1350 RED/WHT

1050 RED

1300 RED

FRC1 FUSE 11 25 A 1140 RED/WHT

1340 RED

FRC1 FUSE 10 20 A 1330 RED/WHT FRC1 FUSE 9 15 A 1320 RED/WHT

1060 RED 1030 RED

FRC1 FUSE 4 5A

1760 RNG/WHT

SHEET 6 SHEET 12

2055 BLK 2030 BLK

85

1795 RNG/WHT

1740 RNG/WHT 8000 TAN 1920 RNG/WHT

Printed In U.S.A. 774 of 1311

C408 6

C492 6 J1A 4 1920 RNG/WHT

1450 RED/WHT

J1B 2 J1B 3

SHEET 8 SHEET 9 SHEET 8 SHEET 8

SHEET 6

Dealer Copy -- Not for Resale SHEET 12

SHEET 11

SHEET 11 SHEET 6 SHEET 6 1660 RNG/WHT 1570 RNG/WHT

FRC1 FUSE 2 25 A 1850 RNG/WHT

C408 43

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 8 SHEET 8 SHEET 8 SHEET 9 SHEET 8 SHEET 9 SHEET 8 SHEET 8

SHEET 10

SHEET 9

Printable Version Click Here SHEET 13 1780 RNG/WHT

SHEET 12 FRC1 FUSE 7 25 A 1730 RNG/WHT FRC1 FUSE 8 25 A 1580 RNG/WHT 1840 RNG/WHT 1830 RNG/WHT

C408 17

1240 RED/WHT 1400 RED/WHT 1420 RED/WHT 1440 RED/WHT

SHEET 7

1790 RNG/WHT

86

J2B 2 J2B 3

SHEET 13 SHEET 13

1720 RNG/WHT

1765 RNG/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

SHEET 5

SWITCHED POWER 87

1450 RED/WHT 1110 RED/WHT 1130 RED/WHT

1460 RED/WHT 1410 RED/WHT

FRC1 FUSE1 25 A 1750 RNG/WHT

30

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

SHEET 9

FRC1 FUSE 3 15 A 1550 RNG/WHT

1050 RED

1180 RED/WHT 1150 RED/WHT

1160 RED/WHT

FC1 FUSE 1 25 A

1290 RED

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

C493 2

FC1 FUSE 2 25 A

SHEET 6

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SHEET 5 SHEET 5

SHEET 5

SHEET 9

C489 A C404 B

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV1100 1 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 3 of 15 (PRINTED DECEMBER 2011) 7171253

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SHEET 5 SHEET 5 SHEET 8 SHEET 8 SHEET 8 SHEET 8

2080 BLK 2070 BLK 2940 BLK 2960 BLK 2920 BLK 2250 BLK

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

2950 BLK

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

2235 BLK 2240 BLK 2950 BLK 2510 BLK 2500 BLK 2540 BLK 2550 BLK

C493 3 C493 4

C408 32

J1B 16 J1B 15 J2B 16 J2B 15

SHEET 11 SHEET 12 SHEET 9 Dealer SHEET 13 SHEET 9 SHEET 11 SHEET 11 SHEET 10 SHEET 11 SHEET 11

SHEET 13 SHEET 9 SHEET 13 SHEET 8

SHEET 7 SHEET 6 SHEET 9 SHEET 7 SHEET 7 SHEET 6 SHEET 6 SHEET 6

2620 BLK 2630 BLK 2650 BLK 2640 BLK 2610 BLK

2785 BLK 2930 BLK 2830 BLK 2700 BLK

3530 LBL 3800 LBL 2370/BRN OR 3910 LBL 3310 LBL 3410 LBL 3110/LBL OR 2189/BRN 3510 LBL 3710 LBL

C489 B

C103 B

2600 BLK

SHEET 6

2900 BLK

SHEET 7 SHEET 13 SHEET 7 SHEET 13 SHEET 5 SHEET 7

C408 42

SHEET 11 SHEET 10 SHEET 10

3010 LBL

J1B 17

GROUND

2765 BLK 2745 BLK 2790 BLK Copy -- Not 2780 BLK 2730 BLK

2110 BLK

T6 BATT GND

2090 BLK

for Resale

2720 BLK 2600 BLK 2810 BLK 2200 BLK 2751/BLK OR 2770/BLK 2450 BLK 2741 BLK 2710 BLK 2480 BLK

T8 BATT GND

2390 BLK

2300 BLK

T1 BATT GND

2900 BLK 2105 BLK 2530 BLK 2520 BLK

2000 BLK

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 4 of 15 (PRINTED DECEMBER 2011)

Printed In U.S.A. 775 of 1311

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION BATT FEED, GENERAL 1000 THROUGH 1499 RED BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

CAN BUS 9160 PUR/WHT 9260 PUR

GWY CTRLR

J1B 8 J1B 9

9200 PUR 9100 PUR/WHT

9270 PUR 9170 PUR/WHT

9210 PUR 9110 PUR/WHT

9280 PUR 9180 PUR/WHT

9230 PUR 9130 PUR/WHT

120 OHM RESISTOR

C408 8

9230 PUR 9130 PUR/WHT

9240 PUR 9140 PUR/WHT

9250 PUR 9150 PUR/WHT

9650 PUR 9550 PUR/WHT

C408 7

9560 PUR/WHT 9660 PUR 9240 PUR 9140 PUR/WHT 9290 PUR 9190 PUR/WHT

9220 PUR 9120 PUR/WHT

C492 1 ACS CTRLR C492 4 C492Copy 7 Dealer -- Not for DRIVE CTRLR C492 8

J2B 8 J2B 9

SHEET 3 SHEET 4

9630 PUR 9530 PUR/WHT

120 OHM RESISTOR 1830 RNG/WHT 2070 BLK

C503 2 C503 4

RH DLX PANEL

C479 4 C479 3

LEFT PANEL

C450

1 2 3 4

# RIGHT JOYSTICK

C449

Resale 9540 PUR/WHT 9640 PUR

SHEET 3 SHEET 4

1840 RNG/WHT 2080 BLK

1 2 3 4

# LEFT JOYSTICK

AUX CTRLR

C426

J1B 14 J1B 20 J1B 21 SHEET 3 SHEET 3 SHEET 4

9500 PUR/WHT 9600 PUR 9400 PUR 1730 RNG/WHT 1165 RED/WHT 2710 BLK

Printed In U.S.A. 776 of 1311

A B D C E F G

#

CONNECTOR DOES NOT EXIST IN 7165991

CAN (Remote Start Tool, ACD)

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 5 of 15 (PRINTED DECEMBER 2011) 7171253

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION RED BATT FEED, GENERAL 1000 THROUGH 1499 BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

1030 RED 2005 BLK

SHEET 12

30 8200 TAN

87 85

ENGINE

C109

STARTER SHEET 3

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

86

8210 TAN

8250 TAN

J1A 22

B A

STARTER

8250 TAN 8200 TAN

R S

M

B

SHEET 3 1015 RED C110

B

J1A 7

G

ALTERNATOR

S L

EXCITATION

2015 BLK

FUEL PULL SHEET 3

1350 RED/WHT

8120 TAN

30

8150 TAN

SHEET 7

85

86

J1B 4

J1A 30 SHEET 4

8110 TAN

D5

Dealer Copy -- Not for Resale8100 TAN 2810 BLK

8800 TAN 2800 BLK

B A C

J1A 15 SHEET 4

A B

SIG GND

3210 LBL 3200 LBL

B A

SIG GND

ENGINE SPEED SENSOR

SHEET 3

3800 LBL

J1B 18

8100 TAN 8800 TAN 2800 BLK

PULL HOLD

24.5 OHM 0.33 OHM

J1A 3

C106

3600 LBL 3610 LBL

SHEET 12

FUEL SHUTOFF SOLENOID

C101

87 2025 BLK

FRC1 FUSE 12 15 A 1815 RNG/WHT

1020 RED 1800 RNG/WHT

ENGINE COOLANT SENSOR (500-3000 OHM)

C104

SHEET 3

1060 RED 2016 BLK 2055 BLK

GLOW PLUG 30 87 85

86

8550 TAN 8500 TAN 8510 TAN

J1A 14 T14 PRE HEATER

J1A 6

C107

SHEET 9 J1A 25 SHEET 4

J1B 12 SHEET 4

3500 LBL 3520 LBL 3510 LBL

B C A

+5V PWR SIG GND

ENGINE OIL PRESSURE SENDER (0.5-4.5V)

C355 C 3100/LBL OR 3180/LBL 3100/LBL OR 3180/LBL 3110/LBL OR 2189/BRN 3110/LBL OR 2180/BRN

C406

A B

SIG GND

C355 D C405

SHEET 4 J1A 16

3710 LBL 3700 LBL

B A

GND SIG

AIR FILTER SWITCH

FUEL SENDER

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 6 of 15 (PRINTED DECEMBER 2011)

Printed In U.S.A. 777 of 1311

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE GROUP NUMBER RANGE WIRE COLOR GROUP DESCRIPTION BATT FEED, GENERAL 1000 THROUGH 1499 RED BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SHEET 3 SHEET 6 SHEET 11

1360 RED/WHT 2025 BLK 2035 BLK

TRACTION LOCK 30 87 85

J1A 13

4110 LGN

J1A 8

J1B 6 SHEET 4

B A C

B A C C362

J2B 5 J2A 2

A B

C414

4440 LGN 2440 BLK

1 2

SIG GND

TRACK MACHINES C308

BRAKE SOLENOID 9.8 OHM 12 V HARN BRAKE ADAPTER 7165061

4200 LGN 2200 BLK

C425

4440 LGN 2440 BLK

HYDRAULIC

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

C425

4150 LGN 4100 LGN

86

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

4200 RED 2200 BLK

A B

WHEEL MACHINES PULL HOLD

0.3 OHM 10.9 OHM

TRACTION LOCK SOLENOID

OPTIONAL REAR AUX DIRECTIONAL SOLENOID FEMALE COUPLER 7.5 OHM 12V

C420

C413

J2B 7 J2A 10

4430 LGN 2430 BLK

C D

4430 LGN 2430 BLK

1 2

SIG GND

OPTIONAL REAR AUX DIRECIONAL SOLENOID MALE COUPLER 7.5 OHM 12V

Dealer Copy -- Not for Resale

2410 BLK 4410 LGN

J1A 1 J1B 13

C105

C416

J2B 4 SHEET 4

4450 LGN 2450 BLK

E F

4450 LGN 2450 BLK

1 2

SIG GND

C417

J2B 6 SHEET 4

4480 LGN 2480 BLK

G H

4480 LGN 2480 BLK

1 2

SIG GND

OPTIONAL REAR AUX BLEED / LOCK VALVE SOLENOID MALE COUPLER 7.5 OHM 12 V OPTIONAL REAR AUX BLEED / LOCK VALVE SOLENOID FEMALE COUPLER 9.8 OHM 12 V

B A

3410 LBL 3420 LBL 3400 LBL

J1B 1 J1B 23 +8V

SHEET 4 J1A 32

B C A C108

3310 LBL 3300 LBL

B A

HYD LOCK SOLENOID 9.8 OHM 12V HYDRAULIC CHARGE PRESSURE 0.5-7.5V HYDRAULIC TEMPERATURE SENDER 500 - 3000 OHM

C112 C415

J2A 26 J2B 26

2460 BLK 4460 LGN

B A

GND SIG

OPTIONAL HIGH FLOW SOLENOID 7.5 OHM 12 V

J1A 34 SHEET 4

3430 LBL 3530 LBL

A B

HYDRAULIC OIL FILTER SWITCH

C418

J2A 18 J2B 19

2330 BLK 4330 LGN

2 1

GND SIG

FRONT ROD SOLENOID (MALE) 3.3 OHM PWM

C419

J2A 1 J2B 13

2340 BLK 4340 LGN

2 1

GND SIG

FRONT BASE SOLENOID (FEMALE) 3.3 OHM PWM

C437

J1A 27 J1B 25

2360 BLK 4360 LGN

2 1

GND SIG

OPTIONAL TWO SPEED MAKEUP SOLENOID

C441

J1A 26 J1B 26

2350 BLK 4350 LGN

2 1

GND SIG

TWO SPEED SOLENOID

GND SIG

HYDRAULIC FAN SOLENOID 7.2 OHM 12 V

C446

J1A 18 J1B 19

Printed In U.S.A. 778 of 1311

2910 BLK 4010 LGN

2 1

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 7 of 15 (PRINTED DECEMBER 2011) 7171253

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK WHITE ACCESSORIES 7000 THROUGH 7999 ENGINE 8000 THROUGH 8999 TAN COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

T13 BUZZER (+)

SHEET 3

1940 RNG/WHT

T2 BUZZER (-)

9320/PUR OR 7040/WHT 2920 BLK

SHEET 4 SHEET 3 SHEET 3

1960 RNG/WHT

SHEET 3

SW9 TRAVEL CONTROL SWITCH OPTIONAL

SHEET 4

2700 BLK

C479 10

CAB DISPLAY J1A 24 J1B 22

C408 4 9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 9350/PUR OR 3040/LBL 9350/PUR OR 3040/LBL SHEET 3 SHEET 3 SHEET 4

5 1 3 6

RH DLX PANEL

C479 2 SHEET 3

1620 RNG/WHT C479 5

SHEET 3

C479 11

SHEET 4

SHEET 13

C408 40 1950 RNG/WHT 1420 RED/WHT 2960 BLK

RH KEY SWITCH

2 4

LEFT PANEL (BLACK)

1440 RED/WHT C479 1

Dealer Copy -- Not for Resale

6450 PNK

C500

1590 RNG/WHT

C503 5

1240 RED/WHT

C503 1

2250 BLK

C503 3

C479 8 6550 PNK SHEET 13 4500/LGN OR 3600/LBL C479 9 SHEET 9 C479 7 4730 LGN

5 6 4 2 3 1

C480

SHEET 9 SHEET 9

4750 LGN 9310/PUR OR 3610/LBL

LEFT PANEL (GRAY)

12 2

Printable Version Click Here

J1A 20 J1A 19

C499 C408 1 9380/PUR OR 3030/LBL 9380/PUR OR 3030/LBL 2 9370/PUR OR 2380/BRN 4 9370/PUR OR 2380/BRN

SHEET 3 SHEET 4

C408 37 1930 RNG/WHT 2940 BLK

1 3

PTOL (Press To Operate Loader)

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV1100 1 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 8 of 15

Printed In U.S.A. (PRINTED DECEMBER 2011) 7171253 779 of 1311

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE 8000 THROUGH 8999 TAN PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

7176098 ONLY

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

SW4 HAND/FOOT (ACS) H/ISO (SJC, AWS) SWITCH 1785 RNG/WHT 2 1 3 2060 BLK 5 6

SHEET 3

4550 LGN C408 5

4550 LGN

4275 LGN C408 3

4275 LGN

4235 LGN C408 2

4235 LGN 4220 LGN

4

C492 5

C492 2 C492 3 4230 LGN 4240 LGN

SHEET 10 SHEET 10

C212

2795 BLK 1375 RED/WHT

SHEET 3

C408 23

1370 RED/WHT

1370 RED/WHT

+ -

POWER SOCKET

C209

C408 24

2790 BLK

SHEET 4

1 2

2790 BLK

*

2010 BLK 1390 RED/WHT 4760 LGN

B A C

DOME LIGHT

C676

1885 RNG/WHT 2885 BLK C129

SHEET 3

C408 16

1580 RNG/WHT

1580 RNG/WHT

*

1210 RED/WHT 1865 RNG/WHT 2820 BLK

C279

A B C

LEFT SPEAKER

C408 33

+

7820 WHT 7830 WHT

3 4

7810 WHT 7800 WHT

6 5

2 1

+

2730 BLK C277

Dealer Copy -- Not1510 forRNG/WHT Resale

4 5

2210 BLK SEATBAR SENSOR

C482

SHEET 4 J1B 11

+5V

J1B 24 SHEET 6

2370/BRN OR 3910 LBL

C408 45

3920/LBL OR 3370/LBL 3930 LBL 3500 LBL

C408 46

3900/LBL OR 5370/YEL

2370/BRN OR 3910 LBL 3920/LBL OR 3370/LBL 3900/LBL OR 5370/YEL

A B

SIG

C

PWR

C250

C667

GND SHEET 8 SHEET 3

4750 LGN 1400 RED/WHT

4740 LGN

4 5

4740 LGN 1400 RED/WHT

6

C408 44 SHEET 3

1850 RNG/WHT

1850 RNG/WHT

1

1850 RNG/WHT

3

7310 WHT

C408 27 SW1 BRAKE SWITCH SHEET 8 SHEET 8 SHEET 3 SHEET 4

4500/LGN OR 3600/LBL 9310/PUR OR 3610/LBL 1775 RNG/WHT 2930 BLK

3 1 4

2 2840 BLK

5

RADIO CONN

C278

RIGHT SPEAKER 2730 BLK

1 2

-

ACCESSORY CONN

SHEET 4

1 2

6 2845 BLK

2

2840 BLK 7310 WHT

AIR RIDE SEAT SOLENOID

SENSOR SHOWN WITH DOOR OPEN

1 2

DOOR SENSOR C251 1860 RNG/WHT D 7330 WHT C 1570 RNG/WHT 7300 WHT A B E 3 1 6 4

SW PWR PARK LOW GND

2 5

SW8 FRONT WIPER SWITCH

C252

L X

(PRINTED DECEMBER 2011) Printed In U.S.A.

WASHER MOTOR

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 9 of 15 Printable Version Click Here

7165991 Standard Cab 7176098 Deluxe Cab

780 of 1311

WIPER MOTOR

*

SPLICE DOES NOT EXIST IN 7165991

7171253

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

MANUAL CONTROLS

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

C409

SHEET 4 SHEET 9 J2A 30 J2A 31 J2B 21 J2A 13 J2B 17 J2B 18 J2B 23

2530 BLK 4230 LGN 1590 RNG/WHT 4940 LGN 4930 LGN 4920 LGN 4910 LGN 4310 LGN 4320 LGN 4300 LGN

K G A H J E F C D B

RIGHT HANDLE

SKI CTRL DETENT FLOW +

C410

Dealer Copy 1570 RNG/WHT 1560 RNG/WHT

SHEET 3 J2B 22

J2A 20 J2A 28 22 for --J2A Not J2A 12 J2A 11

SHEET 9 SHEET 4

4640 LGN 4840 LGN 4830 LGN Resale 4820 LGN 4810 LGN 1710 RNG/WHT 4240 LGN 2520 BLK

TWO SPD PWM

LEFT HANDLE

K D C B G F A J H E

SKI CTRL SIDE SHIFT

C411

E C A D B

C404 A

7100 WHT

C103 C

SHEET 4

7100 WHT 2650 BLK

C412

T19 1 +

-

BACKUP ALARM 7001923

J1A 10 J1B 7

3 1 2

J1A 2 J1B 5

Printed In U.S.A.

HORN

Printable Version Click Here TILT SPOOL LOCK SOLENOID (NOT USED WITH ACS)

C422

2380 BLK 4380 LGN

B A

T20 1 C421

2370 BLK 4370 LGN

TURN SIGNAL

3 1 2

LIFT SPOOL LOCK SOLENOID (NOT USED WITH ACS)

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 10 of 15 (PRINTED DECEMBER 2011) 7171253

781 of 1311

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 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 CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

LIGHTS C434-1

2735 BLK 6100 PNK

2765 BLK

SHEET 4

6000 PNK

C408 28

C408 25

B A

LEFT FRONT WORK LIGHT 37.00 Watts

C434-2

2765 BLK

2750 BLK 6110 PNK

6000 PNK

6120 PNK 2760 BLK

B A

LEFT FRONT WORK LIGHT 50.00 Watts

C435-1

A B

RIGHT FRONT WORK LIGHT 37.00 Watts

C435-2

6130 PNK 2705 BLK FRONT WORK LIGHTS SHEET 3 SHEET 4 J1A 5 J1A 31

1330 RED/WHT

30 87

2105 BLK 2045 BLK 6320 PNK 6330 PNK

85

SHEET 4 6340 PNK

6310 PNK

C103 A

Dealer Copy -- Not for Resale

6310 PNK

SHEET 7 J1A 17 J1A 28

Printed In U.S.A.

1320 RED/WHT 2045 BLK 2035 BLK 6210 PNK 6230 PNK

SHEET 4

85

86

2 1

6330 PNK 2640 BLK

1 2

2620 BLK 6210 PNK

T16 1

LEFT REAR TAIL LIGHT

RIGHT REAR WORK LIGHT

T15 1 6200 PNK

C103 H

T17 1

6200 PNK SHEET 4

2630 BLK

LEFT REAR WORK LIGHT

T18 1

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 11 of 15 (PRINTED DECEMBER 2011)

782 of 1311

RIGHT REAR TAIL LIGHT

C602

SHEET 4

SHEET 3

RIGHT FRONT WORK LIGHT 50.00 Watts

C603

2610 BLK 6320 PNK

86

REAR LIGHT 30 87

A B

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE TAN ENGINE 8000 THROUGH 8999 COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

HVAC C630

7021 WHT 7023 WHT

J1A 11

7020 WHT

C408 34

7020 WHT 2570 BLK 3320 LBL

B C A

THERMOSTAT

C350

B A

7024 WHT

EVAPORATOR (AC PRESS SWITCH)

2560 BLK 1980 RNG/WHT 7220 WHT

C486

C355 A 7024 WHT SHEET 13

C483

7025 WHT

2290 BLK

1 2

2280 BLK

MAGNET CLUTCH (COMPRESSOR)

SHEET 3 SHEET 3 SHEET 6 SHEET 3 SHEET 6 J1A 21 SHEET 4

1140 RED/WHT 2030 BLK 2005 BLK 1790 RNG/WHT 1815 RNG/WHT 8020 TAN 2745 BLK

2130 BLK 1900 RNG/WHT

85

BLK DBL WHT

POTENTIOMETER (TEMP CONTROL SWITCH)

C635

D4

HVAC 30 87

C A B

1910 RNG/WHT

SW10 BLOWER SWITCH

Dealer Copy -- Not for Resale

1500 RNG/WHT C408 211500 RNG/WHT

86

OFF 5 2 1 4 6 3

2100 BLK

HEATER VALVE

A B C D

14.00 Amps 7.50 Amps 5.00 Amps

High Med Low

BLOWER MOTOR

7040 WHT

SW11 AC SWITCH 1 C

SIG GND 12V

C611

1970 RNG/WHT 1520 RNG/WHT 7320 WHT 2580 BLK

2745 BLK C408 22

D C A B E F

3

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 12 of 15 Printed In U.S.A. 783 of 1311

(PRINTED DECEMBER 2011) 7171253

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE TAN 8000 THROUGH 8999 PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

C411

LEFT HANDLE 5 PIN

B C A E D

C408 15

6010 PNK 6515 PNK

6500 PNK

C408 36

6415 PNK

6400 PNK

C408 29

6010 PNK 6550 PNK 6500 PNK 6540 PNK 6400 PNK 6450 PNK

SHEET 8

SHEET 8 C103 E

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

6410 PNK 6510 PNK

1410 RED/WHT

SHEET 3 D1

6530 PNK

D2

6430 PNK

SW3 HAZARD SWITCH

C408 26

1410 RED/WHT 1430 RED/WHT X

2725 BLK 2

1 3 4

SHEET 4

LEFT HANDLE 2 PIN

7210 WHT 1460 RED/WHT

C408 38

2850 BLK

6

2780 BLK C408 30

2780 BLK 6440 PNK Dealer Copy 6540 PNK

Printed In U.S.A.

E D C A F B

-- Not for Resale

2785 BLK 7210 WHT

1200 RED/WHT

BEACON SWITCH 6 5 4 1 2 3

C A B

C355 E 7010/WHT OR 4470/LGN WHT 2751/BLK OR 2770/BLK 2770/BLK OR 2470/BLK BLK 2751/BLK OR 2770/BLK 2290 BLK SHEET 4 SHEET 12 C355 B

B 2775/BLK OR 2480/BLK A 7000 WHT

C355 F

PWR BOB OPEN

SW6 BUCKET POSITION C408 13 1550 RNG/WHT SWITCH

SHEET 4 C408 35

2830 BLK

3 1 4

2 5

C423

6 7022 WHT SHEET 4

SJC HORN/BLINKER

2741 BLK

D3

7030 WHT

A

2740 BLK

B

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 13 of 15 (PRINTED DECEMBER 2011) 7171253

784 of 1311

C408 10 7010/WHT OR 4470/LGN

A B

SHEET 3

7200 WHT 6420 PNK 6520 PNK

7010/WHT OR 4470/LGN

C606

7022 WHT

B A

3 4 6

5

C408 9 7000/WHT OR 4480/LGN

PWR BOB CLOSE C607

RIGHT BLINKER

1550 RNG/WHT

SW5 POWER BOBTACH SWITCH 1 7000/WHT OR 4480/LGN 2

1380 RED/WHT

LEFT BLINKER

C126

C497

J2A 5 J2A 4 J2A 3

STROBE BEACON

C670

6700 PNK 2420 BLK

SHEET 3

B A

T3 FLASHER CONN

6570 PNK

5

SHEET 4

C412

OPTIONS L

(PINS 3 & 6 INTERNALLY INSULATED)

C103 D

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW PINK LIGHTS 6000 THROUGH 6999 ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE 8000 THROUGH 8999 TAN PURPLE COMMUNICATION 9000 THROUGH 9999 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

J1-ACS

H

2280 BLK 2670 BLK 2770/BLK OR 2470/BLK

2250 BLK

C

B C

1190 RED/WHT 1180 RED/WHT C429

C493

4 3 2 1

A E D B

HANDLE TILT HALL SENSOR C409 K G A H J LIFT ACTUATOR E F C D B

J3-ACS

8 7 2 5 3 1 4 6

4450 LGN 4220 LGN 4275 LGN 9240 PUR 9140 PUR/WHT 1740 RNG/WHT

See manual controls for harness connection

2240 BLK 1170 RED/WHT

MAINFRAME HARNESS C492

G

ACS CONTROLS

D

4690 LGN

F J H

4680 LGN 2260 BLK 2270 BLK 4670 LGN 1530 RNG/WHT

8 7 6 5 4 1 2 3

GND

C472 J2-ACS

F

2650 BLK 4650 LGN 1510 RNG/WHT

K

B C A

B C A

GND SIG PWR

HANDLE LIFT HALL SENSOR

4790 LGN

Dealer Copy -- Not for Resale A

4780 LGN 1630 RNG/WHT 4770 LGN 2770/BLK OR 2470/BLK

H E

8 7 6 5 4 3 2 1

K D C B G F A J H E

TILT ACTUATOR

PWR SIG GND

4280 LGN 2510 BLK

2 1 3

SKI CTRL DETENT FLOW TWO SPD PWM

FLOAT SKI CTRL SIDE SHIFT A B

HANDLE LOCK

C411

C467

A B C D

HANDLE LOCK

C410

SIG PWR

C428

A B

LIFT SOLENOID

E C A D B

TURN SIGNAL

C468 C469

2750 BLK 4750 LGN 1610 RNG/WHT

G

B C A

B C A

G E

GND SIG PWR

HANDLE TILT HALL SENSOR

PWR SIG GND

LIFT PEDAL HALL SENSOR

4260 LGN 4220 LGN

4270 LGN 2500 BLK

2 1 3

C412 TILT SOLENOID

B A

HORN

C471

1520 RNG/WHT J

4660 LGN 2660 BLK

1 3 2 C470

1620 RNG/WHT K

4760 LGN 2760 BLK 1610 RNG/WHT 1510 RNG/WHT 1500 RNG/WHT 4275 LGN 4220 LGN 4670 LGN 4770 LGN

1530 RNG/WHT 1630 RNG/WHT

1 3 2

PWR SIG GND

TILT PEDAL HALL SENSOR

Printable Version Click Here

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 14 of 15 (PRINTED DECEMBER 2011)

Printed In U.S.A. 785 of 1311

7171253

HARNESS PART NUMBER SJC WHEEL

33 34

3020 LBL 3080 LBL

40

1640 RNG/WHT

2580 BLK 1540 RNG/WHT

3 1 2 4

3000 LBL 3070 LBL

SIG SIG

PWR GND SIG SIG

RIGHT SPEED SENSOR

8

2 4 3 1

4720 LGN 1710 RNG/WHT

C543

2810 BLK 4720 LGN 1770 RNG/WHT

1 3 2

HARNESS, A22 PUMP 7169309 GND

RIGHT SWASHPLATE

SIG PWR

7

2 4 3 1

4950 LGN 1770 RNG/WHT

2860 BLK 4950 LGN 1770 RNG/WHT

1 3 2

4260 LGN 2660 BLK

1 2

4260 LGN 2660 BLK

44 45

4250 LGN 2650 BLK

3 4

4250 LGN 2650 BLK

31 41

4280 LGN 2680 BLK

5 6

4280 LGN 2680 BLK

21 11

4270 LGN 2670 BLK

7 8

4270 LGN 2670 BLK

26

4210 LGN

1 2

RIGHT FORWARD DRIVE

1 2

RIGHT REVERSE DRIVE

1 2

C474

1 2

LEFT FORWARD DRIVE

C492

8 7 2 5 3 4 1 6

4210 LGN

30 85

1730 RNG/WHT 6600 PNK 2730 BLK 87A 86

Dealer Copy -- Not for Resale

A B C

SEE OPTIONS HARNESS 7151691

BRAKE LIGHT RELAY K A D F H J C B E G

MAINFRAME HARNESS

C493

1235 RED/WHT 2235 BLK 1170 RED/WHT 2240 BLK

4770 LGN

G A F E D B H C

C707

HARNESS, OBW STOP LTS 7151696

A

SIG PWR

C428

1630 RNG/WHT

LEFT REVERSE DRIVE

C544

1750 RNG/WHT 1250 RED/WHT 1260 RED/WHT 2470 BLK 2490 BLK

1610 RNG/WHT

K J E H F G C D B A

C545

50 47 48 27 28

4670 LGN

GND

SJC CONTROLS

TILT ACTUATOR

SCHEMATIC INDEX OVERVIEW POWER GROUND CAN BUS ENGINE HYDRAULICS CAB DISPLAY CABIN MANUAL CONTROLS LIGHTS HVAC OPTIONS ACS CONTROL SJC CONTROL

3 PWR 4 2 SIG 6 1 GND 5 7 8

LEFT SWASHPLATE

C547

9140 PUR/WHT 9240 PUR 1740 RNG/WHT

4690 LGN 2630 BLK

4790 LGN

GND SIG PWR

C546

43 42

9190 PUR/WHT 9290 PUR 4550 LGN 4220 LGN 4275 LGN

5 6 8 1 4 2 7 3

C542

C501

12 22 4 6 16

4680 LGN

4780 LGN

C537

1820 RNG/WHT 2860 BLK

LIFT ACTUATOR

C429

NOTE: SPEED SENSORS NO LONGER FACTORY INSTALLED. SEE SERVICE LETTER SL5323 OR BTI 410

C536

1810 RNG/WHT 2810 BLK

WITHOUT SPEED SENSORS

S630, S650,S750, S770, T630, T650, T750, T770

1500 RNG/WHT 2770/BLK OR 2470/BLK 2250 BLK

1 3 2 4

7163706

T630, T650, T750, T770

WITH SPEED SENSORS

LEFT SPEED SENSOR

C453

1530 RNG/WHT 2570 BLK 23 24

GND PWR

7210504

WITH SPEED SENSORS WITHOUT SPEED SENSORS

2 3 1 4

J2-ACS

2510 BLK

SUSP JSTK

7159458

S630, S650, S750, S770

J1-ACS ACS CONTROLLER

29

SJC TRACK

C454

7210503

J3-ACS

J5 - DRIVE CONTROLLER

7159325

PAGE 1,2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15

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 GROUNDING 2000 THROUGH 2999 BLACK MONITORING 3000 THROUGH 3999 LIGHT BLUE HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW LIGHTS 6000 THROUGH 6999 PINK ACCESSORIES 7000 THROUGH 7999 WHITE ENGINE 8000 THROUGH 8999 TAN COMMUNICATION 9000 THROUGH 9999 PURPLE COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE

COLOR CODE RED RED/WHT RNG/WHT BLK LBL LGN YEL PNK WHT TAN PUR PUR/WHT

C460

1 2 4

1830 RNG/WHT 2070 BLK 9660 PUR

1 2 4

3

9560 PUR/WHT

3

1

1840 RNG/WHT

2

RIGHT JOYSTICK

C459 +12V PWR

1

2080 BLK

GND

2

4

9640 PUR

CAN LOW

4

3

9540 PUR/WHT

CAN HIGH

3

LEFT JOYSTICK

Printable Version Click Here 1760 RNG/WHT 2280 BLK 2270 BLK 2260 BLK 1180 RED/WHT 1190 RED/WHT C404

36

7100 WHT

A B

7100 WHT SHEET4

(CONNECTS TO BACKUP ALARM C404 ON MFR HARNESS)

Printed In U.S.A. 786 of 1311

C103 C +

-

BACKUP ALARM

WIRING SCHEMATIC (ACS & SJC MACHINE) S650 (S/N A3NV11001 - A3NV13098) (S/N A3NW11001 - A3NW11248) Sheet 15 of 15 (PRINTED DECEMBER 2011) 7171253

CONNECTOR ASSIGNMENTS NUM OF DESCRIPTION PINS 2 HYDRAULIC FAN LEFT JOYSTICK (CAB HARN) 4 4 RIGHT JOYSTICK (CAB HARN) 4 RIGHT QUAD A DRIVE 4 LEFT QUAD DRIVE 3 LIFT PEDAL LOCK 3 TILT PEDAL LOCK TILT HANDLE 3 TILT PEDAL 3 LIFT PEDAL 3 LIFT HANDLE 3 BRAKE LIGHT 1 LEFT PANEL(BLACK) 12 12 LEFT PANEL(GRAY)

CONN

DESCRIPTION

C101 C103 C104 C105 C106 C107 C108 C109 C110 C112 C126 C129 C209 C212

FUEL SHUTOFF SOLENOID TAILGATE ENGINE COOLANT SENSOR HYD CHARGE PRESSURE ENGINE SPEED SENSOR ENGINE OIL PRESSURE HYD TEMPERATURE SENDER S/R ADAPTER HARNESS ALTERNATOR HYD OIL FILTER SWITCH HORN CAB ACCESSORY DOME LIGHT POWER SOCKET

NUM OF PINS 3 8 2 3 2 3 2 2 2 2 2 3 3 2

C252 C277 C278 C279 C308 C350 C355 C404 C405 C406 C408

WASHER AIR RIDE SEAT RIGHT SPEAKER LEFT SPEAKER BRAKE SOLENOID AC EVAPORATOR SWITCH DLX or STD FUEL HARNESS BU ALARM-MFR HARN AIR FILTER SWITCH FUEL SENDER CAB - MFR HARN CONNECTOR

2 6 2 2 2 2 6 2 2 2 48

9 13 13 13 7 12 6,12,13 3,10 6 6 3-5,8-9,11-13

C482 C483 C486 C489 C492 C493 C497 C499 C500 C501 C503

SEATBAR SENSOR TEMP CONTROL SWITCH AC COMPRESSOR MFR ACCESSORY ACS/SJC/AWS-MFR HARN ACS/SJC/AWS-MFR HARN SJC HORN/BLINKER PTOL RH KEY SWITCH A22 PUMP HARNESS RH DLX PANEL

3 3 2 2 8 4, 15 3 4 6 8 6

C409 C410 C411 C412 C415 C418 C419

RIGHT HANDLE LEFT HANDLE LEFT HANDLE 5 WAY (FLSHR) LEFT HANDLE 2 WAY (HORN) HIGH FLOW SOLENOID FRONT ROD (MALE) FRONT BASE (FEMALE)

10 10 5 2 2 2 2

10 10 13 13 13 7 7

C542 C543 C544 C545 C546 C547

LEFT SWASHPLATE RIGHT SWASHPLATE LEFT FORWARD DRIVE LEFT REVERSE DRIVE RIGHT FORWARD DRIVE RIGHT REVERSE DRIVE

3 3 2 2 2 2 Dealer

C420 C440 C422 C423 C425 C426 C428 C429 C434-1 C434-2 C435-1 C435-2 C437 C441

HYD LOCK RF BASE TILT SPOOL LCOK BUCKET POSITION BRAKE SOLENOID CAN (Remote Start Tool, ACD) TILT ACTUATOR LIFT ACTUATOR LEFT WORKLIGHT 1 LEFT WORKLIGHT 2 RIGHT WORKLIGHT 1 RIGHT WORKLIGHT 2 TWO SPEED MAKEUP TWO SPEED

2 2 3 2 3 7 8 8 2 2 2 2 2 2

7 14 10 13 7 5 14, 15 14,15 11 11 11 11 13 13

SHEET

CONN

6 4,10,11,13 6 7 6 6 7 6 6 7 13 9 9 9

C446 C449 C450 C453 C454 C467 C468 C469 C470 C471 C472 C474 C479 C480

Printed In U.S.A. 787 of 1311

3 3 3,6,7,11,12

J1A J1B J2A J2B

GATEWA