Бобкэт ошибка 2403

КОД ОПИСАНИЕ ОШИБКИ 01-16 Не подсоединен воздушный фильтр 01-17 Засорен воздушный фильтр 02-16 Не подсоединен гидравлический нагнетательный фильтр 02-17 Засорен гидравлический нагнетательный фильтр 03-09 Низкое напряжение аккумуляторной батареи 03-10 Высокое напряжение аккумуляторной батареи 03-11 Предельно высокое напряжение аккумуляторной батареи 03-14 Предельно низкое напряжение аккумуляторной батареи 03-22 Напряжение аккумуляторной батареи ниже предельно допустимого 04-09 Низкий уровень давления масла в двигателе 04-14 Предельно низкий уровень давления масла в двигателе 04-15 Давление масла в двигателе на уровне экстренного выключения двигателя 04-21 Давление масла в двигателе выше предельно допустимого 04-22 Давление масла в двигателе ниже предельно допустимого 05-09 Низкое давление подпитки в гидравлической системе 05-14 Предельно низкое давление подпитки в гидравлической системе 05-15 Давление подпитки в гидравлической системе на уровне экстренного выключения двигателя 05-21 Давление подпитки в гидравлической системе выше предельно допустимого 05-22 Давление подпитки в гидравлической системе ниже предельно допустимого 06-10 Высокие обороты двигателя 06-11 Предельно высокие обороты двигателя 06-13 Отсутствует сигнал оборотов двигателя 06-15 Обороты двигателя на уровне экстренного выключения двигателя 06-18 Обороты двигателя вне допустимых пределов 07-10 Высокая температура масла в гидравлической системе 07-11 Предельно высокая температура масла в гидравлической системе 07-15 Температура масла в гидравлической системе на уровне экстренного выключения двигателя 07-21 Температура масла в гидравлической системе выше предельно допустимой 07-22 Температура масла в гидравлической системе ниже предельно допустимой 08-10 Высокая температура охлаждающей жидкости двигателя 08-11 Предельно высокая температура охлаждающей жидкости двигателя 08-15 Температура охлаждающей жидкости двигателя на уровне экстренного выключения двигателя 08-21 Температура охлаждающей жидкости двигателя выше предельно допустимой 08-22 Температура охлаждающей жидкости двигателя ниже предельно допустимой 09-09 Низкий уровень топлива 09-21 Уровень топлива выше предельно допустимого 09-22 Уровень топлива ниже предельно допустимого 11-05 Датчик рамы безопасности замкнут на батарею 11-06 Датчик рамы безопасности замкнут на массу 12-21 Сигнал ШИМ-контроллера передней доп. гидравлики за верхней границей диапазона 12-22 ШИМ-контроллер передней доп. гидравлики за нижней границей диапазона 12-23 ШИМ-контроллер передней доп. гидравлики не в нейтральном положении 13-05 Удерживающий соленоид отсечки топлива замкнут на батарею 13-06 Удерживающий соленоид отсечки топлива замкнут на массу 13-07 Разрыв цепи соленоида отсечки топлива 14-02 Втягивающий соленоид отсечки топлива, ошибочное включение 14-03 Втягивающий соленоид отсечки топлива, ошибочное выключение 15-02 Втягивающий соленоид блокировки тяги, ошибочное включение 15-03 Втягивающий соленоид блокировки тяги, ошибочное выключение 16-05 Удерживающий соленоид блокировки тяги замкнут на батарею 16-06 Удерживающий соленоид блокировки тяги замкнут на массу 16-07 Разрыв цепи удерживающего соленоида блокировки тяги 17-05 Соленоид гидравлического запорного клапана замкнут на батарею 17-06 Соленоид гидравлического запорного клапана замкнут на массу 17-07 Разрыв цепи соленоида гидравлического запорного клапана 18-05 Соленоид золотника замкнут на батарею 18-06 Соленоид золотника замкнут на массу 18-07 Разрыв цепи соленоида золотника 19-02 Соленоид позиционирования ковша, ошибочное включение 19-03 Соленоид позиционирования ковша, ошибочное выключение 20-02 Соленоид переключения скоростей, ошибочное включение 20-03 Соленоид переключения скоростей, ошибочное выключение 21-02 Свечи накаливания, ошибочное включение 21-03 Свечи накаливания, ошибочное выключение 22-02 Стартер, ошибочное включение 22-03 Стартер, ошибочное выключение 23-02 Задний базовый соленоид, ошибочное включение 23-03 Задний базовый соленоид, ошибочное выключение 24-02 Задний штоковый соленоид, ошибочное включение 24-03 Задний штоковый соленоид, ошибочное выключение 25-02 Задний вспомогательный пропорциональный соленоид, ошибочное включение 25-03 Задний вспомогательный пропорциональный соленоид, ошибочное выключение 26-02 Ошибочное включение переднего базового соленоида 26-03 Ошибочное выключение переднего базового соленоида 27-02 Ошибочное включение переднего штокового соленоида 27-03 Ошибочное выключение переднего штокового соленоида 28-02 Ошибочное включение соленоида дивертера 28-03 Ошибочное выключение соленоида дивертера 29-02 Соленоид большой подачи, ошибочное включение 29-03 Соленоид большой подачи, ошибочное выключение 30-28 Отказ памяти контроллера 31-28 Неисправность режима восстановления 32-04 Расширенное управление (ACS) не сообщается с контроллером Bobcat 32-23 Расширенное управление ACS не откалибровано 32-31 Отказ исполнительного механизма наклона 32-32 Неисправность электропроводки исполнительного механизма наклона 32-33 Неисправность электропроводки рукоятки наклона ковша 32-34 Исполнительный механизм наклона не в нейтральном положении 32-35 Рукоятка / педаль наклона ковша не в нейтральном положении 32-36 Отказ исполнительного механизма подъема 32-37 Неисправность электропроводки исполнительного механизма подъема 32-38 Неисправность электропроводки рукоятки подъема стрелы 32-39 Исполнительный механизм подъема не в нейтральном положении 32-40 Рукоятка / педаль подъема стрелы не в нейтральном положении 32-41 Нет связи 32-49 Исполнительный механизм подъема замкнут на массу 32-50 Исполнительный механизм наклона замкнут на массу 32-51 Исполнительный механизм подъема замкнут на батарею 32-52 Исполнительный механизм наклона замкнут на батарею 32-53 Рукоятка / педаль подъема стрелы замкнута на массу 32-54 Рукоятка / педаль наклона ковша замкнута на массу 32-55 Рукоятка / педаль подъема стрелы замкнута на батарею 32-56 Рукоятка / педаль наклона ковша замкнута на батарею 32-57 Пониженная производительность исполнительного механизма подъема 32-58 Пониженная производительность исполнительного механизма наклона 32-59 Неправильное направление исполнительного механизма подъема 32-60 Неправильное направление исполнительного механизма наклона 32-61 Блокиратор рукояток замкнут на массу 32-62 Блокиратор рукояток замкнут на батарею 32-63 Цепь блокиратора педалей замкнута на массу 32-64 Цепь блокиратора педалей замкнута на батарею 32-65 Напряжение питания датчика вне допустимых пределов 32-66 Напряжение аккумуляторной батареи вне допустимых пределов 32-67 Переключатель переключился во время работы 32-68 Информационная ошибка рукоятки подъема стрелы 32-69 Переключатель режимов управления переключился во время работы 32-70 Цепь правой рукоятки движения замкнута на массу 32-71 Цепь правой рукоятки движения замкнута на батарею 33-23 Главный контроллер (контроллер Bobcat) не запрограммирован 34-04 Панель с кнопочным запуском не сообщается с контроллером Bobcat 35-02 Двухскоростной переключатель вентилятора, ошибочное включение 35-03 Двухскоростной переключатель вентилятора, ошибочное выключение 36-48 Подключено несколько контроллеров ACD 37-02 Двухскоростной дополнительный переключатель скоростей, ошибочное включение 37-03 Двухскоростной дополнительный переключатель скоростей, ошибочное выключение 38-04 Нет связи с контроллером джойстика 38-05 Ось Х левого джойстика не в нейтральном положении 38-06 Ось X правого джойстика не в нейтральном положении 38-07 Ось Y левого джойстика не в нейтральном положении 38-08 Ось Y правого джойстика не в нейтральном положении 38-09 Переключатель режимов управления — замыкание на батарею или на массу 38-11 Исполнительный механизм подъема не в нейтральном положении 38-12 Исполнительный механизм наклона не в нейтральном положении 38-13 Отказ исполнительного механизма подъема 38-14 Отказ исполнительного механизма наклона 38-15 Неисправность проводки управления скоростью правого колеса 38-16 Неисправность проводки для скорости левого колеса 38-17 Пониженная производительность исполнительного механизма наклона 38-18 Пониженная производительность исполнительного механизма подъема 38-19 Ось X левого джойстика, за верхней границей диапазона 38-20 Ось X правого джойстика, за нижней границей диапазона 38-21 Ось Y левого джойстика, за верхней границей диапазона 38-22 Ось Y правого джойстика, за верхней границей диапазона 38-23 Сигнал переднего правого датчика управления за верхней границей диапазона 38-24 Сигнал переднего левого датчика управления за верхней границей диапазона 38-25 Сигнал заднего правого датчика управления за верхней границей диапазона 38-26 Сигнал заднего левого датчика управления за верхней границей диапазона 38-27 Сигнал исполнительного механизма подъема за верхней границей диапазона 38-28 Сигнал исполнительного механизма наклона за верхней границей диапазона 38-29 Ось X левого джойстика, за нижней границей диапазона 38-30 Ось X правого джойстика, за нижней границей диапазона 38-31 Ось Y левого джойстика, за нижней границей диапазона 38-32 Ось Y правого джойстика, за нижней границей диапазона 38-33 Сигнал переднего правого датчика управления за нижней границей диапазона 38-34 Сигнал переднего левого датчика управления за нижней границей диапазона 38-35 Сигнал заднего правого датчика управления за нижней границей диапазона 38-36 Сигнал заднего левого датчика управления за нижней границей диапазона 38-37 Питание «1» 5-вольтового датчика, за нижней границей диапазона 38-38 Питание «2» 5-вольтового датчика, за нижней границей диапазона 38-39 Исполнительный механизм подъема замкнут на массу / за нижней границей диапазона 38-40 Исполнительный механизм наклона замкнут на массу / сигнал за нижней границей диапазона 38-41 Неправильное направление исполнительного механизма наклона 38-42 Неправильное направление исполнительного механизма подъема 38-43 Соленоид левого переднего привода, ошибочное включение 38-44 Соленоид левого реверсивного привода, ошибочное включение 38-45 Соленоид правого переднего привода, ошибочное включение 38-46 Соленоид правого реверсивного привода, ошибочное включение 38-47 Передний правый соленоид управления, ошибочное включение 38-48 Передний левый соленоид управления, ошибочное включение 38-49 Задний правый соленоид управления, ошибочное включение 38-50 Задний левый соленоид управления, ошибочное включение 38-51 Соленоид давления системы управления, ошибочное включение 38-52 Сигнал заднего хода, ошибочное включение 38-53 Соленоид левого переднего привода, ошибочное выключение 38-54 Соленоид левого реверсивного привода, ошибочное выключение 38-55 Соленоид правого переднего привода, ошибочное выключение 38-56 Соленоид правого реверсивного привода, ошибочное выключение 38-57 Передний правый соленоид управления выдвижением, ошибочное выключение 38-58 Передний правый соленоид управления втягиванием, ошибочное выключение 38-59 Передний левый соленоид управления выдвижением, ошибочное выключение 38-60 Передний левый соленоид управления втягиванием, ошибочное выключение 38-61 Задний правый соленоид управления выдвижением, ошибочное выключение 38-62 Задний правый соленоид управления втягиванием, ошибочное выключение 38-63 Задний левый соленоид управления выдвижением, ошибочное выключение 38-64 Задний левый соленоид управления втягиванием, ошибочное выключение 38-65 Соленоид давления системы управления, ошибочное выключение 38-66 Сигнал заднего хода, ошибочное выключение 38-67 Нет сообщений от контроллера Bobcat 38-68 Углы установки колес (выравнивание) не откалиброваны 38-69 Исполнительные механизмы подъема и наклона не откалиброваны 38-70 Отключение питания 38-71 Напряжение батареи вне допустимых пределов 38-72 Насос привода не откалиброван 38-73 Переключатель режима управления/режима движения переключился во время работы 38-74 Скорость неуправляемого правого колеса, ошибочное включение 38-75 Скорость неуправляемого левого колеса, ошибочное включение 38-76 Соленоид давления системы управления — недостаточный ток 38-77 Передний правый соленоид управления выдвижением — недостаточный ток 38-78 Передний правый соленоид управления втягиванием — недостаточный ток 38-79 Передний левый соленоид управления выдвижением — недостаточный ток 38-80 Передний левый соленоид управления втягиванием — недостаточный ток 38-81 Задний правый соленоид управления выдвижением — недостаточный ток 38-82 Задний правый соленоид управления втягиванием — недостаточный ток 38-83 Задний левый соленоид управления выдвижением — недостаточный ток 38-84 Задний левый соленоид управления втягиванием — недостаточный ток 38-85 Питание «1» 5-вольтового датчика за верхней границей диапазона 38-86 Питание «2» 5-вольтового датчика за верхней границей диапазона 38-87 Блокировка правого переднего колеса (механическая неисправность управления) 38-88 Блокировка левого переднего колеса (механическая неисправность управления) 38-89 Блокировка правого заднего колеса (механическая неисправность управления) 38-90 Ошибка заднего левого управления 38-91 Отсутствуют импульсы датчика скорости правого колеса 38-92 Отсутствуют импульсы датчика скорости левого колеса 38-93 Датчик скорости правого колеса не отвечает 38-94 Датчик скорости левого колеса не отвечает 38-98 Контроллер в режиме калибровки привода 38-99 Контроллер в режиме калибровки положения колеса 45-03 Правый указатель поворота, ошибочное выключение 46-02 Левый указатель поворота, ошибочное включение 46-03 Левый указатель поворота, ошибочное выключение 47-21 Питание 8-вольтового датчика за верхней границей диапазона 47-22 Питание 8-вольтового датчика, за нижней границей диапазона 48-02 Реле переднего света, ошибочное включение 48-03 Реле переднего света, ошибочное выключение 49-02 Реле заднего света, ошибочное включение 49-03 Реле заднего света, ошибочное выключение 60-21 Сигнал рычага управления задней доп. гидравликой за верхней границей диапазона 60-22 Сигнал рычага управления задней доп. гидравликой за нижней границей диапазона 60-23 Рычаг управления задней доп. гидравликой не возвращается в нейтральное положение 64-02 Ошибочное включение реле мощности 64-03 Ошибочное выключение реле мощности 74-72 Сбой загрузочного кода контроллера Bobcat 74-73 Левая панель, ошибка приемного устройства 80-02 ACD, выход «A», ошибочное включение 80-03 ACD, выход «A», ошибочное выключение 81-02 ACD, выход «B», ошибочное включение 81-03 ACD, выход «B», ошибочное выключение 82-02 ACD, выход «C», ошибочное включение 82-03 ACD, выход «C», ошибочное выключение 83-02 ACD, выход «D», ошибочное включение 83-03 ACD, выход «D», ошибочное выключение 84-02 ACD, выход «E», ошибочное включение 84-03 ACD, выход «E», ошибочное выключение 90-02 Сервисный выход «C», ошибочное включение 90-03 Сервисный выход «C», ошибочное выключение 91-02 Сервисный выход «D», ошибочное включение 91-03 Сервисный выход «D», ошибочное выключение 92-02 Сервисный выход «Е», ошибочное включение 92-03 Сервисный выход «Е», ошибочное выключение 93-02 Сервисный выход «F», ошибочное включение 93-03 Сервисный выход «F», ошибочное выключение A0618 Скорость вращения колеса вне допустимого диапазона A3623 ACD (устройство управления навесным оборудованием), не запрограммировано A4621 Напряжение питания датчика 5 В выше допустимого диапазона A4622 Питание датчика 5 В ниже допустимого диапазона A4721 Напряжение питания датчика 8 В выше допустимого диапазона A4722 Питание датчика 8 В ниже допустимого диапазона A7701 Машинный ключ активен A7901 E-stop активен A8002 Acd / racd выход «a» — ошибочное включение A8003 Acd / racd выход «a» — ошибочное выключение A8005 Acd выход ‘a’ короткое замыкание на батарею A8006 Короткое замыкание выхода ACD на землю A8007 Acd выход ‘a’ (обрыв цепи) A8032 Acd выход ‘a’ (перегрузка по току) A8102 Acd / racd выход «b» — ошибочное включение A8103 Acd / racd выход «b» — ошибочное выключение A8105 Короткое замыкание на выходе ACD ‘b’ на аккумуляторную батарею A8106 Короткое замыкание выхода Acd на землю A8107 Acd выход ‘b’ (обрыв цепи) A8132 Acd выход ‘b’ (перегрузка по току) A8202 Acd / racd выход «c» — ошибочное включение A8203 Acd / racd выход «c» — ошибочное выключение A8205 Короткое замыкание на выходе ACD ‘c’ на аккумуляторную батарею A8206 Короткое замыкание выхода Acd на землю A8207 Разрыв цепи выхода ACD ‘c’ A8232 Acd выход ‘c’ (перегрузка по току) A8302 Acd выход ‘d’ — ошибочное включение A8303 Acd / racd выход «d» — ошибочное выключение A8305 Короткое замыкание выхода Acd на батарею A8306 Короткое замыкание выхода ACD на землю A8307 Разрыв цепи выхода ACD ‘d’ A8332 Acd выход ‘d’ (перегрузка по току) A8402 Acd / racd выход «e» — ошибочное включение A8403 Acd / racd выход «e» — ошибочное выключение A8405 Acd выход ‘e’ короткое замыкание на батарею A8406 Короткое замыкание выхода Acd на землю A8407 Acd выход ‘e’ (обрыв цепи) A8432 Acd выход ‘e’ (перегрузка по току) A8502 Acd / racd выход «f» — ошибочное включение A8503 Acd / racd выход «f» — ошибочное выключение A8505 Короткое замыкание на выходе Acd ‘f’ на аккумуляторную батарею A8506 Короткое замыкание выхода Acd на землю A8507 Acd выход ‘f’ (обрыв цепи) A8532 Acd выход ‘f’ (перегрузка по току) A8602 Acd выход ‘g’ — ошибочное включение A8603 Acd / racd выход «g» — ошибочное выключение A8605 Замыкание выхода ACD ‘g’ на аккумуляторную батарею A8606 Короткое замыкание выхода Acd на землю A8607 Разрыв цепи выхода ACD ‘g’ A8702 Acd / racd выход «h» — ошибочное включение A8703 Acd / racd выход «h» — ошибочное выключение A8705 Acd выход ‘h’ короткое замыкание на батарею A8706 Acd выход ‘h’: короткое замыкание на массу A8707 Acd выход ‘h’ (обрыв цепи) A8802 Реверсивный соленоид — ошибочное включение A8803 Реверсивный соленоид — ошибочное выключение C0216 Гидравлический / гидростатический фильтр не подключен C0217 Гидравлический / гидростатический фильтр засорен C0309 Низкое напряжение батареи C0310 Напряжение аккумулятора высокое C0311 Напряжение аккумулятора очень высокое C0314 Напряжение батареи крайне низкое C0315 Напряжение батареи при выключении C0322 Напряжение аккумулятора ниже допустимого диапазона C0414 Предельно низкое давление моторного масла C0415 Давление моторного масла при остановке C0610 Обороты двигателя высокая C0611 Предельно высокие обороты двигателя C0613 Нет сигнала оборотов двигателя C0615 Обороты двигателя при остановке C0618 Обороты двигателя вне допустимого диапазона C0710 Высокая температура гидравлического масла C0711 Предельно высокая температура гидравлического масла C0715 Температура гидравлического масла при останове C0722 Температура гидравлического масла вне допустимого диапазона, низкая C0810 Высокая температура охлаждающей жидкости двигателя C0811 Предельно высокая температура охлаждающей жидкости двигателя C0815 Температура охлаждающей жидкости двигателя при остановке C0821 Температура охлаждающей жидкости двигателя вне допустимого диапазона C0822 Температура охлаждающей жидкости двигателя вне допустимого диапазона, низкая C0921 Уровень топлива выше допустимого диапазона C0922 Уровень топлива ниже допустимого диапазона C1221 Дополнительный ШИМ-переключатель выше допустимого диапазона C1222 Дополнительный ШИМ-переключатель ниже допустимого диапазона C1223 Дополнительный ШИМ-переключатель не в нейтральном положении C1305 Замыкание соленоида блокировки отключения подачи топлива на аккумуляторную батарею C1306 Замыкание соленоида блокировки отключения подачи топлива на массу C1307 Обрыв цепи соленоида блокировки отключения подачи топлива Код Описание C1402 Соленоид отсечки подачи топлива — ошибочное включение C1403 Соленоид тяги отключения подачи топлива — ошибочное выключение C2005 Две скорости — ошибочное включение C2006 Две скорости — ошибочное выключение C2102 Свечи накаливания — ошибочное включение C2103 Свечи накаливания — ошибочное выключение C2202 Стартер — ошибочное включение C2203 Стартер — ошибочное выключение C2305 Электромагнитный клапан смещения базы: замыкание на аккумуляторную батарею C2306 Замыкание базового соленоида смещения на массу C2307 Обрыв цепи соленоида смещения основания C2405 Замыкание соленоида штока смещения на напряжение аккумулятора C2406 Замыкание соленоида смещающей штанги на массу C2407 Обрыв цепи соленоида смещающей штанги C2505 Возврат смещения: короткое замыкание на батарею C2506 Смещение возврата: короткое замыкание на массу C2507 Разомкнутая цепь возврата смещения C2605 Замыкание соленоида вспомогательной базы на напряжение аккумулятора C2606 Замыкание соленоида вспомогательной базы на массу C2607 Обрыв цепи вспомогательного базового соленоида C2705 Замыкание соленоида вспомогательной тяги на напряжение аккумулятора C2706 Замыкание соленоида вспомогательной тяги на массу C2707 Обрыв цепи соленоида вспомогательной тяги C2802 Гидравлический обмен — ошибочное включение C2803 Гидравлический обмен — ошибочное выключение C3028 Ошибка памяти контроллера C3128 Прерывистый сбой питания C3323 Главный контроллер не запрограммирован C3397 Главный контроллер запрограммирован C4021 Угол управления отвалом вне допустимого диапазона, высокий C4022 Угол управления отвалом ниже допустимого диапазона C4023 Угловой отвал не в нейтральном положении C4105 Электромагнитный клапан основания углового лезвия: замыкание на аккумуляторную батарею C4106 Электромагнитный клапан основания углового отвала: замыкание на массу C4107 Обрыв цепи соленоида основания углового лезвия C4205 Электромагнитный клапан стержня углового ножа: замыкание на аккумуляторную батарею C4206 Электромагнитный клапан стержня углового отвала: замыкание на массу C4207 Обрыв цепи соленоида стержня углового ножа C4321 Давление считывания нагрузки вне допустимого диапазона C4322 Давление измерения нагрузки ниже допустимого диапазона C4516 Контроллер дроссельной заслонки (нет связи) C6021 Контроль смещения вне допустимого диапазона C6022 Контроль смещения ниже допустимого диапазона C6023 Управление смещением не в нейтральном положении C6204 Ошибка мониторинга момента нагрузки C6305 Замыкание переключателя консоли на аккумулятор C6306 Замыкание переключателя консоли на массу C6405 Переключаемое реле питания, короткое замыкание на батарею C6406 Короткое замыкание переключаемого силового реле на массу C6407 Обрыв цепи переключаемого силового реле C6505 Замыкание соленоида блокировки рабочей группы на напряжение аккумулятора C6506 Замыкание соленоида блокировки рабочей группы на массу C6507 Обрыв цепи соленоида блокировки рабочей группы D3905 Левый джойстик Ось X не в нейтральном положении D3907 Левый джойстик Ось Y не в нейтральном положении D4007 Правый джойстик ось Y не в нейтральном положении D7501 Ошибка информации джойстика D7504 Привод (нет связи) с контроллером привода D7505 Левый джойстик привода оси X не в нейтральном положении D7507 Левый джойстик привода оси Y не в нейтральном положении D7508 Управляйте правым джойстиком, ось Y не в нейтральном положении D7509 Замыкание переключателя рабочего режима на массу или аккумулятор D7510 Установлены неправильные джойстики привода D7511 Левый датчик скорости привода не подключен D7512 Датчик скорости правого привода не подключен D7513 Правое переднее колесо не отвечает D7514 Левое переднее колесо не отвечает D7515 Правое заднее колесо не отвечает D7516 Левое заднее колесо не отвечает D7517 Левая тарелка автомата перекоса не в нейтральном положении D7518 Правая качающаяся пластина не в нейтральном положении D7519 Ось X левого джойстика движения вне допустимого диапазона D7521 Перемещение по оси Y левого джойстика вне допустимого диапазона D7522 Правый джойстик движения по оси Y вне допустимого диапазона D7523 Правый передний датчик рулевого управления выше допустимого диапазона D7524 Левый передний датчик рулевого управления выше допустимого диапазона D7525 Правый задний датчик рулевого управления выше допустимого диапазона D7526 Левый задний датчик рулевого управления выше допустимого диапазона сигнала D7527 Левая наклонная пластина не на своем месте D7528 Правая наклонная пластина не на своем месте D7529 Левый джойстик движения по оси X ниже допустимого диапазона D7531 Ведите левый джойстик по оси Y за пределы допустимого диапазона D7532 Двигайтесь правым джойстиком по оси Y ниже допустимого диапазона D7533 Правый передний датчик рулевого управления ниже допустимого диапазона D7534 Левый передний датчик рулевого управления ниже допустимого диапазона D7535 Правый задний датчик рулевого управления ниже допустимого диапазона D7536 Левый задний датчик рулевого управления ниже допустимого диапазона D7537 Питание датчика 5,0 В 1 ниже допустимого диапазона D7538 Питание датчика 5 Вольт 2 ниже допустимого диапазона D7539 Левый датчик наклонной пластины выше допустимого диапазона D7540 Левый датчик наклонной пластины ниже допустимого диапазона D7541 Датчик правой наклонной пластины выше допустимого диапазона D7542 Датчик правой наклонной пластины ниже допустимого диапазона D7543 Соленоид левого переднего привода — ошибочное включение D7544 Соленоид левого реверсивного привода — ошибочное включение D7545 Соленоид правого переднего привода — ошибочное включение D7546 Соленоид правого реверсивного привода — ошибочное включение D7547 Соленоид выдвижения правого переднего колеса — ошибочное включение D7548 Соленоид рулевого управления выдвижения левого переднего колеса — ошибочное включение D7549 Соленоид выдвижения правого заднего рулевого механизма — ошибочное включение D7550 Соленоид выдвижения левого заднего рулевого механизма — ошибочное включение D7551 Соленоид рулевого управления с регулировкой давления — ошибочное включение D7552 Резервное копирование — ошибочное включение D7553 Соленоид левого переднего привода — ошибочное выключение D7554 Соленоид левого реверсивного привода — ошибочное выключение D7555 Соленоид правого переднего привода — ошибочное выключение D7556 Соленоид правого реверсивного привода — ошибочное выключение D7557 Соленоид выдвижения правого переднего колеса — ошибочное выключение D7558 Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное выключение D7559 Соленоид рулевого механизма выдвижения левого переднего колеса — ошибочное выключение D7560 Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное выключение D7561 Соленоид выдвижения правого заднего рулевого механизма — ошибочное выключение D7562 Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное выключение D7563 Соленоид выдвижения левого заднего рулевого механизма — ошибочное выключение D7564 Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное выключение D7565 Соленоид рулевого управления с регулировкой давления — ошибочное выключение D7566 Аварийный сигнал резервного копирования — ошибочное выключение D7567 Нет связи от контроллера шлюза D7568 Датчики угла не откалиброваны D7569 Напряжение аккумулятора выше допустимого диапазона D7570 Прерванная мощность D7571 Напряжение аккумулятора ниже допустимого диапазона D7572 Приводной насос — не откалиброван D7573 Переключатель режима работы перевернут во время работы D7574 Неуправляемое движение со скоростью правого колеса D7575 Неуправляемое движение со скоростью левого колеса D7576 Привод отсутствует связь с контроллером ACS D7577 Левый датчик скорости выше допустимого диапазона D7578 Датчик правой скорости выше допустимого диапазона D7579 Левый датчик скорости ниже допустимого диапазона D7580 Датчик правой скорости ниже допустимого диапазона D7581 Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное включение D7582 Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное включение D7583 Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное включение D7584 Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное включение D7585 Подача питания датчика 1 на 5,0 В выше допустимого диапазона D7586 Питание датчика 2 выше допустимого диапазона D7587 Требуется обновление программного обеспечения D7588 Переключенное питание застряло во включенном состоянии D7589 Электропитание привода — ошибочное выключение D7590 Калибровка привода выполнена D7591 Левый датчик наклонной пластины — перевернутый D7592 Правый датчик наклонной пластины — перевернутый D7593 Не отвечает правый датчик скорости D7594 Не отвечает левый датчик скорости D7595 Левый датчик скорости заднего хода D7596 Направление заднего хода правого датчика скорости D7597 Запрограммирован контроллер Drive / Drive Plus D7598 Контроллер Drive / Drive Plus в режиме калибровки D7599 Контроллер Drive Plus в режиме калибровки положения колес E00002700 Ошибка управления EGR E00002701 Ошибка управления EGR E00002703 EGR Ошибка положения привода E00002704 EGR Ошибка положения привода E00002709 EGR Ошибка положения привода E00002710 EGR Ошибка положения привода E00002720 Ошибка обучения позиции EGR E00002730 Ошибка обучения позиции EGR E00002903 Неисправность датчика положения дроссельной заслонки E00002904 Неисправность датчика положения дроссельной заслонки E00008100 Ошибка SCR E00008107 Ошибка SCR E00008111 Ошибка SCR E00009102 Неисправность датчика положения дроссельной заслонки E00009103 Неисправность датчика положения дроссельной заслонки E00009104 Неисправность датчика положения дроссельной заслонки E00009119 Неисправность датчика положения дроссельной заслонки E00009411 Неисправность управления давлением в рампе E00009416 Неисправность управления давлением в рампе E00009418 Неисправность управления давлением в рампе E00009703 Неисправность датчика воды в топливе E00009704 Неисправность датчика воды в топливе E00009709 Неисправность датчика воды в топливе E00009731 Обнаружена вода в топливе E00010001 Давление моторного масла слишком низкое E00010003 Неисправность давления моторного масла E00010004 Неисправность давления моторного масла E00010203 Неисправность датчика давления всасываемого воздуха E00010204 Неисправность датчика давления всасываемого воздуха E00010502 Ошибка температуры впускного коллектора E00010503 Неисправность датчика температуры впускного коллектора E00010504 Неисправность датчика температуры впускного коллектора E00010509 Неисправность датчика температуры впускного коллектора E00010510 Неисправность датчика температуры впускного коллектора E00010603 Неисправность датчика давления в коллекторе E00010604 Неисправность датчика давления в коллекторе E00010609 Неисправность датчика давления в коллекторе E00010803 Ошибка атмосферного давления E00010804 Ошибка атмосферного давления E00010809 Ошибка атмосферного давления E00011000 Предельно высокая температура двигателя E00011002 Ошибка температуры охлаждающей жидкости двигателя E00011003 Неисправность датчика температуры воды E00011004 Неисправность датчика температуры воды E00011031 Неисправность датчика температуры охлаждающей жидкости двигателя E00013200 Неисправность объема всасываемого воздуха E00013201 Неисправность объема всасываемого воздуха E00013203 Неисправность датчика Maf E00013204 Неисправность датчика Maf E00013209 Неисправность датчика Maf E00013215 Ошибка давления наддува E00013231 Неисправность датчика Maf E00015700 Неисправность давления в рампе E00015702 Неисправность датчика давления в рампе E00015703 Неисправность датчика давления в рампе E00015704 Неисправность датчика давления в рампе E00015710 Неисправность давления в рампе E00015711 Неисправность давления в рампе E00015721 Неисправность управления давлением в рампе E00015722 Неисправность управления давлением в рампе E00016803 Напряжение в системе слишком высокое E00016804 Напряжение в системе слишком низкое E00017103 Неисправность датчика Maf E00017104 Неисправность датчика Maf E00017200 Слишком высокая температура всасываемого воздуха E00017202 Неисправность датчика температуры всасываемого воздуха E00017203 Неисправность датчика температуры всасываемого воздуха E00017204 Неисправность датчика температуры всасываемого воздуха E00017209 Неисправность датчика температуры всасываемого воздуха E00017300 Ошибка перегрева выхлопных газов E00017301 Док. Ошибка экзотермической эффективности E00017302 Неисправность датчика температуры на впуске Scr E00017400 Слишком высокая температура топлива E00017402 Ошибка температуры топлива E00017403 Неисправность датчика температуры топлива E00017404 Неисправность датчика температуры топлива E00017409 Неисправность датчика температуры топлива E00017502 Ошибка температуры моторного масла E00017531 Неисправность датчика температуры моторного масла E00019000 Предельно высокие обороты двигателя E00062802 Ошибка ЭБУ E00062912 Ошибка ЭБУ E00063011 Ошибка данных форсунки E00063023 Ошибка ЭБУ E00063024 Ошибка ЭБУ E00063025 Ошибка ЭБУ E00063031 Ошибка ЭБУ E00063307 Неисправность давления в рампе E00063600 Неисправность датчика положения коленчатого вала E00063601 Неисправность датчика положения коленчатого вала E00063602 Неисправность датчика положения коленчатого вала E00063607 Неисправность кулачка или датчика кривошипа E00063608 Неисправность датчика положения коленчатого вала E00063611 Неисправность датчика положения коленчатого вала E00063702 Ошибка сигнала кулачка E00063708 Ошибка сигнала кулачка E00063720 Ошибка сигнала кулачка E00063730 Ошибка сигнала кулачка E00063919 Ошибка связи ЭБУ E00064103 Ошибка контроля наддува E00064104 Ошибка контроля наддува E00065103 Неисправность форсунки №1 E00065105 Неисправность форсунки №1 E00065106 Неисправность форсунки №1 E00065120 Неисправность форсунки №1 E00065121 Неисправность форсунки №1 E00065131 Неисправность форсунки №1 E00065203 Неисправность форсунки №2 E00065205 Неисправность форсунки №2 E00065206 Неисправность форсунки №2 E00065220 Неисправность форсунки №2 E00065221 Неисправность форсунки №2 E00065231 Неисправность форсунки №2 E00065303 Неисправность форсунки №3 E00065305 Неисправность форсунки №3 E00065306 Неисправность форсунки №3 E00065320 Неисправность форсунки №3 E00065321 Неисправность форсунки №3 E00065331 Неисправность форсунки №3 E00065403 Неисправность форсунки №4 E00065405 Неисправность форсунки №4 E00065406 Неисправность форсунки №4 E00065420 Неисправность форсунки №4 E00065421 Неисправность форсунки №4 E00065431 Неисправность форсунки №4 E00067603 Неисправность реле свечей накаливания E00067604 Неисправность реле свечей накаливания E00067605 Неисправность реле свечей накаливания E00072302 Неисправность датчика положения распределительного вала E00072308 Неисправность датчика положения распределительного вала E00073120 Неисправность акселерометра E00073121 Неисправность акселерометра E00107600 Неисправность управления давлением в рампе E00107601 Неисправность управления давлением в рампе E00107603 Неисправность управления давлением в рампе E00107604 Неисправность управления давлением в рампе E00107609 Неисправность управления давлением в рампе E00107615 Неисправность управления давлением в рампе E00107616 Неисправность управления давлением в рампе E00107617 Неисправность управления давлением в рампе E00107618 Неисправность управления давлением в рампе E00107620 Неисправность управления давлением в рампе E00107631 Неисправность управления давлением в рампе E00107702 Ошибка ЭБУ E00118002 Ошибка температуры турбо E00118003 Неисправность датчика температуры турбо E00118004 Неисправность датчика температуры турбо E00118009 Неисправность датчика температуры турбо E00118010 Неисправность датчика температуры турбо E00118031 Неисправность датчика температуры турбо E00122100 Ошибка ЭБУ E00122101 Ошибка ЭБУ E00122102 Ошибка ЭБУ E00122103 Ошибка мониторинга безопасности ЭБУ E00122104 Ошибка мониторинга безопасности ЭБУ E00122105 Ошибка ЭБУ E00122106 Ошибка ЭБУ E00122107 Ошибка ЭБУ E00122108 Ошибка ЭБУ E00122109 Ошибка ЭБУ E00122110 Ошибка ЭБУ E00122111 Ошибка мониторинга безопасности ЭБУ E00122112 Ошибка ЭБУ E00122113 Ошибка ЭБУ E00122114 Ошибка ЭБУ E00122115 Ошибка ЭБУ E00122116 Ошибка ЭБУ E00122117 Ошибка ЭБУ E00122118 Ошибка ЭБУ E00122119 Ошибка мониторинга безопасности ЭБУ E00122120 Ошибка ЭБУ E00122121 Ошибка ЭБУ E00122122 Ошибка ЭБУ E00122123 Ошибка ЭБУ E00122124 Ошибка ЭБУ E00122125 Ошибка ЭБУ E00122126 Ошибка мониторинга безопасности ЭБУ E00122127 Ошибка мониторинга безопасности ЭБУ E00122128 Ошибка мониторинга безопасности ЭБУ E00122129 Ошибка мониторинга безопасности ЭБУ E00122130 Ошибка ЭБУ E00122131 Ошибка мониторинга безопасности ЭБУ E00122132 Ошибка ЭБУ E00122133 Ошибка ЭБУ E00122134 Ошибка ЭБУ E00122135 Ошибка ЭБУ E00122136 Ошибка ЭБУ E00122137 Ошибка ЭБУ E00122138 Ошибка ЭБУ E00122139 Ошибка ЭБУ E00122140 Ошибка ЭБУ E00122141 Ошибка ЭБУ E00122142 Ошибка ЭБУ E00122143 Ошибка ЭБУ E00122144 Ошибка ЭБУ E00122145 Ошибка ЭБУ E00122146 Ошибка ЭБУ E00122147 Ошибка ЭБУ E00122148 Ошибка ЭБУ E00122149 Ошибка ЭБУ E00122150 Ошибка ЭБУ E00122151 Ошибка ЭБУ E00122152 Ошибка ЭБУ E00122153 Ошибка ЭБУ E00122154 Ошибка ЭБУ E00122155 Ошибка ЭБУ E00122156 Ошибка ЭБУ E00122157 Ошибка ЭБУ E00122158 Ошибка ЭБУ E00122159 Ошибка ЭБУ E00122160 Ошибка ЭБУ E00122161 Ошибка ЭБУ E00122162 Ошибка ЭБУ E00122163 Ошибка ЭБУ E00122164 Ошибка ЭБУ E00122165 Ошибка ЭБУ E00122166 Ошибка ЭБУ E00122167 Ошибка ЭБУ E00122168 Ошибка ЭБУ E00122169 Ошибка ЭБУ E00122170 Ошибка ЭБУ E00122171 Ошибка ЭБУ E00122172 Ошибка ЭБУ E00122173 Ошибка ЭБУ E00122174 Ошибка ЭБУ E00122175 Ошибка ЭБУ E00122176 Ошибка ЭБУ E00122177 Ошибка ЭБУ E00122178 Ошибка ЭБУ E00122179 Ошибка ЭБУ E00122180 Ошибка ЭБУ E00122181 Ошибка ЭБУ E00122182 Ошибка ЭБУ E00122183 Ошибка ЭБУ E00122184 Ошибка ЭБУ E00122185 Ошибка ЭБУ E00122186 Ошибка ЭБУ E00122187 Ошибка ЭБУ E00122188 Ошибка ЭБУ E00122189 Ошибка ЭБУ E00122190 Ошибка ЭБУ E00122191 Ошибка ЭБУ E00122192 Ошибка ЭБУ E00122193 Ошибка ЭБУ E00122194 Ошибка ЭБУ E00122195 Ошибка ЭБУ E00122196 Ошибка ЭБУ E00122197 Ошибка ЭБУ E00122198 Ошибка ЭБУ E00122199 Ошибка ЭБУ E00123901 Утечка топлива под высоким давлением E00134703 Неисправность насоса высокого давления E00134704 Неисправность насоса высокого давления E00134707 Неисправность насоса высокого давления E00148502 Неисправность главного реле ЭБУ E00148507 Неисправность главного реле ЭБУ E00148511 Неисправность главного реле ЭБУ E00161203 Неисправность форсунок №1 и №4 E00161204 Неисправность форсунок №1 и №4 E00161211 Неисправность форсунок №1 и №4 E00161303 Неисправность форсунок № 2 и № 3 E00161304 Неисправность форсунок № 2 и № 3 E00161311 Неисправность форсунок № 2 и № 3 E00279103 Egr Motor Fault (неисправность двигателя) E00279104 Egr Motor Fault (неисправность двигателя) E00279105 Egr Motor Fault (неисправность двигателя) E00279107 Заблокированная неисправность EGR E00279108 Ошибка положения EGR E00324200 Предельно высокая температура выхлопных газов E00324203 Неисправность датчика температуры выхлопных газов E00324204 Неисправность датчика температуры выхлопных газов E00324216 Неисправность датчика температуры выхлопных газов E00324600 Предельно высокая температура выхлопных газов E00324603 Ошибка датчика температуры EGR E00324604 Ошибка датчика температуры EGR E00324616 Неисправность датчика температуры выхлопных газов E00325100 Неисправность датчика перепада давления E00325101 Неисправность датчика перепада давления E00325103 Ошибка датчика температуры EGR E00325104 Ошибка датчика температуры EGR E00325200 Слишком высокая температура выхлопных газов E00350903 Сбой напряжения питания датчика E00350904 Сбой напряжения питания датчика E00350911 Неисправность источника питания 5-вольтного датчика №1 E00351003 Сбой напряжения питания датчика E00351004 Сбой напряжения питания датчика E00351011 Неисправность источника питания 5-вольтного датчика №2 E00351111 Неисправность питания 5-вольтового вспомогательного датчика №2 E00370100 Предельно высокое содержание твердых частиц E00370115 Предупреждение о твердых частицах E00370116 Слишком высокое содержание твердых частиц E00408203 Неисправность впускного дозирующего клапана E00408204 Неисправность впускного дозирующего клапана E00408205 Неисправность впускного дозирующего клапана E00408206 Неисправность впускного дозирующего клапана E00425600 Неизвестная неисправность Scr E00476500 Предельно высокая температура выхлопных газов E00476503 Неисправность датчика температуры выхлопных газов E00476504 Неисправность датчика температуры выхлопных газов E00476518 Неисправность датчика температуры выхлопных газов E00524600 Уровень защиты пустой E00524615 Уровень защиты слишком низкий E00524616 Уровень защиты Предельно низкий E00524617 Уровень защиты слишком низкий E00524619 Dcu может сбой связи E00524621 Заблокированная ошибка EGR E00524622 Прерванная ошибка дозирования E00524623 Ошибка расхода Def E00524624 Ошибка качества Def E00524625 Ошибка взлома E00524626 Ошибка расхода Def E00532403 Ошибка сигнала свечей накаливания E00532404 Ошибка сигнала свечей накаливания E0105 Замыкание привода дроссельной заслонки на напряжение аккумулятора E0106 Замыкание привода дроссельной заслонки на массу E0107 Обрыв цепи привода дроссельной заслонки E0123 Контроллер дроссельной заслонки не откалиброван E0321 Напряжение питания датчика 5 В выше допустимого диапазона E0322 Питание датчика 5 В ниже допустимого диапазона E0421 Диск управления частотой вращения двигателя выше допустимого диапазона E0422 Диск управления частотой вращения двигателя ниже допустимого диапазона E0521 Обратная связь привода дроссельной заслонки вне допустимого диапазона E0522 Обратная связь привода дроссельной заслонки ниже допустимого диапазона E52352302 Неисправность форсунок №1 и №4 E52352303 Неисправность форсунок №1 и №4 E52352304 Неисправность форсунок №1 и №4 E52352402 Неисправность форсунок № 2 и № 3 E52352403 Неисправность форсунок № 2 и № 3 E52352404 Неисправность форсунок № 2 и № 3 E52352501 Неисправность форсунки E52352702 Ошибка ЭБУ E52353500 Неисправность форсунки E52353602 Ошибка EGR E52353702 Ошибка EGR E52353802 Ошибка ЭБУ E52353807 Ошибка ЭБУ E52353902 Неисправность топливного насоса E52354002 Неисправность топливного насоса E52354103 Ошибка EGR E52354104 Ошибка EGR E52354302 Неисправность датчика положения дроссельной заслонки E52354403 Неисправность впускного нагревателя E52354404 Неисправность впускного нагревателя E52354702 Ошибка связи ЭБУ E52354802 Ошибка связи ЭБУ E52357204 Ошибка датчика положения EGR E52357403 Egr Actuator Fault (Неисправность привода) E52357404 Egr Неисправность привода E52357507 Egr Actuator Fault (Неисправность привода) E52357602 Egr Motor Fault (Неисправность двигателя) E52357702 Ошибка датчика температуры EGR E52357802 Ошибка EGR E52358002 Неисправность впускного дросселя E52358203 Неисправность датчика подъема дроссельной заслонки на впуске E52358204 Неисправность датчика подъема дроссельной заслонки на впуске E52358917 Низкая температура воды при парковке регенерации E52359016 Припаркованный тайм-аут регенерации E52359102 Ошибка связи ЭБУ E52359202 Ошибка связи ЭБУ E52359302 Ошибка связи ЭБУ E52359402 Ошибка связи ЭБУ E52359502 Ошибка связи ЭБУ E52359602 Ошибка связи ЭБУ E52359800 Отказ Doc E52359802 Ошибка связи ЭБУ E52359900 Неисправность датчика температуры выхлопных газов E52360000 Ошибка калибровки насоса E52360100 Неисправность датчика температуры выхлопных газов E52360200 Ошибка DPF E52360315 Неисправность датчика температуры воды E52360402 Ошибка связи ЭБУ E52370013 Ошибка ЭБУ H0921 Датчик наддува выше допустимого диапазона H0922 Датчик наддува ниже допустимого диапазона H1221 Передний вспомогательный подрулевой переключатель выше допустимого диапазона H1222 Передний вспомогательный подрулевой переключатель ниже допустимого диапазона H1224 Передний вспомогательный подрулевой переключатель не в нейтральном положении H1321 Левый переключатель для большого пальца вне допустимого диапазона — высокий уровень H1322 Левый большой переключатель ниже допустимого диапазона H1324 Задний вспомогательный подрулевой переключатель не в нейтральном положении H2305 Замыкание заднего базового соленоида на аккумулятор H2306 Замыкание заднего базового соленоида на массу H2307 Обрыв цепи заднего базового соленоида H2332 Перегрузка заднего базового соленоида H2405 Замыкание соленоида задней тяги на аккумулятор Код Описание H2406 Замыкание соленоида задней тяги на массу H2407 Обрыв цепи соленоида задней тяги H2432 Перегрузка соленоида задней тяги H2505 Короткое замыкание дивертора №2 на аккумуляторную батарею H2506 Дивертер №2, замыкающий на землю H2507 Обрыв цепи дивертора №2 H2605 Замыкание переднего базового соленоида на напряжение аккумулятора H2606 Замыкание переднего базового соленоида на массу H2607 Обрыв цепи переднего базового соленоида H2632 Перегрузка переднего базового соленоида H2705 Замыкание соленоида передней тяги на напряжение аккумулятора H2706 Замыкание соленоида передней тяги на массу H2707 Обрыв цепи соленоида передней тяги H2732 Перегрузка соленоида передней тяги H2805 Замыкание электромагнитного клапана дивертора на напряжение аккумулятора H2806 Замыкание электромагнитного клапана дивертора на массу H2807 Обрыв цепи электромагнитного клапана дивертора H2905 Электромагнитный клапан высокого расхода: замыкание на аккумуляторную батарею H2906 Замыкание соленоида высокого потока на массу H2907 Обрыв цепи соленоида высокого расхода H2932 Перегрузка по току соленоида с высоким расходом H3028 Сбой памяти вспомогательного контроллера H3128 Прерывистый сбой питания H3648 Наличие нескольких Acds (устройство управления навесным оборудованием) H3904 Левый джойстик неисправен H3912 Большой палец на левом джойстике не в нейтральном положении H3913 Левый джойстик захвата (нет связи) H3916 Левый джойстик базы (нет связи) H3928 Внутренняя неисправность левого джойстика H3948 Левый джойстик несколько H4004 Правый джойстик неисправен H4012 Большой палец на правом джойстике не в нейтральном положении H4013 Правая ручка джойстика (нет связи) H4016 Правая консоль джойстика (нет связи) H4028 Внутренняя неисправность правого джойстика H4048 Правый джойстик несколько H4302 Реле звукового сигнала — ошибочное включение H4303 Реле звукового сигнала — ошибочное выключение H4423 Вспомогательный контроллер не запрограммирован H4497 Вспомогательный контроллер запрограммирован H4502 Правый указатель поворота — ошибочное включение H4503 Правый указатель поворота — ошибочное выключение H4602 Левый поворотник — ошибочное включене H4603 Левый поворотник — ошибочное выключение H4721 Напряжение питания датчика 8 В выше допустимого диапазона H4722 Питание датчика 8 В ниже допустимого диапазона H7404 Контроллер шлюза (нет связи) H7604 Левая панель дисплея Нет кода связи Описание L0102 Кнопка освещения — ошибочное включение L0202 Кнопка высокого расхода — ошибочное включение L0302 Вспомогательная кнопка — ошибочное включение L0402 Инфорсационная кнопка — ошибочное включение L7404 Контроллер шлюза (нет связи) L7672 Ошибка программирования левой панели M0116 Воздушный фильтр не подключен M0117 Засорен воздушный фильтр M0216 Фильтр гидравлического агрегата не подключен M0217 Засорен фильтр гидравлического агрегата M0309 Низкое напряжение батареи M0310 Напряжение аккумулятора высокое M0311 Напряжение аккумулятора очень высокое M0314 Напряжение батареи крайне низкое M0322 Напряжение аккумулятора ниже допустимого диапазона M0409 Давление моторного масла низкое M0414 Предельно низкое давление моторного масла M0415 Давление моторного масла при остановке M0421 Давление моторного масла вне допустимого диапазона M0422 Давление моторного масла ниже допустимого диапазона M0509 Низкое давление наддува гидросистемы M0510 Гидравлическое давление наддува высокое M0511 Предельно высокое гидравлическое давление наддува M0514 Предельно низкое гидравлическое давление наддува M0515 Гидравлическое давление наддува при останове M0521 Гидравлическое давление наддува выше допустимого диапазона M0522 Гидравлическое давление наддува ниже допустимого диапазона M0610 Обороты двигателя высокая M0611 Предельно высокие обороты двигателя M0613 Нет сигнала оборотов двигателя M0615 Обороты двигателя при остановке M0618 Обороты двигателя вне допустимого диапазона M0634 Недействительная информация об оборотах двигателя от ЭБУ M0710 Высокая температура гидравлического масла M0711 Предельно высокая температура гидравлического масла M0715 Температура гидравлического масла при останове M0721 Температура гидравлического масла вне допустимого диапазона M0722 Температура гидравлического масла вне допустимого диапазона, низкая M0810 Высокая температура охлаждающей жидкости двигателя M0811 Предельно высокая температура охлаждающей жидкости двигателя M0815 Температура охлаждающей жидкости двигателя при остановке M0821 Температура охлаждающей жидкости двигателя вне допустимого диапазона M0822 Температура охлаждающей жидкости двигателя вне допустимого диапазона, низкая M0826 Температура охлаждающей жидкости двигателя перед остановкой M0909 Низкий уровень топлива M4110 Высокое напряжение генератора M0921 Уровень топлива выше допустимого диапазона M0922 Уровень топлива ниже допустимого диапазона M1016 Гидравлический заправочный фильтр не подключен M1017 Засорен гидравлический заправочный фильтр M1121 Датчик дуги безопасности выше допустимого диапазона M1122 Датчик дуги безопасности ниже допустимого диапазона M1128 Отказ датчика подседельного штыря M1305 Замыкание катушки отключения подачи топлива на аккумулятор M1306 Замыкание катушки отключения подачи топлива на массу M1307 Разрыв цепи соленоида удержания топлива M1402 Соленоид втягивания топлива — ошибочное включение M1403 Соленоид втягивания топлива — ошибочное включение M1407 Разрыв цепи соленоида втягивания топлива M1428 Сбой соленоида втягивания топлива M1502 Втягивающий соленоид блокировки тяги — ошибочное включение M1503 Втягивающий соленоид блокировки тяги — ошибочное выключение M1507 Разрыв цепи выхода соленоида втягивания блокировки тяги M1528 Сбой втягивающего соленоида блокировки тяги M1605 Удерживающий соленоид блокировки тяги замкнут на батарею M1606 Удерживающий соленоид блокировки тяги замкнут на заземление M1607 Разрыв цепи удерживающего соленоида блокировки тяги M1705 Гидравлический запорный клапан замкнут на батарею M1706 Гидравлический запорный клапан замкнут на землю M1707 Разрыв цепи гидравлического запорного клапана M1732 Перегрузка по току гидравлического запорного клапана M1805 Выход соленоида золотника замкнут на батарею M1806 Выход соленоида золотника замкнут на землю M1807 Разрыв цепи выхода соленоида золотника M1832 Перегрузка по току выхода соленоида золотника M2005 Двухскоростной первичный соленоид замкнут на батарею M2006 Двухскоростной первичный соленоид замкнут на землю M2007 Разрыв цепи двухскоростного первичного соленоида M2032 Перегрузка по току в двухскоростном первичном соленоиде M2102 Выход свечей накаливания — ошибочное включение M2103 Выход свечей накаливания — ошибочное выключение M2107 Выход свечей накаливания, разрыв цепи M2128 Сбой на выходе свечей накаливания M2202 Ошибочное включение выхода стартера M2203 Ошибочное выключение выхода стартера M2207 Обрыв цепи выхода стартера M2228 Сбой на выходе стартера M2302 Реле стартера — ошибочное включение M2303 Реле стартера — ошибочное выключение M2307 Обрыв цепи реле стартера M2402 Реле втягивания топлива — ошибочное включение M2403 Реле втягивания топлива — ошибочное выключение M2407 Обрыв цепи выхода подачи топлива M2502 Реле блокировки тягового усилия — ошибочное включение M2503 Тяговое реле блокировки тяги — ошибочное выключение M2507 Обрыв цепи выхода блокировки тягового усилия M2602 Реле свечей накаливания — ошибочное включение M2603 Реле свечей накаливания — ошибочное выключение M2607 Обрыв цепи выхода свечи предпускового подогрева M2721 Сигнал первичного датчика дросселя за верхней границей диапазона M2722 Сигнал первичного датчика дросселя за нижней границей диапазона M2805 Замыкание выхода вспомогательной блокировки на аккумулятор M2806 Замыкание выхода вспомогательной блокировки на массу M2807 Обрыв цепи выхода вспомогательной блокировки M2821 Сигнал вторичного датчика дросселя за верхней границей диапазона M2822 Сигнал вторичного датчика дросселя за нижней границей диапазона M3028 Отказ памяти контроллера M3128 Неисправность режима восстановления M3204 ACS (AHC), нет сообщений контроллеру Bobcat M3304 Нет связи с панелью Deluxe M3323 Контроллер шлюза не запрограммирован M3404 Панель Deluxe в состоянии ошибки M3505 Вентилятор гидравлики замкнут на батарею M3506 Вентилятор гидравлики замкнут на землю M3507 Разрыв цепи вентилятора гидравлики M3532 Перегрузка по току вентилятора гидравлики M3648 Наличие нескольких Acds (устройство управления навесным оборудованием) M3705 Выход двухскоростной вторичной обмотки замкнут на батарею M3706 Выход двухскоростной вторичной обмотки замкнут на землю M3707 Разрыв цепи выхода двухскоростной вторичной обмотки M3732 Перегрузка по току выхода двухскоростной вторичной обмотки M3805 Блокировка доп. гидравлики замкнута на батарею M3806 Блокировка доп.гидравлики замкнута на землю M3807 Разрыв цепи блокировки доп.гидравлики M3832 Перегрузка по току блокировки доп.гидравлики M4028 Обнаружен неправильный ЭБУ M4109 Предельно низкая мощность генератора M4110 Высокая скорость генератора M4111 Предельно высокая мощность генератора M4304 Нет связи с кнопочной панелью M4404 Нет сигнала от доп. гидравлики M4510 Вода в датчике топлива слишком высока M4511 Вода в датчике топлива предельно высока M4521 Вода в датчике топлива за верхней границей диапазона M4522 Вода в датчике топлива за нижней границей диапазона M4621 Питание 5-вольтового датчика за верхней границей диапазона M4622 Питание 5-вольтового датчика, за нижней границей диапазона M4721 Питание 8-вольтового датчика за верхней границей диапазона M4722 Питание 8-вольтового датчика, за нижней границей диапазона M4802 Реле переднего света, ошибочное включение M4803 Реле переднего света, ошибочное выключение M4807 Обрыв цепи выхода переднего фонаря M4902 Реле заднего света, ошибочное включение M4903 Реле заднего света, ошибочное выключение M4907 Обрыв цепи выхода заднего фонаря M5002 Выход переднего фонаря, ошибочное включение M5003 Выход переднего фонаря, ошибочное выключение M5007 Разрыв цепи выхода передних фар M5028 Неисправность выхода передних фар M5102 Выход фонарей заднего света, ошибочное включение M5103 Выход фонарей заднего света, ошибочное выключение M5107 Разрыв цепи выхода задних фар M5128 Неисправность выхода задних фар M5202 Кнопка включения погрузчика, ошибочное включение M5221 Кнопка включения погрузчика за верхней границей диапазона M5222 Кнопка включения погрузчика за нижней границей диапазона M5305 Подсветка кнопки включения погрузчика замкнута на батарею M5306 Подсветка кнопки включения погрузчика замкнута на землю M5405 Соленоид золотника наклона замкнут на батарею M5406 Соленоид золотника наклона замкнут на землю M5407 Разрыв цепи соленоида золотника наклона M5432 Перегрузка по току соленоида золотника наклона M5810 Слишком высокая температура топлива M5811 Предельно высокая температура топлива M5815 Температура топлива при останове M5826 Предварительное отключение по температуре топлива M5902 Выключатель регенерации DPF, ошибочное включение M6002 Выключатель регенерации при замедлении DPF, ошибочное включение M6102 Выключатель регенерации при удаленной парковке, ошибочное включение M6402 Ошибочное включение реле мощности M6403 Ошибочное выключение реле мощности M6407 Обрыв цепи коммутируемой выходной мощности M6505 Питание ECU замкнуто на батарею M6506 Питание ECU замкнуто на землю M6507 Разрыв цепи питания ECU M6604 Отсутствие связи с ECU M6702 Ошибочное включение выхода системы HVAC M6703 Ошибочное выключение выхода системы HVAC M6707 Разрыв цепи выхода системы HVAC M6728 Сбой на выходе системы HVAC M6802 Ошибочное включение реле системы HVAC M6803 Ошибочное выключение реле системы HVAC M7002 Выход импульсного источника питания, ошибочное включение M7003 Выход импульсного источника питания, ошибочное выключение M7007 Выход импульсного источника питания, разрыв цепи M7028 Ошибка на выходе импульсного источника питания M7304 Дистанционное управление — отсутствует сигнал M7316 Дистанционное управление, нет сообщений датчику M7423 Главный контроллер не запрограммирован M7472 Главный контроллер нуждается в программировании M7497 Главный контроллер запрограммирован M7504 Нет сигнала от привода M7604 Нет связи с левой панелью дисплея M7748 Замок зажигания, многорежимный M7839 Значение счетчика моточасов изменено M7974 Дверь открыта M8541 Автоматическая регенерация DPF активна M8542 Автоматическая регенерация DPF активна (включать погрузчик под нагрузкой) M8543 Главный контроллер не запрограммирован M8551 Необходима регенерация DPF – замедление активно M8552 Необходима регенерация DPF – замедление активно (включать погрузчик под нагрузкой) M8553 Требуется регенерация DPF при удаленной парковке (требуется комплект удаленной регенерации) M8554 Требуется регенерация DPF при обслуживании (обратиться к дилеру Bobcat) M8555 Требуется услуга DPF M8560 Регенерация службы DPF активна M8561 Регенерация службы DPF активна M8562 Регенерация службы DPF активна M8563 Регенерация службы DPF активна M8564 Регенерация службы DPF активна M8615 Снижение скорости двигателя при выключении M8625 Обороты двигателя снижается, не отвечает P0117 Датчик температуры охлаждающей жидкости двигателя ниже допустимого диапазона P0118 Датчик температуры охлаждающей жидкости двигателя выше допустимого диапазона P0119 Прерывистый сигнал датчика температуры охлаждающей жидкости двигателя P0122 Датчик акселератора ниже допустимого диапазона P0123 Датчик акселератора выше допустимого диапазона P0124 Прерывистое подключение датчика акселератора P0217 Высокая температура охлаждающей жидкости двигателя P0340 Нет сигнала датчика частоты вращения двигателя P0562 Низкое напряжение батареи P0563 Напряжение аккумулятора высокое P0605 E-ecu Internal Flashrom Checksum Error A (основное программное обеспечение) P0634 Высокий уровень сигнала датчика температуры электронного блока управления P0642 Питание датчика 5 В ниже допустимого диапазона P0643 Напряжение питания датчика 5 В выше допустимого диапазона P0668 Датчик температуры E-ecu ниже допустимого диапазона P0669 Датчик температуры электронного блока управления выше допустимого диапазона P1202 Датчик положения стойки ниже допустимого диапазона P1203 Датчик положения стойки выше допустимого диапазона P1211 Застрял соленоид привода стойки P1212 Минимальный ток соленоида привода стойки P1213 Перегрузка по току соленоида привода стойки P1222 Реле привода стойки — ошибочное включение P1223 Реле привода стойки — ошибочное выключение P1224 Прерывистое соединение реле привода стойки P1232 Реле предварительного нагрева — ошибочное включение P1233 Реле предварительного нагрева — ошибочное выключение P1234 Прерывистое соединение реле подогрева P1242 Электромагнитный клапан CSD — ошибочное включение P1243 Электромагнитный клапан CSD — ошибочное выключение P1244 Прерывистое соединение электромагнитного клапана Csd P1402 EGR-клапан Фаза A — ошибочное включение P1403 EGR-клапан Фаза A — ошибочное выключение P1412 EGR-клапан Фаза B — ошибочное включение P1413 EGR-клапан Фаза B — ошибочное выключение P1422 EGR-клапан Фаза C — ошибочное включение P1423 EGR-клапан Фаза C — ошибочное выключение P1432 EGR-клапан Фаза D — ошибочное включение P1433 EGR-клапан Фаза D — ошибочное выключение P1605 E-ecu Internal Flashrom Checksum Error B (основное программное обеспечение) P1606 Ошибка контрольной суммы внутренней флеш-памяти E-ecu C (основное программное обеспечение) P1644 Прерывистое соединение питания датчика 5 В P1664 Прерывистое подключение датчика температуры E-ecu R7404 Нет связи с главным контроллером T9002 Cервисный инструмент выход ‘c’ — ошибочное включение T9003 Cервисный инструмент выход ‘c’ — ошибочное выключение T9102 Cервисный инструмент выход ‘d’ — ошибочное включение T9103 Cервисный инструмент выход ‘d’ — ошибочное выключение T9202 Cервисный инструмент выход ‘e’ — ошибочное включение T9203 Cервисный инструмент выход ‘e’ — ошибочное выключение T9302 Cервисный инструмент выход ‘f’ — ошибочное включение T9303 Cервисный инструмент выход ‘f’ — ошибочное выключение W3204 ACS (AHS) (нет связи) с контроллером Bobcat W3223 Контроллер ACS не откалиброван W3224 Калибровка контроллера ACS выполнена успешно W3225 Ошибка калибровки контроллера ACS W3231 ACS Tilt Actuator Fault (Неисправность привода наклона ACS) W3232 Электропроводка привода наклона ACS (AHS) W3233 Электропроводка ручки наклона ACS (AHS) W3234 Привод наклона ACS не в нейтральном положении W3235 Ручка / педаль наклона ACS не в нейтральном положении W3236 ACS Lift Actuator Fault (Неисправность привода лифта ACS) W3237 Электропроводка привода лифта ACS (AHS) W3238 Электропроводка ручки подъемника ACS (AHS) W3239 Привод лифта ACS не в нейтральном положении (только ACS) W3240 Рукоятка подъема ACS (AHC)/педаль не в
нейтральном положении W3241 Отсутствие связи с ACS (AHC) W3249 Исполнительный механизм подъема ACS (AHC)
замкнут на землю W3250 Исполнительный механизм наклона ACS (AHC)
замкнут на землю W3251 Исполнительный механизм подъема ACS (AHC)
замкнут на батарею W3252 Исполнительный механизм наклона ACS (AHC)
замкнут на батарею W3253 Рукоятка подъема ACS (AHC) / педаль замкнута на
землю W3254 Рукоятка наклона ACS (AHC) / педаль замкнута на
землю W3255 Рукоятка наклона ACS (AHC) / педаль замкнута на
батарею W3256 Рукоятка наклона ACS (AHC) / педаль замкнута на
батарею W3257 Пониженная производительность исполнительного
механизма подъема ACS (AHC) W3258 Пониженная производительность исполнительного
механизма наклона ACS (AHC) W3259 Неправильное направление исполнительного
механизма подъема ACS (AHC) W3260 Неправильное направление исполнительного
механизма наклона ACS (AHC) W3261 Блокиратор рукоятки ACS (AHC) замкнут на землю W3262 Блокиратор рукоятки ACS (AHC) замкнут на
батарею W3263 Блокиратор педали ACS (AHC) замкнут на землю W3264 Блокиратор педали ACS (AHC) замкнут на батарею W3265 Напряжение питания датчика ACS (AHC) вне
допустимых пределов W3266 Напряжение батареи ACS (AHC) вне допустимых
пределов W3267 Переключатель ACS (AHC) переключился во время
работы W3268 Информационная ошибка рукоятки подъема ACS
(AHC) W3269 Переключатель режима управления ACS (AHS) переключается во время работы W3270 Рукоятка правого привода ACS (AHC) замкнута на
землю W3271 Рукоятка правого привода ACS (AHC) замкнута на
батарею W3274 Ось X левого джойстика ACS (AHC) вне
допустимых пределов W3275 Прерванное некоммутируемое питание ACS (AHC) W3276 Информационная ошибка джойстика CAN, ACS
(AHC) W3277 Информационная ошибка дистанционного
управления, ACS (AHC) W3297 Контроллер ACS (AHC) запрограммирован W3905 Ось Х левого джойстика не в нейтральном
положении W4005 Ось X правого джойстика не в нейтральном
положении W4007 Ось Y правого джойстика не в нейтральном
положении

Время создания страницы: 0.09 секунд

Техника Bobcat подходит для ежедневной и интенсивной эксплуатации. Но все же без выхода из строя и различных дефектов не обойтись. Преимущественно они связаны с поломками узлов и агрегатов техники из-за чрезмерных нагрузок или использования в течение длительного времени. Разобраться со сбоями в работе спецтехники Bobcat можно с помощью кодов ошибок, которые отображаются на панели управления.

Ниже представлен список с кодами ошибок и описанием к ним. Для того, чтобы узнать информацию по интересующей ошибке воспользуйтесь функцией быстрого поиска (комбинация клавиш CTRL+F, далее Enter) и введите код ошибки для ознакомления.

Описание ошибок соответствует моделям техники Bobcat, среди которых и популярные модели S530, S770, S650, S175 и другие.

Если вы находитесь в Красноярске, то можете обратиться в сервисный центр для устранения неполадок у техники Bobcat. 

Код ошибки
Описание

01-16
Воздушный фильтр не подключен

01-17
Засорен воздушный фильтр

02-16
Фильтр гидравлического агрегата не подключен

02-17
Засорен фильтр гидравлического агрегата

03-09
Низкое напряжение батареи

03-10
Напряжение аккумулятора высокое

03-11
Напряжение аккумулятора очень высокое

03-14
Напряжение аккумулятора очень низкое

03-15
Напряжение батареи при выключении

03-22
Напряжение аккумулятора ниже допустимого диапазона

04-09
Давление моторного масла низкое

04-14
Предельно низкое давление моторного масла

04-15
Давление моторного масла при остановке

04-21
Давление моторного масла вне допустимого диапазона

04-22
Давление моторного масла ниже допустимого диапазона

05-09
Низкое давление наддува гидросистемы

05-10
Гидравлическое давление наддува высокое

05-11
Предельно высокое гидравлическое давление наддува

05-14
Предельно низкое гидравлическое давление наддува

05-15
Гидравлическое давление наддува при останове

05-21
Гидравлическое давление наддува выше допустимого диапазона

05-22
Гидравлическое давление наддува ниже допустимого диапазона

06-10
Обороты двигателя высокая

06-11
Предельно высокие обороты двигателя

06-13
Нет сигнала оборотов двигателя

06-15
Обороты двигателя при остановке

06-18
Обороты двигателя вне допустимого диапазона

07-10
Высокая температура гидравлического масла

07-11
Предельно высокая температура гидравлического масла

07-15
Температура гидравлического масла при останове

07-21
Температура гидравлического масла вне допустимого диапазона

07-22
Температура гидравлического масла вне допустимого диапазона, низкая

08-10
Высокая температура охлаждающей жидкости двигателя

08-11
Предельно высокая температура охлаждающей жидкости двигателя

08-15
Температура охлаждающей жидкости двигателя при остановке

08-21
Температура охлаждающей жидкости двигателя вне допустимого диапазона

08-22
Температура охлаждающей жидкости двигателя вне допустимого диапазона, низкая

09-09
Низкий уровень топлива

09-21
Уровень топлива выше допустимого диапазона

09-22
Уровень топлива ниже допустимого диапазона

10-16
Гидравлический заправочный фильтр не подключен

10-17
Засорен гидравлический заправочный фильтр

11-05
Замыкание датчика планки сиденья на напряжение аккумулятора

11-06
Замыкание датчика поперечной планки на массу

12-21
Передний вспомогательный подрулевой переключатель выше допустимого диапазона

12-22
Передний вспомогательный подрулевой переключатель ниже допустимого диапазона

12-23
Передний вспомогательный ШИМ-переключатель не в нейтральном положении

13-05
Замыкание катушки отключения подачи топлива на аккумулятор

13-06
Замыкание соленоида блокировки отключения подачи топлива на массу

13-07
Обрыв цепи соленоида блокировки отключения подачи топлива

14-02
Втягивающий соленоид отсечки топлива — ошибочное включение

14-03
Втягивающий соленоид отсечки топлива — ошибочное выключение

15-02
Катушка тяги блокировки — ошибочное включение

15-03
Втягивающий соленоид блокировки тяги — ошибочное выключение

16-05
Замыкание катушки фиксации тяги на аккумулятор

16-06
Замыкание катушки фиксации противобуксовочной системы на массу

16-07
Обрыв цепи соленоида блокировки блокировки тяги

17-05
Замыкание соленоида гидравлической блокировки на напряжение аккумулятора

17-06
Замыкание соленоида гидравлической блокировки на массу

17-07
Обрыв цепи электромагнитного клапана гидравлической блокировки

18-05
Катушка блокировки катушки: короткое замыкание на батарею

18-06
Катушка блокировки катушки: короткое замыкание на массу

18-07
Обрыв цепи катушки блокировки катушки

19-02
Соленоид положения ковша — ошибочное включение

19-03
Соленоид положения ковша — ошибочное выключение

20-02
Двухскоростной соленоид — ошибочное включение

20-03
Двухскоростной соленоид — ошибочное выключение

21-02
Свечи накаливания — ошибочное включение

21-03
Свечи накаливания — ошибочное выключение

22-02
Стартер — ошибочное включение

22-03
Стартер — ошибочное выключение

23-02
Задний базовый соленоид — ошибочное включение

23-03
Задний базовый соленоид — ошибочное выключение

24-02
Соленоид задней тяги — ошибочное включение

24-03
Соленоид задней тяги — ошибочное выключение

25-02
Задний вспомогательный предохранительный соленоид — ошибочное включение

25-03
Задний вспомогательный предохранительный соленоид — ошибочное выключение

26-02
Соленоид передней базы — ошибочное включение

26-03
Соленоид передней базы — ошибочное выключение

26-05
ШИМ передней базы, короткое замыкание на батарею

26-06
ШИМ передней базы: замыкание на массу

26-07
Обрыв цепи ШИМ передней базы

27-02
Соленоид передней тяги — ошибочное включение

27-03
Соленоид передней тяги — ошибочное выключение

27-05
ШИМ передней тяги: короткое замыкание на батарею

27-06
ШИМ передней тяги: короткое замыкание на массу

27-07
Обрыв цепи ШИМ передней тяги

28-02
Соленоид дивертора — ошибочное включение

28-03
Соленоид дивертора — ошибочное выключение

29-02
Соленоид высокого расхода — ошибочное включение

29-03
Соленоид высокого расхода — ошибочное выключение

30-28
Ошибка памяти контроллера

31-28
Прерванная мощность

32-04
Нет связи с контроллером ACS

32-23
Контроллер ACS не откалиброван

32-24
Калибровка контроллера ACS выполнена

32-25
Ошибка калибровки контроллера ACS

32-31
ACS / AHS Tilt Actuator Fault (Неисправность привода наклона ACS / AHS)

32-32
Неисправность проводки привода наклона AHS

32-33
Неисправность проводки ручки наклона AHS

32-34
Привод наклона ACS / AHS не в нейтральном положении

32-35
Ручка / педаль наклона ACS / AHS не в нейтральном положении, правый джойстик SJC Ось X не в нейтральном положении

32-36
ACS / AHS Lift Actuator Fault (Неисправность привода лифта)

32-37
Неисправность проводки привода лифта AHS

32-38
Неисправность проводки ручки подъемника AHS

32-39
Привод лифта AC / AHS не в нейтральном положении

32-40
Подъемная ручка / педаль ACS / AHS не в нейтральном положении, правый джойстик SJC, ось Y не в нейтральном положении

32-41
Контроллер AHS (нет связи)

32-49
Замыкание привода подъема ACS на массу — ошибочное выключение

32-50
Замыкание исполнительного механизма наклона ACS на массу — ошибочное выключение

32-51
Замыкание привода подъема ACS на аккумуляторную батарею — ошибочное включение

32-52
Замыкание привода наклона ACS на аккумуляторную батарею — ошибочное включение

32-53
Ручка подъема / педаль ACS короткое замыкание на массу, ось Y правого джойстика SJC замыкание на массу

32-54
Короткое замыкание ручки / педали наклона ACS на массу, короткое замыкание оси X правого джойстика SJC на массу

32-55
Короткое замыкание ручки / педали подъема ACS на аккумулятор, короткое замыкание на оси Y правого джойстика SJC на аккумуляторную батарею

32-56
Педаль наклона ACS, короткое замыкание на батарею, правый джойстик SJC, короткое замыкание на батарею, ось X

32-57
Снижение производительности привода подъема ACS

32-58
Привод наклона ACS пониженная производительность

32-59
Неправильное направление привода подъема ACS

32-60
Неправильное направление привода наклона ACS

32-61
Замыкание ручки управления ACS на массу

32-62
Замок ручки ACS от замыкания на аккумуляторную батарею

32-63
Замыкание педали акселератора на массу

32-64
Замыкание педали акселератора от замыкания на батарею

32-65
Напряжение питания датчика ACS вне допустимого диапазона

32-66
Напряжение аккумуляторной батареи переменного тока вне допустимого диапазона

32-67
Переключатель режима работы ACS перевернут во время работы

32-68
Ошибка информации о рукоятке подъемника ACS

32-70
Ось Y правого джойстика вне диапазона, низкий уровень

32-71
Ось Y правого джойстика вне допустимого диапазона

32-75
Прерванная некоммутируемая мощность

32-76
Ошибка информации о джойстике

32-97
Контроллер ACS запрограммирован

33-23
Контроллер Bobcat не запрограммирован

34-04
Ошибка панели Deluxe

35-02
Ошибка гидравлического вентилятора — ошибочное включение

35-03
Гидравлический вентилятор — ошибочное выключение

35-05
Короткое замыкание вентилятора гидравлической системы на аккумуляторную батарею

35-06
Короткое замыкание вентилятора гидравлической системы на массу

36-48
Наличие нескольких Acds (несколько контроллеров)

37-02
Двухскоростной соленоид подпитки — ошибочное включение

37-03
Двухскоростная подпитка — ошибочное выключение

37-07
Обрыв цепи двухскоростного вторичного соленоида

38-01
Ошибка информации джойстика

38-02
Ошибка информации пульта дистанционного управления

38-03
Ошибка калибровки привода

38-04
Контроллер AWS / SJC (нет связи)

38-05
Левый аналоговый джойстик Ось X не в нейтральном положении

38-06
Правый аналоговый джойстик Ось X не в нейтральном положении

38-07
Левый аналоговый джойстик Ось Y не в нейтральном положении

38-08
Ось Y правого джойстика не в нейтральном положении

38-09
Замыкание переключателя рабочего режима на массу или аккумулятор

38-10
Калибровка привода выполнена

38-11
Привод подъемника AWS / SJC не в нейтральном положении

38-12
Привод наклона AWS / SJC не в нейтральном положении

38-13
Aws / SJC Lift Actuator Fault (Неисправность привода лифта)

38-14
Aws / SJC Tilt Actuator Fault (Неисправность привода наклона Aws / SJC)

38-15
Aws / SJC Ошибка скорости вращения правого колеса

38-16
Aws / SJC Ошибка скорости левого колеса

38-17
Привод наклона AWS / SJC пониженная производительность

38-18
Снижение производительности привода подъема Aws / SJC

38-19
Ось X левого джойстика вне допустимого диапазона

38-20
Ось X правого джойстика вне допустимого диапазона

38-21
Ось Y левого джойстика вне допустимого диапазона

38-22
Ось Y правого джойстика вне допустимого диапазона

38-23
Правый передний датчик рулевого управления выше допустимого диапазона

38-24
Левый передний датчик рулевого управления выше допустимого диапазона

38-25
Правый задний датчик рулевого управления выше допустимого диапазона

38-26
Левый задний датчик рулевого управления выше допустимого диапазона сигнала

38-27
Привод подъема AWS / SJC вне допустимого диапазона

38-28
Привод наклона AWS / SJC вне допустимого диапазона

38-29
Ось X левого джойстика ниже допустимого диапазона

38-30
Ось X правого джойстика ниже допустимого диапазона

38-31
Левый джойстик по оси Y вне диапазона, низкий уровень

38-32
Ось Y правого джойстика вне диапазона, низкий уровень

38-33
Правый передний датчик рулевого управления ниже допустимого диапазона

38-34
Левый передний датчик рулевого управления ниже допустимого диапазона

38-35
Правый задний датчик рулевого управления ниже допустимого диапазона

38-36
Левый задний датчик рулевого управления ниже допустимого диапазона

38-37
Питание датчика 5 Вольт 1 ниже допустимого диапазона

38-38
Питание датчика 5 Вольт 2 ниже допустимого диапазона

38-39
Замыкание привода подъема AWS / SJC на массу

38-40
Короткое замыкание исполнительного механизма наклона AWS / SJC на массу

38-41
Неправильное направление привода наклона

38-42
Неправильное направление привода подъема

38-43
Соленоид левого переднего привода — ошибочное включение

38-44
Соленоид левого реверсивного привода — ошибочное включение

38-45
Соленоид правого переднего привода — ошибочное включение

38-46
Соленоид правого реверсивного привода — ошибочное включение

38-47
Соленоид правого переднего рулевого управления — ошибочное включение

38-48
Соленоид левого переднего рулевого управления — ошибочное включение

38-49
Соленоид правого заднего рулевого управления — ошибочное включение

38-50
Соленоид левого заднего рулевого управления — ошибочное включение

38-51
Соленоид рулевого управления с регулировкой давления — ошибочное включение

38-52
Резервное копирование — ошибочное включение

38-53
Соленоид левого переднего привода — ошибочное выключение

38-54
Соленоид левого реверсивного привода — ошибочное выключение

38-55
Соленоид правого переднего привода — ошибочное выключение

38-56
Соленоид правого реверсивного привода — ошибочное выключение

38-57
Соленоид выдвижения правого переднего колеса — ошибочное выключение

38-58
Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное выключение

38-59
Соленоид рулевого механизма выдвижения левого переднего колеса — ошибочное выключение

38-60
Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное выключение

38-61
Соленоид выдвижения правого заднего рулевого механизма — ошибочное выключение

38-62
Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное выключение

38-63
Соленоид выдвижения левого заднего рулевого механизма — ошибочное выключение

38-64
Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное выключение

38-65
Соленоид рулевого управления с регулировкой давления — ошибочное выключение

38-66
Замыкание резервного аварийного сигнала на массу

38-67
Нет связи с контроллером Bobcat

38-68
Датчики угла поворота колес не откалиброваны

38-69
Контроллер AWS / SJC не откалиброван

38-70
Прерванная мощность

38-71
Напряжение аккумулятора вне допустимого диапазона

38-72
Насос привода не откалиброван

38-73
Переключатель режима работы нажат во время работы

38-74
Неуправляемое движение со скоростью правого колеса

38-75
Неуправляемое движение со скоростью левого колеса

38-85
Подача питания датчика 1 на 5,0 В выше допустимого диапазона

38-86
Питание датчика 2 выше допустимого диапазона

38-87
Ошибка соленоида правого переднего рулевого механизма

38-88
Ошибка соленоида левого переднего рулевого механизма

38-89
Ошибка соленоида правого заднего рулевого механизма

38-90
Ошибка соленоида левого заднего рулевого управления

38-93
Датчик правой скорости не отвечает

38-94
Левый датчик скорости не отвечает

38-95
Левый датчик скорости заднего хода

38-96
Направление заднего хода правого датчика скорости

38-97
Контроллер AWS / SJC запрограммирован

38-98
Контроллер в режиме калибровки привода

38-99
Контроллер AWS в режиме калибровки положения колес

39-04
Неисправность переключателей левого джойстика

39-05
Левый джойстик Ось X не в нейтральном положении

39-07
Левый джойстик Ось Y не в нейтральном положении

39-12
Подрулевой переключатель левого джойстика не в нейтральном положении

39-13
Левый джойстик захвата (нет связи)

39-16
Левый джойстик базы (нет связи)

39-28
Внутренняя неисправность левого джойстика

39-48
Левый джойстик несколько

40-04
Неисправность переключателей правого джойстика

40-05
Правый джойстик Ось X не в нейтральном положении

40-07
Правый джойстик ось Y не в нейтральном положении

40-12
Правый рычаг джойстика — подрулевой переключатель не в нейтральном положении

40-13
Правая ручка джойстика (нет связи)

40-16
Правая консоль джойстика (нет связи)

40-28
Внутренняя неисправность правого джойстика

40-48
Правый джойстик несколько

41-09
Низкая мощность генератора

41-10
Высокое напряжение генератора

41-11
Напряжение генератора Предельно высокое

44-02
Реле звукового сигнала — ошибочное включение

44-03
Реле звукового сигнала — ошибочное выключение

45-02
Реле правого указателя поворота — ошибочное включение

45-03
Реле правого указателя поворота — ошибочное выключение

46-02
Реле левого поворотника — ошибочное включение

46-03
Реле левого указателя поворота — ошибочное выключение

47-21
Напряжение питания датчика 8 В выше допустимого диапазона

47-22
Питание датчика 8 В ниже допустимого диапазона

48-02
Реле переднего света — ошибочное включение

48-03
Реле переднего света — ошибочное выключение

49-02
Реле заднего фонаря — ошибочное включение

49-03
Реле заднего фонаря — ошибочное выключение

50-01
Педаль движения выше допустимого диапазона

50-02
Педаль движения ниже допустимого диапазона

50-03
Педаль хода не откалибрована

50-04
Педаль тормоза выше допустимого диапазона

50-05
Педаль тормоза ниже допустимого диапазона

50-06
Педаль тормоза не откалибрована

50-07
Рычаг управления направлением движения (нет сигнала)

50-08
Рычаг управления направлением движения Несколько входов

50-09
Датчик скорости переднего колеса выше допустимого диапазона

50-10
Датчик скорости переднего колеса ниже допустимого диапазона

50-11
Датчик скорости заднего колеса выше допустимого диапазона

50-12
Датчик скорости заднего колеса ниже допустимого диапазона

50-13
Нет сигнала датчика скорости переднего колеса

50-14
Нет сигнала датчика скорости заднего колеса

50-15
Неисправность двойного датчика скорости вращения колес

50-16
Контроль подачи не откалиброван

50-19
Датчик наклонной пластины выше допустимого диапазона

50-20
Датчик наклонной пластины ниже допустимого диапазона

50-21
Низкое давление в штанге вне допустимого диапазона

50-23
Контроллер привода не запрограммирован

50-24
Повышенное напряжение аккумулятора

50-25
Напряжение аккумулятора ниже напряжения

50-26
Прерванная мощность

50-27
Подача питания датчика 1 на 5,0 В выше допустимого диапазона

50-28
Питание датчика 5,0 В 1 ниже допустимого диапазона

50-29
Подача питания датчика 2 на 5,0 В выше допустимого диапазона

50-30
Подача питания датчика 2 на 5,0 В ниже допустимого диапазона

50-31
Соленоид ШИМ переднего привода — ошибочное включение

50-32
Катушка привода переднего хода: короткое замыкание на батарею

50-33
Соленоид ШИМ переднего привода (нет сигнала)

50-34
Соленоид ШИМ переднего привода не откалиброван

50-35
Соленоид переднего привода переднего привода — ошибочное включение

50-36
Соленоид переднего привода переднего привода — ошибочное выключение

50-37
Соленоид заднего хода переднего привода — ошибочное включение

50-38
Соленоид заднего хода переднего привода — ошибочное выключение

50-39
Соленоид Pwm заднего привода — ошибочное включение

50-40
Катушка реверсивного привода: короткое замыкание на батарею

50-41
Электромагнитный ШИМ заднего привода (нет сигнала)

50-42
Соленоид ШИМ заднего привода не откалиброван

50-43
Соленоид переднего привода заднего привода — ошибочное включение

50-44
Соленоид переднего привода заднего привода — ошибочное выключение

50-45
Соленоид заднего хода — ошибочное включение

50-46
Соленоид заднего хода: — ошибочное выключение

50-47
Две скорости — ошибочное выключение

50-48
Две скорости — ошибочное включение

50-49
Соленоид тормоза — ошибочное включение

50-50
Соленоид тормоза — ошибочное выключение

50-51
Соленоид тормоза (нет сигнала)

50-52
Замыкание стоп-сигналов на аккумулятор

50-53
Замыкание стоп-сигналов на массу

50-54
Блокировка дифференциала — ошибочное включение

50-55
Блокировка дифференциала — ошибочное выключение

50-56
Возможен сбой связи

50-57
Контроллер привода не откалиброван

50-58
Возможно устаревание обеспечения RPM

50-59
Отсутствуют импульсы датчика скорости переднего колеса

50-60
Замыкание удаленной гидравлики на аккумулятор

50-61
Замыкание удаленной гидравлики на массу

50-63
Ошибка калибровки датчика переднего угла

50-64
Обратный ход насоса привода — ошибочное выключение

50-65
Замыкание вспомогательной базовой катушки на массу или разрыв цепи

50-66
Ошибка калибровки датчика заднего угла

50-67
Передний привод вперед (нет сигнала)

50-68
Передний привод заднего хода (нет сигнала)

50-69
Задний привод вперед (нет сигнала)

50-70
Задний ход заднего хода (нет сигнала)

50-72
Фанкойл: замыкание на массу

50-73
Штанга вспомогательной гидравлики — ошибочное выключение

50-74
Датчик дроссельной заслонки, канал A, ниже допустимого диапазона

50-75
Датчик дроссельной заслонки, канал B, выше допустимого диапазона

50-76
Датчик дроссельной заслонки, канал B, ниже допустимого диапазона

50-77
Вспомогательный переключатель — ошибочное включение

50-78
Вспомогательный переключатель — ошибочное выключение

50-79
Реле поплавка стрелы — ошибочное выключение

50-80
Датчик скорости ВОМ выше допустимого диапазона

50-81
Датчик скорости ВОМ ниже допустимого диапазона

50-82
Обрыв цепи датчика скорости ВОМ

50-99
В режиме калибровки

60-21
Задний вспомогательный элемент управления выше допустимого диапазона

60-22
Задний вспомогательный элемент управления ниже допустимого диапазона

60-23
Задний вспомогательный регулятор не в нейтральном положении

62-04
Ошибка мониторинга момента нагрузки

63-05
Замыкание переключателя консоли на аккумулятор

63-06
Замыкание переключателя консоли на массу

64-02
Переключатель реле питания — ошибочное включение

64-03
Переключатель реле питания — ошибочное выключение

64-05
Переключаемое реле питания, короткое замыкание на батарею

64-06
Короткое замыкание переключаемого силового реле на массу

64-07
Обрыв цепи переключаемого силового реле

65-05
Замыкание соленоида блокировки рабочей группы на напряжение аккумулятора

65-06
Замыкание соленоида блокировки рабочей группы на массу

65-07
Обрыв цепи соленоида блокировки рабочей группы

66-05
Замыкание давления пилота на аккумуляторную батарею

66-06
Давление управления ходом: короткое замыкание на массу

66-07
Обрыв цепи управляющего давления хода

67-05
Bobtach от короткого замыкания на батарею

67-06
Bobtach короткое замыкание на землю

69-05
Короткое замыкание реле присутствия оператора на аккумуляторную батарею

69-06
Короткое замыкание реле присутствия оператора на массу

69-07
Обрыв цепи реле присутствия оператора

70-28
Отказ тормозного давления

74-72
Главный контроллер Bobcat в загрузочном коде

75-01
Ошибка информации джойстика

75-04
Нет связи от контроллера привода

75-05
Ось X левого джойстика не в нейтральном левом положении (только в режиме ISO)

75-07
Ось Y левого джойстика не в нейтральном положении

75-08
Ось Y правого джойстика не в нейтральном положении (только h-образный)

75-09
Замыкание переключателя рабочего режима на массу или аккумулятор

75-13
Правое переднее колесо не отвечает

75-14
Левое переднее колесо не отвечает

75-15
Правое заднее колесо не отвечает

75-16
Левое заднее колесо не отвечает

75-17
Левая тарелка автомата перекоса не в нейтральном положении

75-18
Правая качающаяся пластина не в нейтральном положении

75-19
Ось X левого джойстика вне допустимого диапазона

75-21
Ось Y левого джойстика вне допустимого диапазона

75-23
Правый передний датчик рулевого управления выше допустимого диапазона

75-24
Левый передний датчик рулевого управления выше допустимого диапазона

75-25
Правый задний датчик рулевого управления выше допустимого диапазона

75-26
Левый задний датчик рулевого управления выше допустимого диапазона сигнала

75-27
Левая наклонная пластина не на своем месте

75-28
Правая наклонная пластина не на своем месте

75-29
Ось X левого джойстика ниже допустимого диапазона

75-31
Левый джойстик по оси Y вне диапазона, низкий уровень

75-33
Правый передний датчик рулевого управления ниже допустимого диапазона

75-34
Левый передний датчик рулевого управления ниже допустимого диапазона

75-35
Правый задний датчик рулевого управления ниже допустимого диапазона

75-36
Левый задний датчик рулевого управления ниже допустимого диапазона

75-37
Питание датчика 5,0 В 1 ниже допустимого диапазона

75-38
Питание датчика 5 Вольт 2 ниже допустимого диапазона

75-39
Левый датчик наклонной пластины выше допустимого диапазона

75-40
Левый датчик наклонной пластины ниже допустимого диапазона

75-41
Датчик правой наклонной пластины выше допустимого диапазона

75-42
Датчик правой наклонной пластины ниже допустимого диапазона

75-43
Соленоид левого переднего привода — ошибочное включение

75-44
Соленоид левого реверсивного привода — ошибочное включение

75-45
Соленоид правого переднего привода — ошибочное включение

75-46
Соленоид правого реверсивного привода — ошибочное включение

75-47
Соленоид выдвижения правого переднего колеса — ошибочное включение

75-48
Соленоид рулевого управления выдвижения левого переднего колеса — ошибочное включение

75-49
Соленоид выдвижения правого заднего рулевого механизма — ошибочное включение

75-50
Соленоид выдвижения левого заднего рулевого механизма — ошибочное включение

75-51
Соленоид рулевого управления с регулировкой давления — ошибочное включение

75-52
Резервное копирования — ошибочное включение

75-53
Соленоид левого переднего привода — ошибочное выключение

75-54
Соленоид левого реверсивного привода — ошибочное выключение

75-55
Соленоид правого переднего привода — ошибочное выключение

75-56
Соленоид правого реверсивного привода — ошибочное выключение

75-57
Соленоид выдвижения правого переднего колеса — ошибочное выключение

75-58
Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное выключение

75-59
Соленоид рулевого механизма выдвижения левого переднего колеса — ошибочное выключение

75-60
Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное выключение

75-61
Соленоид выдвижения правого заднего рулевого механизма — ошибочное выключение

75-62
Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное выключение

75-63
Соленоид выдвижения левого заднего рулевого механизма — ошибочное выключение

75-64
Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное выключение

75-65
Соленоид рулевого управления с регулировкой давления — ошибочное выключение

75-66
Аварийный сигнал резервного копирования — ошибочное выключение

75-67
Нет связи с контроллером Bobcat

75-68
Датчики угла не откалиброваны

75-69
Напряжение аккумулятора выше допустимого диапазона

75-70
Прерванная мощность

75-71
Напряжение аккумулятора ниже допустимого диапазона

75-72
Приводной насос — не откалиброван

75-73
Переключатель режима работы перевернут во время работы

75-74
Неуправляемое движение со скоростью правого колеса

75-75
Неуправляемое движение со скоростью левого колеса

75-76
Нет связи с контроллером ACS

75-77
Левый датчик скорости выше допустимого диапазона

75-78
Датчик правой скорости выше допустимого диапазона

75-79
Левый датчик скорости ниже допустимого диапазона

75-80
Датчик правой скорости ниже допустимого диапазона

75-81
Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное включение

75-82
Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное включение

75-83
Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное включение

75-84
Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное включение

75-85
Подача питания датчика 1 на 5,0 В выше допустимого диапазона

75-86
Питание датчика 2 выше допустимого диапазона

75-87
Требуется обновление программного обеспечения

75-88
Переключение питания — ошибочное включение

75-91
Левый датчик наклонной пластины — перевернутый

75-92
Правый датчик наклонной пластины — перевернутый

75-93
Не отвечает правый датчик скорости

75-94
Не отвечает левый датчик скорости

75-95
Левый датчик скорости заднего хода

75-96
Направление заднего хода правого датчика скорости

75-97
Запрограммирован контроллер Drive / Drive Plus

75-98
Контроллер в режиме калибровки

75-99
Контроллер Drive Plus в режиме калибровки положения колес

76-73
Ошибка Rx системы левой панели дисплея

77-48
Ключевой переключатель несколько

78-74
Дверь / Транспортный замок открыт / Активен

80-02
Acd / racd выход «a» — ошибочное включение

80-03
Acd / racd выход «a» — ошибочное выключение

81-02
Acd / racd выход «b» — ошибочное включение

81-03
Acd / racd выход «b» — ошибочное выключение

82-02
Acd / racd выход «c» — ошибочное включение

82-03
Acd / racd выход «c» — ошибочное выключение

83-02
Acd / racd выход «d» — ошибочное включение

83-03
Acd / racd выход «d» — ошибочное выключение

84-02
Acd / racd выход «e» — ошибочное включение

84-03
Acd / racd выход «e» — ошибочное выключение

85-02
Acd / racd выход «f» — ошибочное включение

85-03
Acd / racd выход «f» — ошибочное выключение

86-02
Acd / racd выход «g» — ошибочное включение

86-03
Acd / racd выход «g» — ошибочное выключение

87-02
Acd / racd выход «h» — ошибочное включение

87-03
Acd / racd выход «h» — ошибочное выключение

90-02
Сервисный выход «c» — ошибочное включение

90-03
Сервисный выход «c» — ошибочное выключение

91-02
Сервисный выход «d» — ошибочное включение

91-03
Сервисный выход «d» — ошибочное выключение

92-02
Сервисный выход «e» — ошибочное включение

92-03
Сервисный выход «e» — ошибочное выключение

93-02
Сервисный выход «f» — ошибочное включение

93-03
Сервисный выход «F» — ошибочное выключение

A0618
Скорость вращения колеса вне допустимого диапазона

A3623
ACD (устройство управления навесным оборудованием), не запрограммировано

A4621
Напряжение питания датчика 5 В выше допустимого диапазона

A4622
Питание датчика 5 В ниже допустимого диапазона

A4721
Напряжение питания датчика 8 В выше допустимого диапазона

A4722
Питание датчика 8 В ниже допустимого диапазона

A7701
Машинный ключ активен

A7901
E-stop активен

A8002
Acd / racd выход «a» — ошибочное включение

A8003
Acd / racd выход «a» — ошибочное выключение

A8005
Acd выход ‘a’ короткое замыкание на батарею

A8006
Короткое замыкание выхода ACD на землю

A8007
Acd выход ‘a’ (обрыв цепи)

A8032
Acd выход ‘a’ (перегрузка по току)

A8102
Acd / racd выход «b» — ошибочное включение

A8103
Acd / racd выход «b» — ошибочное выключение

A8105
Короткое замыкание на выходе ACD ‘b’ на аккумуляторную батарею

A8106
Короткое замыкание выхода Acd на землю

A8107
Acd выход ‘b’ (обрыв цепи)

A8132
Acd выход ‘b’ (перегрузка по току)

A8202
Acd / racd выход «c» — ошибочное включение

A8203
Acd / racd выход «c» — ошибочное выключение

A8205
Короткое замыкание на выходе ACD ‘c’ на аккумуляторную батарею

A8206
Короткое замыкание выхода Acd на землю

A8207
Разрыв цепи выхода ACD ‘c’

A8232
Acd выход ‘c’ (перегрузка по току)

A8302
Acd выход ‘d’ — ошибочное включение

A8303
Acd / racd выход «d» — ошибочное выключение

A8305
Короткое замыкание выхода Acd на батарею

A8306
Короткое замыкание выхода ACD на землю

A8307
Разрыв цепи выхода ACD ‘d’

A8332
Acd выход ‘d’ (перегрузка по току)

A8402
Acd / racd выход «e» — ошибочное включение

A8403
Acd / racd выход «e» — ошибочное выключение

A8405
Acd выход ‘e’ короткое замыкание на батарею

A8406
Короткое замыкание выхода Acd на землю

A8407
Acd выход ‘e’ (обрыв цепи)

A8432
Acd выход ‘e’ (перегрузка по току)

A8502
Acd / racd выход «f» — ошибочное включение

A8503
Acd / racd выход «f» — ошибочное выключение

A8505
Короткое замыкание на выходе Acd ‘f’ на аккумуляторную батарею

A8506
Короткое замыкание выхода Acd на землю

A8507
Acd выход ‘f’ (обрыв цепи)

A8532
Acd выход ‘f’ (перегрузка по току)

A8602
Acd выход ‘g’ — ошибочное включение

A8603
Acd / racd выход «g» — ошибочное выключение

A8605
Замыкание выхода ACD ‘g’ на аккумуляторную батарею

A8606
Короткое замыкание выхода Acd на землю

A8607
Разрыв цепи выхода ACD ‘g’

A8702
Acd / racd выход «h» — ошибочное включение

A8703
Acd / racd выход «h» — ошибочное выключение

A8705
Acd выход ‘h’ короткое замыкание на батарею

A8706
Acd выход ‘h’: короткое замыкание на массу

A8707
Acd выход ‘h’ (обрыв цепи)

A8802
Реверсивный соленоид — ошибочное включение

A8803
Реверсивный соленоид — ошибочное выключение

C0216
Гидравлический / гидростатический фильтр не подключен

C0217
Гидравлический / гидростатический фильтр засорен

C0309
Низкое напряжение батареи

C0310
Напряжение аккумулятора высокое

C0311
Напряжение аккумулятора очень высокое

C0314
Напряжение батареи крайне низкое

C0315
Напряжение батареи при выключении

C0322
Напряжение аккумулятора ниже допустимого диапазона

C0414
Предельно низкое давление моторного масла

C0415
Давление моторного масла при остановке

C0610
Обороты двигателя высокая

C0611
Предельно высокие обороты двигателя

C0613
Нет сигнала оборотов двигателя

C0615
Обороты двигателя при остановке

C0618
Обороты двигателя вне допустимого диапазона

C0710
Высокая температура гидравлического масла

C0711
Предельно высокая температура гидравлического масла

C0715
Температура гидравлического масла при останове

C0722
Температура гидравлического масла вне допустимого диапазона, низкая

C0810
Высокая температура охлаждающей жидкости двигателя

C0811
Предельно высокая температура охлаждающей жидкости двигателя

C0815
Температура охлаждающей жидкости двигателя при остановке

C0821
Температура охлаждающей жидкости двигателя вне допустимого диапазона

C0822
Температура охлаждающей жидкости двигателя вне допустимого диапазона, низкая

C0921
Уровень топлива выше допустимого диапазона

C0922
Уровень топлива ниже допустимого диапазона

C1221
Дополнительный ШИМ-переключатель выше допустимого диапазона

C1222
Дополнительный ШИМ-переключатель ниже допустимого диапазона

C1223
Дополнительный ШИМ-переключатель не в нейтральном положении

C1305
Замыкание соленоида блокировки отключения подачи топлива на аккумуляторную батарею

C1306
Замыкание соленоида блокировки отключения подачи топлива на массу

C1307
Обрыв цепи соленоида блокировки отключения подачи топлива Код Описание

C1402
Соленоид отсечки подачи топлива — ошибочное включение

C1403
Соленоид тяги отключения подачи топлива — ошибочное выключение

C2005
Две скорости — ошибочное включение

C2006
Две скорости — ошибочное выключение

C2102
Свечи накаливания — ошибочное включение

C2103
Свечи накаливания — ошибочное выключение

C2202
Стартер — ошибочное включение

C2203
Стартер — ошибочное выключение

C2305
Электромагнитный клапан смещения базы: замыкание на аккумуляторную батарею

C2306
Замыкание базового соленоида смещения на массу

C2307
Обрыв цепи соленоида смещения основания

C2405
Замыкание соленоида штока смещения на напряжение аккумулятора

C2406
Замыкание соленоида смещающей штанги на массу

C2407
Обрыв цепи соленоида смещающей штанги

C2505
Возврат смещения: короткое замыкание на батарею

C2506
Смещение возврата: короткое замыкание на массу

C2507
Разомкнутая цепь возврата смещения

C2605
Замыкание соленоида вспомогательной базы на напряжение аккумулятора

C2606
Замыкание соленоида вспомогательной базы на массу

C2607
Обрыв цепи вспомогательного базового соленоида

C2705
Замыкание соленоида вспомогательной тяги на напряжение аккумулятора

C2706
Замыкание соленоида вспомогательной тяги на массу

C2707
Обрыв цепи соленоида вспомогательной тяги

C2802
Гидравлический обмен — ошибочное включение

C2803
Гидравлический обмен — ошибочное выключение

C3028
Ошибка памяти контроллера

C3128
Прерывистый сбой питания

C3323
Главный контроллер не запрограммирован

C3397
Главный контроллер запрограммирован

C4021
Угол управления отвалом вне допустимого диапазона, высокий

C4022
Угол управления отвалом ниже допустимого диапазона

C4023
Угловой отвал не в нейтральном положении

C4105
Электромагнитный клапан основания углового лезвия: замыкание на аккумуляторную батарею

C4106
Электромагнитный клапан основания углового отвала: замыкание на массу

C4107
Обрыв цепи соленоида основания углового лезвия

C4205
Электромагнитный клапан стержня углового ножа: замыкание на аккумуляторную батарею

C4206
Электромагнитный клапан стержня углового отвала: замыкание на массу

C4207
Обрыв цепи соленоида стержня углового ножа

C4321
Давление считывания нагрузки вне допустимого диапазона

C4322
Давление измерения нагрузки ниже допустимого диапазона

C4516
Контроллер дроссельной заслонки (нет связи)

C6021
Контроль смещения вне допустимого диапазона

C6022
Контроль смещения ниже допустимого диапазона

C6023
Управление смещением не в нейтральном положении

C6204
Ошибка мониторинга момента нагрузки

C6305
Замыкание переключателя консоли на аккумулятор

C6306
Замыкание переключателя консоли на массу

C6405
Переключаемое реле питания, короткое замыкание на батарею

C6406
Короткое замыкание переключаемого силового реле на массу

C6407
Обрыв цепи переключаемого силового реле

C6505
Замыкание соленоида блокировки рабочей группы на напряжение аккумулятора

C6506
Замыкание соленоида блокировки рабочей группы на массу

C6507
Обрыв цепи соленоида блокировки рабочей группы

D3905
Левый джойстик Ось X не в нейтральном положении

D3907
Левый джойстик Ось Y не в нейтральном положении

D4007
Правый джойстик ось Y не в нейтральном положении

D7501
Ошибка информации джойстика

D7504
Привод (нет связи) с контроллером привода

D7505
Левый джойстик привода оси X не в нейтральном положении

D7507
Левый джойстик привода оси Y не в нейтральном положении

D7508
Управляйте правым джойстиком, ось Y не в нейтральном положении

D7509
Замыкание переключателя рабочего режима на массу или аккумулятор

D7510
Установлены неправильные джойстики привода

D7511
Левый датчик скорости привода не подключен

D7512
Датчик скорости правого привода не подключен

D7513
Правое переднее колесо не отвечает

D7514
Левое переднее колесо не отвечает

D7515
Правое заднее колесо не отвечает

D7516
Левое заднее колесо не отвечает

D7517
Левая тарелка автомата перекоса не в нейтральном положении

D7518
Правая качающаяся пластина не в нейтральном положении

D7519
Ось X левого джойстика движения вне допустимого диапазона

D7521
Перемещение по оси Y левого джойстика вне допустимого диапазона

D7522
Правый джойстик движения по оси Y вне допустимого диапазона

D7523
Правый передний датчик рулевого управления выше допустимого диапазона

D7524
Левый передний датчик рулевого управления выше допустимого диапазона

D7525
Правый задний датчик рулевого управления выше допустимого диапазона

D7526
Левый задний датчик рулевого управления выше допустимого диапазона сигнала

D7527
Левая наклонная пластина не на своем месте

D7528
Правая наклонная пластина не на своем месте

D7529
Левый джойстик движения по оси X ниже допустимого диапазона

D7531
Ведите левый джойстик по оси Y за пределы допустимого диапазона

D7532
Двигайтесь правым джойстиком по оси Y ниже допустимого диапазона

D7533
Правый передний датчик рулевого управления ниже допустимого диапазона

D7534
Левый передний датчик рулевого управления ниже допустимого диапазона

D7535
Правый задний датчик рулевого управления ниже допустимого диапазона

D7536
Левый задний датчик рулевого управления ниже допустимого диапазона

D7537
Питание датчика 5,0 В 1 ниже допустимого диапазона

D7538
Питание датчика 5 Вольт 2 ниже допустимого диапазона

D7539
Левый датчик наклонной пластины выше допустимого диапазона

D7540
Левый датчик наклонной пластины ниже допустимого диапазона

D7541
Датчик правой наклонной пластины выше допустимого диапазона

D7542
Датчик правой наклонной пластины ниже допустимого диапазона

D7543
Соленоид левого переднего привода — ошибочное включение

D7544
Соленоид левого реверсивного привода — ошибочное включение

D7545
Соленоид правого переднего привода — ошибочное включение

D7546
Соленоид правого реверсивного привода — ошибочное включение

D7547
Соленоид выдвижения правого переднего колеса — ошибочное включение

D7548
Соленоид рулевого управления выдвижения левого переднего колеса — ошибочное включение

D7549
Соленоид выдвижения правого заднего рулевого механизма — ошибочное включение

D7550
Соленоид выдвижения левого заднего рулевого механизма — ошибочное включение

D7551
Соленоид рулевого управления с регулировкой давления — ошибочное включение

D7552
Резервное копирование — ошибочное включение

D7553
Соленоид левого переднего привода — ошибочное выключение

D7554
Соленоид левого реверсивного привода — ошибочное выключение

D7555
Соленоид правого переднего привода — ошибочное выключение

D7556
Соленоид правого реверсивного привода — ошибочное выключение

D7557
Соленоид выдвижения правого переднего колеса — ошибочное выключение

D7558
Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное выключение

D7559
Соленоид рулевого механизма выдвижения левого переднего колеса — ошибочное выключение

D7560
Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное выключение

D7561
Соленоид выдвижения правого заднего рулевого механизма — ошибочное выключение

D7562
Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное выключение

D7563
Соленоид выдвижения левого заднего рулевого механизма — ошибочное выключение

D7564
Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное выключение

D7565
Соленоид рулевого управления с регулировкой давления — ошибочное выключение

D7566
Аварийный сигнал резервного копирования — ошибочное выключение

D7567
Нет связи от контроллера шлюза

D7568
Датчики угла не откалиброваны

D7569
Напряжение аккумулятора выше допустимого диапазона

D7570
Прерванная мощность

D7571
Напряжение аккумулятора ниже допустимого диапазона

D7572
Приводной насос — не откалиброван

D7573
Переключатель режима работы перевернут во время работы

D7574
Неуправляемое движение со скоростью правого колеса

D7575
Неуправляемое движение со скоростью левого колеса

D7576
Привод отсутствует связь с контроллером ACS

D7577
Левый датчик скорости выше допустимого диапазона

D7578
Датчик правой скорости выше допустимого диапазона

D7579
Левый датчик скорости ниже допустимого диапазона

D7580
Датчик правой скорости ниже допустимого диапазона

D7581
Соленоид рулевого механизма втягивания правого переднего колеса — ошибочное включение

D7582
Соленоид рулевого механизма втягивания левого переднего колеса — ошибочное включение

D7583
Соленоид рулевого механизма втягивания правого заднего колеса — ошибочное включение

D7584
Соленоид рулевого механизма втягивания заднего левого колеса — ошибочное включение

D7585
Подача питания датчика 1 на 5,0 В выше допустимого диапазона

D7586
Питание датчика 2 выше допустимого диапазона

D7587
Требуется обновление программного обеспечения

D7588
Переключенное питание застряло во включенном состоянии

D7589
Электропитание привода — ошибочное выключение

D7590
Калибровка привода выполнена

D7591
Левый датчик наклонной пластины — перевернутый

D7592
Правый датчик наклонной пластины — перевернутый

D7593
Не отвечает правый датчик скорости

D7594
Не отвечает левый датчик скорости

D7595
Левый датчик скорости заднего хода

D7596
Направление заднего хода правого датчика скорости

D7597
Запрограммирован контроллер Drive / Drive Plus

D7598
Контроллер Drive / Drive Plus в режиме калибровки

D7599
Контроллер Drive Plus в режиме калибровки положения колес

E00002700
Ошибка управления EGR

E00002701
Ошибка управления EGR

E00002703
EGR Ошибка положения привода

E00002704
EGR Ошибка положения привода

E00002709
EGR Ошибка положения привода

E00002710
EGR Ошибка положения привода

E00002720
Ошибка обучения позиции EGR

E00002730
Ошибка обучения позиции EGR

E00002903
Неисправность датчика положения дроссельной заслонки

E00002904
Неисправность датчика положения дроссельной заслонки

E00008100
Ошибка SCR

E00008107
Ошибка SCR

E00008111
Ошибка SCR

E00009102
Неисправность датчика положения дроссельной заслонки

E00009103
Неисправность датчика положения дроссельной заслонки

E00009104
Неисправность датчика положения дроссельной заслонки

E00009119
Неисправность датчика положения дроссельной заслонки

E00009411
Неисправность управления давлением в рампе

E00009416
Неисправность управления давлением в рампе

E00009418
Неисправность управления давлением в рампе

E00009703
Неисправность датчика воды в топливе

E00009704
Неисправность датчика воды в топливе

E00009709
Неисправность датчика воды в топливе

E00009731
Обнаружена вода в топливе

E00010001
Давление моторного масла слишком низкое

E00010003
Неисправность давления моторного масла

E00010004
Неисправность давления моторного масла

E00010203
Неисправность датчика давления всасываемого воздуха

E00010204
Неисправность датчика давления всасываемого воздуха

E00010502
Ошибка температуры впускного коллектора

E00010503
Неисправность датчика температуры впускного коллектора

E00010504
Неисправность датчика температуры впускного коллектора

E00010509
Неисправность датчика температуры впускного коллектора

E00010510
Неисправность датчика температуры впускного коллектора

E00010603
Неисправность датчика давления в коллекторе

E00010604
Неисправность датчика давления в коллекторе

E00010609
Неисправность датчика давления в коллекторе

E00010803
Ошибка атмосферного давления

E00010804
Ошибка атмосферного давления

E00010809
Ошибка атмосферного давления

E00011000
Предельно высокая температура двигателя

E00011002
Ошибка температуры охлаждающей жидкости двигателя

E00011003
Неисправность датчика температуры воды

E00011004
Неисправность датчика температуры воды

E00011031
Неисправность датчика температуры охлаждающей жидкости двигателя

E00013200
Неисправность объема всасываемого воздуха

E00013201
Неисправность объема всасываемого воздуха

E00013203
Неисправность датчика Maf

E00013204
Неисправность датчика Maf

E00013209
Неисправность датчика Maf

E00013215
Ошибка давления наддува

E00013231
Неисправность датчика Maf

E00015700
Неисправность давления в рампе

E00015702
Неисправность датчика давления в рампе

E00015703
Неисправность датчика давления в рампе

E00015704
Неисправность датчика давления в рампе

E00015710
Неисправность давления в рампе

E00015711
Неисправность давления в рампе

E00015721
Неисправность управления давлением в рампе

E00015722
Неисправность управления давлением в рампе

E00016803
Напряжение в системе слишком высокое

E00016804
Напряжение в системе слишком низкое

E00017103
Неисправность датчика Maf

E00017104
Неисправность датчика Maf

E00017200
Слишком высокая температура всасываемого воздуха

E00017202
Неисправность датчика температуры всасываемого воздуха

E00017203
Неисправность датчика температуры всасываемого воздуха

E00017204
Неисправность датчика температуры всасываемого воздуха

E00017209
Неисправность датчика температуры всасываемого воздуха

E00017300
Ошибка перегрева выхлопных газов

E00017301
Док. Ошибка экзотермической эффективности

E00017302
Неисправность датчика температуры на впуске Scr

E00017400
Слишком высокая температура топлива

E00017402
Ошибка температуры топлива

E00017403
Неисправность датчика температуры топлива

E00017404
Неисправность датчика температуры топлива

E00017409
Неисправность датчика температуры топлива

E00017502
Ошибка температуры моторного масла

E00017531
Неисправность датчика температуры моторного масла

E00019000
Предельно высокие обороты двигателя

E00062802
Ошибка ЭБУ

E00062912
Ошибка ЭБУ

E00063011
Ошибка данных форсунки

E00063023
Ошибка ЭБУ

E00063024
Ошибка ЭБУ

E00063025
Ошибка ЭБУ

E00063031
Ошибка ЭБУ

E00063307
Неисправность давления в рампе

E00063600
Неисправность датчика положения коленчатого вала

E00063601
Неисправность датчика положения коленчатого вала

E00063602
Неисправность датчика положения коленчатого вала

E00063607
Неисправность кулачка или датчика кривошипа

E00063608
Неисправность датчика положения коленчатого вала

E00063611
Неисправность датчика положения коленчатого вала

E00063702
Ошибка сигнала кулачка

E00063708
Ошибка сигнала кулачка

E00063720
Ошибка сигнала кулачка

E00063730
Ошибка сигнала кулачка

E00063919
Ошибка связи ЭБУ

E00064103
Ошибка контроля наддува

E00064104
Ошибка контроля наддува

E00065103
Неисправность форсунки №1

E00065105
Неисправность форсунки №1

E00065106
Неисправность форсунки №1

E00065120
Неисправность форсунки №1

E00065121
Неисправность форсунки №1

E00065131
Неисправность форсунки №1

E00065203
Неисправность форсунки №2

E00065205
Неисправность форсунки №2

E00065206
Неисправность форсунки №2

E00065220
Неисправность форсунки №2

E00065221
Неисправность форсунки №2

E00065231
Неисправность форсунки №2

E00065303
Неисправность форсунки №3

E00065305
Неисправность форсунки №3

E00065306
Неисправность форсунки №3

E00065320
Неисправность форсунки №3

E00065321
Неисправность форсунки №3

E00065331
Неисправность форсунки №3

E00065403
Неисправность форсунки №4

E00065405
Неисправность форсунки №4

E00065406
Неисправность форсунки №4

E00065420
Неисправность форсунки №4

E00065421
Неисправность форсунки №4

E00065431
Неисправность форсунки №4

E00067603
Неисправность реле свечей накаливания

E00067604
Неисправность реле свечей накаливания

E00067605
Неисправность реле свечей накаливания

E00072302
Неисправность датчика положения распределительного вала

E00072308
Неисправность датчика положения распределительного вала

E00073120
Неисправность акселерометра

E00073121
Неисправность акселерометра

E00107600
Неисправность управления давлением в рампе

E00107601
Неисправность управления давлением в рампе

E00107603
Неисправность управления давлением в рампе

E00107604
Неисправность управления давлением в рампе

E00107609
Неисправность управления давлением в рампе

E00107615
Неисправность управления давлением в рампе

E00107616
Неисправность управления давлением в рампе

E00107617
Неисправность управления давлением в рампе

E00107618
Неисправность управления давлением в рампе

E00107620
Неисправность управления давлением в рампе

E00107631
Неисправность управления давлением в рампе

E00107702
Ошибка ЭБУ

E00118002
Ошибка температуры турбо

E00118003
Неисправность датчика температуры турбо

E00118004
Неисправность датчика температуры турбо

E00118009
Неисправность датчика температуры турбо

E00118010
Неисправность датчика температуры турбо

E00118031
Неисправность датчика температуры турбо

E00122100
Ошибка ЭБУ

E00122101
Ошибка ЭБУ

E00122102
Ошибка ЭБУ

E00122103
Ошибка мониторинга безопасности ЭБУ

E00122104
Ошибка мониторинга безопасности ЭБУ

E00122105
Ошибка ЭБУ

E00122106
Ошибка ЭБУ

E00122107
Ошибка ЭБУ

E00122108
Ошибка ЭБУ

E00122109
Ошибка ЭБУ

E00122110
Ошибка ЭБУ

E00122111
Ошибка мониторинга безопасности ЭБУ

E00122112
Ошибка ЭБУ

E00122113
Ошибка ЭБУ

E00122114
Ошибка ЭБУ

E00122115
Ошибка ЭБУ

E00122116
Ошибка ЭБУ

E00122117
Ошибка ЭБУ

E00122118
Ошибка ЭБУ

E00122119
Ошибка мониторинга безопасности ЭБУ

E00122120
Ошибка ЭБУ

E00122121
Ошибка ЭБУ

E00122122
Ошибка ЭБУ

E00122123
Ошибка ЭБУ

E00122124
Ошибка ЭБУ

E00122125
Ошибка ЭБУ

E00122126
Ошибка мониторинга безопасности ЭБУ

E00122127
Ошибка мониторинга безопасности ЭБУ

E00122128
Ошибка мониторинга безопасности ЭБУ

E00122129
Ошибка мониторинга безопасности ЭБУ

E00122130
Ошибка ЭБУ

E00122131
Ошибка мониторинга безопасности ЭБУ

E00122132
Ошибка ЭБУ

E00122133
Ошибка ЭБУ

E00122134
Ошибка ЭБУ

E00122135
Ошибка ЭБУ

E00122136
Ошибка ЭБУ

E00122137
Ошибка ЭБУ

E00122138
Ошибка ЭБУ

E00122139
Ошибка ЭБУ

E00122140
Ошибка ЭБУ

E00122141
Ошибка ЭБУ

E00122142
Ошибка ЭБУ

E00122143
Ошибка ЭБУ

E00122144
Ошибка ЭБУ

E00122145
Ошибка ЭБУ

E00122146
Ошибка ЭБУ

E00122147
Ошибка ЭБУ

E00122148
Ошибка ЭБУ

E00122149
Ошибка ЭБУ

E00122150
Ошибка ЭБУ

E00122151
Ошибка ЭБУ

E00122152
Ошибка ЭБУ

E00122153
Ошибка ЭБУ

E00122154
Ошибка ЭБУ

E00122155
Ошибка ЭБУ

E00122156
Ошибка ЭБУ

E00122157
Ошибка ЭБУ

E00122158
Ошибка ЭБУ

E00122159
Ошибка ЭБУ

E00122160
Ошибка ЭБУ

E00122161
Ошибка ЭБУ

E00122162
Ошибка ЭБУ

E00122163
Ошибка ЭБУ

E00122164
Ошибка ЭБУ

E00122165
Ошибка ЭБУ

E00122166
Ошибка ЭБУ

E00122167
Ошибка ЭБУ

E00122168
Ошибка ЭБУ

E00122169
Ошибка ЭБУ

E00122170
Ошибка ЭБУ

E00122171
Ошибка ЭБУ

E00122172
Ошибка ЭБУ

E00122173
Ошибка ЭБУ

E00122174
Ошибка ЭБУ

E00122175
Ошибка ЭБУ

E00122176
Ошибка ЭБУ

E00122177
Ошибка ЭБУ

E00122178
Ошибка ЭБУ

E00122179
Ошибка ЭБУ

E00122180
Ошибка ЭБУ

E00122181
Ошибка ЭБУ

E00122182
Ошибка ЭБУ

E00122183
Ошибка ЭБУ

E00122184
Ошибка ЭБУ

E00122185
Ошибка ЭБУ

E00122186
Ошибка ЭБУ

E00122187
Ошибка ЭБУ

E00122188
Ошибка ЭБУ

E00122189
Ошибка ЭБУ

E00122190
Ошибка ЭБУ

E00122191
Ошибка ЭБУ

E00122192
Ошибка ЭБУ

E00122193
Ошибка ЭБУ

E00122194
Ошибка ЭБУ

E00122195
Ошибка ЭБУ

E00122196
Ошибка ЭБУ

E00122197
Ошибка ЭБУ

E00122198
Ошибка ЭБУ

E00122199
Ошибка ЭБУ

E00123901
Утечка топлива под высоким давлением

E00134703
Неисправность насоса высокого давления

E00134704
Неисправность насоса высокого давления

E00134707
Неисправность насоса высокого давления

E00148502
Неисправность главного реле ЭБУ

E00148507
Неисправность главного реле ЭБУ

E00148511
Неисправность главного реле ЭБУ

E00161203
Неисправность форсунок №1 и №4

E00161204
Неисправность форсунок №1 и №4

E00161211
Неисправность форсунок №1 и №4

E00161303
Неисправность форсунок № 2 и № 3

E00161304
Неисправность форсунок № 2 и № 3

E00161311
Неисправность форсунок № 2 и № 3

E00279103
Egr Motor Fault (неисправность двигателя)

E00279104
Egr Motor Fault (неисправность двигателя)

E00279105
Egr Motor Fault (неисправность двигателя)

E00279107
Заблокированная неисправность EGR

E00279108
Ошибка положения EGR

E00324200
Предельно высокая температура выхлопных газов

E00324203
Неисправность датчика температуры выхлопных газов

E00324204
Неисправность датчика температуры выхлопных газов

E00324216
Неисправность датчика температуры выхлопных газов

E00324600
Предельно высокая температура выхлопных газов

E00324603
Ошибка датчика температуры EGR

E00324604
Ошибка датчика температуры EGR

E00324616
Неисправность датчика температуры выхлопных газов

E00325100
Неисправность датчика перепада давления

E00325101
Неисправность датчика перепада давления

E00325103
Ошибка датчика температуры EGR

E00325104
Ошибка датчика температуры EGR

E00325200
Слишком высокая температура выхлопных газов

E00350903
Сбой напряжения питания датчика

E00350904
Сбой напряжения питания датчика

E00350911
Неисправность источника питания 5-вольтного датчика №1

E00351003
Сбой напряжения питания датчика

E00351004
Сбой напряжения питания датчика

E00351011
Неисправность источника питания 5-вольтного датчика №2

E00351111
Неисправность питания 5-вольтового вспомогательного датчика №2

E00370100
Предельно высокое содержание твердых частиц

E00370115
Предупреждение о твердых частицах

E00370116
Слишком высокое содержание твердых частиц

E00408203
Неисправность впускного дозирующего клапана

E00408204
Неисправность впускного дозирующего клапана

E00408205
Неисправность впускного дозирующего клапана

E00408206
Неисправность впускного дозирующего клапана

E00425600
Неизвестная неисправность Scr

E00476500
Предельно высокая температура выхлопных газов

E00476503
Неисправность датчика температуры выхлопных газов

E00476504
Неисправность датчика температуры выхлопных газов

E00476518
Неисправность датчика температуры выхлопных газов

E00524600
Уровень защиты пустой

E00524615
Уровень защиты слишком низкий

E00524616
Уровень защиты Предельно низкий

E00524617
Уровень защиты слишком низкий

E00524619
Dcu может сбой связи

E00524621
Заблокированная ошибка EGR

E00524622
Прерванная ошибка дозирования

E00524623
Ошибка расхода Def

E00524624
Ошибка качества Def

E00524625
Ошибка взлома

E00524626
Ошибка расхода Def

E00532403
Ошибка сигнала свечей накаливания

E00532404
Ошибка сигнала свечей накаливания

E0105
Замыкание привода дроссельной заслонки на напряжение аккумулятора

E0106
Замыкание привода дроссельной заслонки на массу

E0107
Обрыв цепи привода дроссельной заслонки

E0123
Контроллер дроссельной заслонки не откалиброван

E0321
Напряжение питания датчика 5 В выше допустимого диапазона

E0322
Питание датчика 5 В ниже допустимого диапазона

E0421
Диск управления частотой вращения двигателя выше допустимого диапазона

E0422
Диск управления частотой вращения двигателя ниже допустимого диапазона

E0521
Обратная связь привода дроссельной заслонки вне допустимого диапазона

E0522
Обратная связь привода дроссельной заслонки ниже допустимого диапазона

E52352302
Неисправность форсунок №1 и №4

E52352303
Неисправность форсунок №1 и №4

E52352304
Неисправность форсунок №1 и №4

E52352402
Неисправность форсунок № 2 и № 3

E52352403
Неисправность форсунок № 2 и № 3

E52352404
Неисправность форсунок № 2 и № 3

E52352501
Неисправность форсунки

E52352702
Ошибка ЭБУ

E52353500
Неисправность форсунки

E52353602
Ошибка EGR

E52353702
Ошибка EGR

E52353802
Ошибка ЭБУ

E52353807
Ошибка ЭБУ

E52353902
Неисправность топливного насоса

E52354002
Неисправность топливного насоса

E52354103
Ошибка EGR

E52354104
Ошибка EGR

E52354302
Неисправность датчика положения дроссельной заслонки

E52354403
Неисправность впускного нагревателя

E52354404
Неисправность впускного нагревателя

E52354702
Ошибка связи ЭБУ

E52354802
Ошибка связи ЭБУ

E52357204
Ошибка датчика положения EGR

E52357403
Egr Actuator Fault (Неисправность привода)

E52357404
Egr Неисправность привода

E52357507
Egr Actuator Fault (Неисправность привода)

E52357602
Egr Motor Fault (Неисправность двигателя)

E52357702
Ошибка датчика температуры EGR

E52357802
Ошибка EGR

E52358002
Неисправность впускного дросселя

E52358203
Неисправность датчика подъема дроссельной заслонки на впуске

E52358204
Неисправность датчика подъема дроссельной заслонки на впуске

E52358917
Низкая температура воды при парковке регенерации

E52359016
Припаркованный тайм-аут регенерации

E52359102
Ошибка связи ЭБУ

E52359202
Ошибка связи ЭБУ

E52359302
Ошибка связи ЭБУ

E52359402
Ошибка связи ЭБУ

E52359502
Ошибка связи ЭБУ

E52359602
Ошибка связи ЭБУ

E52359800
Отказ Doc

E52359802
Ошибка связи ЭБУ

E52359900
Неисправность датчика температуры выхлопных газов

E52360000
Ошибка калибровки насоса

E52360100
Неисправность датчика температуры выхлопных газов

E52360200
Ошибка DPF

E52360315
Неисправность датчика температуры воды

E52360402
Ошибка связи ЭБУ

E52370013
Ошибка ЭБУ

H0921
Датчик наддува выше допустимого диапазона

H0922
Датчик наддува ниже допустимого диапазона

H1221
Передний вспомогательный подрулевой переключатель выше допустимого диапазона

H1222
Передний вспомогательный подрулевой переключатель ниже допустимого диапазона

H1224
Передний вспомогательный подрулевой переключатель не в нейтральном положении

H1321
Левый переключатель для большого пальца вне допустимого диапазона — высокий уровень

H1322
Левый большой переключатель ниже допустимого диапазона

H1324
Задний вспомогательный подрулевой переключатель не в нейтральном положении

H2305
Замыкание заднего базового соленоида на аккумулятор

H2306
Замыкание заднего базового соленоида на массу

H2307
Обрыв цепи заднего базового соленоида

H2332
Перегрузка заднего базового соленоида

H2405
Замыкание соленоида задней тяги на аккумулятор Код Описание

H2406
Замыкание соленоида задней тяги на массу

H2407
Обрыв цепи соленоида задней тяги

H2432
Перегрузка соленоида задней тяги

H2505
Короткое замыкание дивертора №2 на аккумуляторную батарею

H2506
Дивертер №2, замыкающий на землю

H2507
Обрыв цепи дивертора №2

H2605
Замыкание переднего базового соленоида на напряжение аккумулятора

H2606
Замыкание переднего базового соленоида на массу

H2607
Обрыв цепи переднего базового соленоида

H2632
Перегрузка переднего базового соленоида

H2705
Замыкание соленоида передней тяги на напряжение аккумулятора

H2706
Замыкание соленоида передней тяги на массу

H2707
Обрыв цепи соленоида передней тяги

H2732
Перегрузка соленоида передней тяги

H2805
Замыкание электромагнитного клапана дивертора на напряжение аккумулятора

H2806
Замыкание электромагнитного клапана дивертора на массу

H2807
Обрыв цепи электромагнитного клапана дивертора

H2905
Электромагнитный клапан высокого расхода: замыкание на аккумуляторную батарею

H2906
Замыкание соленоида высокого потока на массу

H2907
Обрыв цепи соленоида высокого расхода

H2932
Перегрузка по току соленоида с высоким расходом

H3028
Сбой памяти вспомогательного контроллера

H3128
Прерывистый сбой питания

H3648
Наличие нескольких Acds (устройство управления навесным оборудованием)

H3904
Левый джойстик неисправен

H3912
Большой палец на левом джойстике не в нейтральном положении

H3913
Левый джойстик захвата (нет связи)

H3916
Левый джойстик базы (нет связи)

H3928
Внутренняя неисправность левого джойстика

H3948
Левый джойстик несколько

H4004
Правый джойстик неисправен

H4012
Большой палец на правом джойстике не в нейтральном положении

H4013
Правая ручка джойстика (нет связи)

H4016
Правая консоль джойстика (нет связи)

H4028
Внутренняя неисправность правого джойстика

H4048
Правый джойстик несколько

H4302
Реле звукового сигнала — ошибочное включение

H4303
Реле звукового сигнала — ошибочное выключение

H4423
Вспомогательный контроллер не запрограммирован

H4497
Вспомогательный контроллер запрограммирован

H4502
Правый указатель поворота — ошибочное включение

H4503
Правый указатель поворота — ошибочное выключение

H4602
Левый поворотник — ошибочное включене

H4603
Левый поворотник — ошибочное выключение

H4721
Напряжение питания датчика 8 В выше допустимого диапазона

H4722
Питание датчика 8 В ниже допустимого диапазона

H7404
Контроллер шлюза (нет связи)

H7604
Левая панель дисплея Нет кода связи Описание

L0102
Кнопка освещения — ошибочное включение

L0202
Кнопка высокого расхода — ошибочное включение

L0302
Вспомогательная кнопка — ошибочное включение

L0402
Инфорсационная кнопка — ошибочное включение

L7404
Контроллер шлюза (нет связи)

L7672
Ошибка программирования левой панели

M0116
Воздушный фильтр не подключен

M0117
Засорен воздушный фильтр

M0216
Фильтр гидравлического агрегата не подключен

M0217
Засорен фильтр гидравлического агрегата

M0309
Низкое напряжение батареи

M0310
Напряжение аккумулятора высокое

M0311
Напряжение аккумулятора очень высокое

M0314
Напряжение батареи крайне низкое

M0322
Напряжение аккумулятора ниже допустимого диапазона

M0409
Давление моторного масла низкое

M0414
Предельно низкое давление моторного масла

M0415
Давление моторного масла при остановке

M0421
Давление моторного масла вне допустимого диапазона

M0422
Давление моторного масла ниже допустимого диапазона

M0509
Низкое давление наддува гидросистемы

M0510
Гидравлическое давление наддува высокое

M0511
Предельно высокое гидравлическое давление наддува

M0514
Предельно низкое гидравлическое давление наддува

M0515
Гидравлическое давление наддува при останове

M0521
Гидравлическое давление наддува выше допустимого диапазона

M0522
Гидравлическое давление наддува ниже допустимого диапазона

M0610
Обороты двигателя высокая

M0611
Предельно высокие обороты двигателя

M0613
Нет сигнала оборотов двигателя

M0615
Обороты двигателя при остановке

M0618
Обороты двигателя вне допустимого диапазона

M0634
Недействительная информация об оборотах двигателя от ЭБУ

M0710
Высокая температура гидравлического масла

M0711
Предельно высокая температура гидравлического масла

M0715
Температура гидравлического масла при останове

M0721
Температура гидравлического масла вне допустимого диапазона

M0722
Температура гидравлического масла вне допустимого диапазона, низкая

M0810
Высокая температура охлаждающей жидкости двигателя

M0811
Предельно высокая температура охлаждающей жидкости двигателя

M0815
Температура охлаждающей жидкости двигателя при остановке

M0821
Температура охлаждающей жидкости двигателя вне допустимого диапазона

M0822
Температура охлаждающей жидкости двигателя вне допустимого диапазона, низкая

M0826
Температура охлаждающей жидкости двигателя перед остановкой

M0909
Низкий уровень топлива M4110 Высокое напряжение генератора

M0921
Уровень топлива выше допустимого диапазона

M0922
Уровень топлива ниже допустимого диапазона

M1016
Гидравлический заправочный фильтр не подключен

M1017
Засорен гидравлический заправочный фильтр

M1121
Датчик дуги безопасности выше допустимого диапазона

M1122
Датчик дуги безопасности ниже допустимого диапазона

M1128
Отказ датчика подседельного штыря

M1305
Замыкание катушки отключения подачи топлива на аккумулятор

M1306
Замыкание катушки отключения подачи топлива на массу

M1307
Разрыв цепи соленоида удержания топлива

M1402
Соленоид втягивания топлива — ошибочное включение

M1403
Соленоид втягивания топлива — ошибочное включение

M1407
Разрыв цепи соленоида втягивания топлива

M1428
Сбой соленоида втягивания топлива

M1502
Втягивающий соленоид блокировки тяги — ошибочное включение

M1503
Втягивающий соленоид блокировки тяги — ошибочное выключение

M1507
Разрыв цепи выхода соленоида втягивания блокировки тяги

M1528
Сбой втягивающего соленоида блокировки тяги

M1605
Удерживающий соленоид блокировки тяги замкнут на батарею

M1606
Удерживающий соленоид блокировки тяги замкнут на заземление

M1607
Разрыв цепи удерживающего соленоида блокировки тяги

M1705
Гидравлический запорный клапан замкнут на батарею

M1706
Гидравлический запорный клапан замкнут на землю

M1707
Разрыв цепи гидравлического запорного клапана

M1732
Перегрузка по току гидравлического запорного клапана

M1805
Выход соленоида золотника замкнут на батарею

M1806
Выход соленоида золотника замкнут на землю

M1807
Разрыв цепи выхода соленоида золотника

M1832
Перегрузка по току выхода соленоида золотника

M2005
Двухскоростной первичный соленоид замкнут на батарею

M2006
Двухскоростной первичный соленоид замкнут на землю

M2007
Разрыв цепи двухскоростного первичного соленоида

M2032
Перегрузка по току в двухскоростном первичном соленоиде

M2102
Выход свечей накаливания — ошибочное включение

M2103
Выход свечей накаливания — ошибочное выключение

M2107
Выход свечей накаливания, разрыв цепи

M2128
Сбой на выходе свечей накаливания

M2202
Ошибочное включение выхода стартера

M2203
Ошибочное выключение выхода стартера

M2207
Обрыв цепи выхода стартера

M2228
Сбой на выходе стартера

M2302
Реле стартера — ошибочное включение

M2303
Реле стартера — ошибочное выключение

M2307
Обрыв цепи реле стартера

M2402
Реле втягивания топлива — ошибочное включение

M2403
Реле втягивания топлива — ошибочное выключение

M2407
Обрыв цепи выхода подачи топлива

M2502
Реле блокировки тягового усилия — ошибочное включение

M2503
Тяговое реле блокировки тяги — ошибочное выключение

M2507
Обрыв цепи выхода блокировки тягового усилия

M2602
Реле свечей накаливания — ошибочное включение

M2603
Реле свечей накаливания — ошибочное выключение

M2607
Обрыв цепи выхода свечи предпускового подогрева

M2721
Сигнал первичного датчика дросселя за верхней границей диапазона

M2722
Сигнал первичного датчика дросселя за нижней границей диапазона

M2805
Замыкание выхода вспомогательной блокировки на аккумулятор

M2806
Замыкание выхода вспомогательной блокировки на массу

M2807
Обрыв цепи выхода вспомогательной блокировки

M2821
Сигнал вторичного датчика дросселя за верхней границей диапазона

M2822
Сигнал вторичного датчика дросселя за нижней границей диапазона

M3028
Отказ памяти контроллера

M3128
Неисправность режима восстановления

M3204
ACS (AHC), нет сообщений контроллеру Bobcat

M3304
Нет связи с панелью Deluxe

M3323
Контроллер шлюза не запрограммирован

M3404
Панель Deluxe в состоянии ошибки

M3505
Вентилятор гидравлики замкнут на батарею

M3506
Вентилятор гидравлики замкнут на землю

M3507
Разрыв цепи вентилятора гидравлики

M3532
Перегрузка по току вентилятора гидравлики

M3648
Наличие нескольких Acds (устройство управления навесным оборудованием)

M3705
Выход двухскоростной вторичной обмотки замкнут на батарею

M3706
Выход двухскоростной вторичной обмотки замкнут на землю

M3707
Разрыв цепи выхода двухскоростной вторичной обмотки

M3732
Перегрузка по току выхода двухскоростной вторичной обмотки

M3805
Блокировка доп. гидравлики замкнута на батарею

M3806
Блокировка доп.гидравлики замкнута на землю

M3807
Разрыв цепи блокировки доп.гидравлики

M3832
Перегрузка по току блокировки доп.гидравлики

M4028
Обнаружен неправильный ЭБУ

M4109
Предельно низкая мощность генератора

M4110
Высокая скорость генератора

M4111
Предельно высокая мощность генератора

M4304
Нет связи с кнопочной панелью

M4404
Нет сигнала от доп. гидравлики

M4510
Вода в датчике топлива слишком высока

M4511
Вода в датчике топлива предельно высока

M4521
Вода в датчике топлива за верхней границей диапазона

M4522
Вода в датчике топлива за нижней границей диапазона

M4621
Питание 5-вольтового датчика за верхней границей диапазона

M4622
Питание 5-вольтового датчика, за нижней границей диапазона

M4721
Питание 8-вольтового датчика за верхней границей диапазона

M4722
Питание 8-вольтового датчика, за нижней границей диапазона

M4802
Реле переднего света, ошибочное включение

M4803
Реле переднего света, ошибочное выключение

M4807
Обрыв цепи выхода переднего фонаря

M4902
Реле заднего света, ошибочное включение

M4903
Реле заднего света, ошибочное выключение

M4907
Обрыв цепи выхода заднего фонаря

M5002
Выход переднего фонаря, ошибочное включение

M5003
Выход переднего фонаря, ошибочное выключение

M5007
Разрыв цепи выхода передних фар

M5028
Неисправность выхода передних фар

M5102
Выход фонарей заднего света, ошибочное включение

M5103
Выход фонарей заднего света, ошибочное выключение

M5107
Разрыв цепи выхода задних фар

M5128
Неисправность выхода задних фар

M5202
Кнопка включения погрузчика, ошибочное включение

M5221
Кнопка включения погрузчика за верхней границей диапазона

M5222
Кнопка включения погрузчика за нижней границей диапазона

M5305
Подсветка кнопки включения погрузчика замкнута на батарею

M5306
Подсветка кнопки включения погрузчика замкнута на землю

M5405
Соленоид золотника наклона замкнут на батарею

M5406
Соленоид золотника наклона замкнут на землю

M5407
Разрыв цепи соленоида золотника наклона

M5432
Перегрузка по току соленоида золотника наклона

M5810
Слишком высокая температура топлива

M5811
Предельно высокая температура топлива

M5815
Температура топлива при останове

M5826
Предварительное отключение по температуре топлива

M5902
Выключатель регенерации DPF, ошибочное включение

M6002
Выключатель регенерации при замедлении DPF, ошибочное включение

M6102
Выключатель регенерации при удаленной парковке, ошибочное включение

M6402
Ошибочное включение реле мощности

M6403
Ошибочное выключение реле мощности

M6407
Обрыв цепи коммутируемой выходной мощности

M6505
Питание ECU замкнуто на батарею

M6506
Питание ECU замкнуто на землю

M6507
Разрыв цепи питания ECU

M6604
Отсутствие связи с ECU

M6702
Ошибочное включение выхода системы HVAC

M6703
Ошибочное выключение выхода системы HVAC

M6707
Разрыв цепи выхода системы HVAC

M6728
Сбой на выходе системы HVAC

M6802
Ошибочное включение реле системы HVAC

M6803
Ошибочное выключение реле системы HVAC

M7002
Выход импульсного источника питания, ошибочное включение

M7003
Выход импульсного источника питания, ошибочное выключение

M7007
Выход импульсного источника питания, разрыв цепи

M7028
Ошибка на выходе импульсного источника питания

M7304
Дистанционное управление — отсутствует сигнал

M7316
Дистанционное управление, нет сообщений датчику

M7423
Главный контроллер не запрограммирован

M7472
Главный контроллер нуждается в программировании

M7497
Главный контроллер запрограммирован

M7504
Нет сигнала от привода

M7604
Нет связи с левой панелью дисплея

M7748
Замок зажигания, многорежимный

M7839
Значение счетчика моточасов изменено

M7974
Дверь открыта

M8541
Автоматическая регенерация DPF активна

M8542
Автоматическая регенерация DPF активна (включать погрузчик под нагрузкой)

M8543
Главный контроллер не запрограммирован

M8551
Необходима регенерация DPF – замедление активно

M8552
Необходима регенерация DPF – замедление активно (включать погрузчик под нагрузкой)

M8553
Требуется регенерация DPF при удаленной парковке (требуется комплект удаленной регенерации)

M8554
Требуется регенерация DPF при обслуживании (обратиться к дилеру Bobcat)

M8555
Требуется услуга DPF

M8560
Регенерация службы DPF активна

M8561
Регенерация службы DPF активна

M8562
Регенерация службы DPF активна

M8563
Регенерация службы DPF активна

M8564
Регенерация службы DPF активна

M8615
Снижение скорости двигателя при выключении

M8625
Обороты двигателя снижается, не отвечает

P0117
Датчик температуры охлаждающей жидкости двигателя ниже допустимого диапазона

P0118
Датчик температуры охлаждающей жидкости двигателя выше допустимого диапазона

P0119
Прерывистый сигнал датчика температуры охлаждающей жидкости двигателя

P0122
Датчик акселератора ниже допустимого диапазона

P0123
Датчик акселератора выше допустимого диапазона

P0124
Прерывистое подключение датчика акселератора

P0217
Высокая температура охлаждающей жидкости двигателя

P0340
Нет сигнала датчика частоты вращения двигателя

P0562
Низкое напряжение батареи

P0563
Напряжение аккумулятора высокое

P0605
E-ecu Internal Flashrom Checksum Error A (основное программное обеспечение)

P0634
Высокий уровень сигнала датчика температуры электронного блока управления

P0642
Питание датчика 5 В ниже допустимого диапазона

P0643
Напряжение питания датчика 5 В выше допустимого диапазона

P0668
Датчик температуры E-ecu ниже допустимого диапазона

P0669
Датчик температуры электронного блока управления выше допустимого диапазона

P1202
Датчик положения стойки ниже допустимого диапазона

P1203
Датчик положения стойки выше допустимого диапазона

P1211
Застрял соленоид привода стойки

P1212
Минимальный ток соленоида привода стойки

P1213
Перегрузка по току соленоида привода стойки

P1222
Реле привода стойки — ошибочное включение

P1223
Реле привода стойки — ошибочное выключение

P1224
Прерывистое соединение реле привода стойки

P1232
Реле предварительного нагрева — ошибочное включение

P1233
Реле предварительного нагрева — ошибочное выключение

P1234
Прерывистое соединение реле подогрева

P1242
Электромагнитный клапан CSD — ошибочное включение

P1243
Электромагнитный клапан CSD — ошибочное выключение

P1244
Прерывистое соединение электромагнитного клапана Csd

P1402
EGR-клапан Фаза A — ошибочное включение

P1403
EGR-клапан Фаза A — ошибочное выключение

P1412
EGR-клапан Фаза B — ошибочное включение

P1413
EGR-клапан Фаза B — ошибочное выключение

P1422
EGR-клапан Фаза C — ошибочное включение

P1423
EGR-клапан Фаза C — ошибочное выключение

P1432
EGR-клапан Фаза D — ошибочное включение

P1433
EGR-клапан Фаза D — ошибочное выключение

P1605
E-ecu Internal Flashrom Checksum Error B (основное программное обеспечение)

P1606
Ошибка контрольной суммы внутренней флеш-памяти E-ecu C (основное программное обеспечение)

P1644
Прерывистое соединение питания датчика 5 В

P1664
Прерывистое подключение датчика температуры E-ecu

R7404
Нет связи с главным контроллером

T9002
Cервисный инструмент выход ‘c’ — ошибочное включение

T9003
Cервисный инструмент выход ‘c’ — ошибочное выключение

T9102
Cервисный инструмент выход ‘d’ — ошибочное включение

T9103
Cервисный инструмент выход ‘d’ — ошибочное выключение

T9202
Cервисный инструмент выход ‘e’ — ошибочное включение

T9203
Cервисный инструмент выход ‘e’ — ошибочное выключение

T9302
Cервисный инструмент выход ‘f’ — ошибочное включение

T9303
Cервисный инструмент выход ‘f’ — ошибочное выключение

W3204
ACS (AHS) (нет связи) с контроллером Bobcat

W3223
Контроллер ACS не откалиброван

W3224
Калибровка контроллера ACS выполнена успешно

W3225
Ошибка калибровки контроллера ACS

W3231
ACS Tilt Actuator Fault (Неисправность привода наклона ACS)

W3232
Электропроводка привода наклона ACS (AHS)

W3233
Электропроводка ручки наклона ACS (AHS)

W3234
Привод наклона ACS не в нейтральном положении

W3235
Ручка / педаль наклона ACS не в нейтральном положении

W3236
ACS Lift Actuator Fault (Неисправность привода лифта ACS)

W3237
Электропроводка привода лифта ACS (AHS)

W3238
Электропроводка ручки подъемника ACS (AHS)

W3239
Привод лифта ACS не в нейтральном положении (только ACS)

W3240
Рукоятка подъема ACS (AHC)/педаль не в
нейтральном положении

W3241
Отсутствие связи с ACS (AHC)

W3249
Исполнительный механизм подъема ACS (AHC)
замкнут на землю

W3250
Исполнительный механизм наклона ACS (AHC)
замкнут на землю

W3251
Исполнительный механизм подъема ACS (AHC)
замкнут на батарею

W3252
Исполнительный механизм наклона ACS (AHC)
замкнут на батарею

W3253
Рукоятка подъема ACS (AHC) / педаль замкнута на
землю

W3254
Рукоятка наклона ACS (AHC) / педаль замкнута на
землю

W3255
Рукоятка наклона ACS (AHC) / педаль замкнута на
батарею

W3256
Рукоятка наклона ACS (AHC) / педаль замкнута на
батарею

W3257
Пониженная производительность исполнительного
механизма подъема ACS (AHC)

W3258
Пониженная производительность исполнительного
механизма наклона ACS (AHC)

W3259
Неправильное направление исполнительного
механизма подъема ACS (AHC)

W3260
Неправильное направление исполнительного
механизма наклона ACS (AHC)

W3261
Блокиратор рукоятки ACS (AHC) замкнут на землю

W3262
Блокиратор рукоятки ACS (AHC) замкнут на
батарею

W3263
Блокиратор педали ACS (AHC) замкнут на землю

W3264
Блокиратор педали ACS (AHC) замкнут на батарею

W3265
Напряжение питания датчика ACS (AHC) вне
допустимых пределов

W3266
Напряжение батареи ACS (AHC) вне допустимых
пределов

W3267
Переключатель ACS (AHC) переключился во время
работы

W3268
Информационная ошибка рукоятки подъема ACS
(AHC)

W3269
Переключатель режима управления ACS (AHS) переключается во время работы

W3270
Рукоятка правого привода ACS (AHC) замкнута на
землю

W3271
Рукоятка правого привода ACS (AHC) замкнута на
батарею

W3274
Ось X левого джойстика ACS (AHC) вне
допустимых пределов

W3275
Прерванное некоммутируемое питание ACS (AHC)

W3276
Информационная ошибка джойстика CAN, ACS
(AHC)

W3277
Информационная ошибка дистанционного
управления, ACS (AHC)

W3297
Контроллер ACS (AHC) запрограммирован

W3905
Ось Х левого джойстика не в нейтральном
положении

W4005
Ось X правого джойстика не в нейтральном
положении

W4007
Ось Y правого джойстика не в нейтральном
положении

Коды ошибок мини погрузчиков Bobcat помогут вам идентифицировать неисправный исполнительный механизм и быстрее произвести ремонт отказавшего механизма как ДВС, так и гидравлической системы

Расшифровка кодов ошибок Bobcat

КОД	ОПИСАНИЕ
01-16	Не подсоединен воздушный фильтр
01-17	Засорен воздушный фильтр
02-16	Не подсоединен гидравлический нагнетательный фильтр
02-17	Засорен гидравлический нагнетательный фильтр
03-09	Низкое напряжение аккумуляторной батареи
03-10	Высокое напряжение аккумуляторной батареи
03-11	Предельно высокое напряжение аккумуляторной батареи
03-14	Предельно низкое напряжение аккумуляторной батареи
03-22	Напряжение аккумуляторной батареи ниже предельно допустимого
04-09	Низкий уровень давления масла в двигателе
04-14	Предельно низкий уровень давления масла в двигателе
04-15	Давление масла в двигателе на уровне экстренного выключения двигателя
04-21	Давление масла в двигателе выше предельно допустимого
04-22	Давление масла в двигателе ниже предельно допустимого
05-09	Низкое давление подпитки в гидравлической системе
05-14	Предельно низкое давление подпитки в гидравлической системе
05-15	Давление подпитки в гидравлической системе на уровне экстренного выключения двигателя
05-21	Давление подпитки в гидравлической системе выше предельно допустимого
05-22	Давление подпитки в гидравлической системе ниже предельно допустимого
06-10	Высокие обороты двигателя
06-11	Предельно высокие обороты двигателя
06-13	Отсутствует сигнал оборотов двигателя
06-15	Обороты двигателя на уровне экстренного выключения двигателя
06-18	Обороты двигателя вне допустимых пределов
07-10	Высокая температура масла в гидравлической системе
07-11	Предельно высокая температура масла в гидравлической системе
07-15	Температура масла в гидравлической системе на уровне экстренного выключения двигателя
07-21	Температура масла в гидравлической системе выше предельно допустимой
07-22	Температура масла в гидравлической системе ниже предельно допустимой
08-10	Высокая температура охлаждающей жидкости двигателя
08-11	Предельно высокая температура охлаждающей жидкости двигателя
08-15	Температура охлаждающей жидкости двигателя на уровне экстренного выключения двигателя
08-21	Температура охлаждающей жидкости двигателя выше предельно допустимой
08-22	Температура охлаждающей жидкости двигателя ниже предельно допустимой
09-09	Низкий уровень топлива
09-21	Уровень топлива выше предельно допустимого
09-22	Уровень топлива ниже предельно допустимого
11-05	Датчик рамы безопасности замкнут на батарею
11-06	Датчик рамы безопасности замкнут на массу
12-21	Сигнал ШИМ-контроллера передней доп. гидравлики за верхней границей диапазона
12-22	ШИМ-контроллер передней доп. гидравлики за нижней границей диапазона
12-23	ШИМ-контроллер передней доп. гидравлики не в нейтральном положении
13-05	Удерживающий соленоид отсечки топлива замкнут на батарею
13-06	Удерживающий соленоид отсечки топлива замкнут на массу
13-07	Разрыв цепи соленоида отсечки топлива
14-02	Втягивающий соленоид отсечки топлива, ошибочное включение
14-03	Втягивающий соленоид отсечки топлива, ошибочное выключение
15-02	Втягивающий соленоид блокировки тяги, ошибочное включение
15-03	Втягивающий соленоид блокировки тяги, ошибочное выключение
16-05	Удерживающий соленоид блокировки тяги замкнут на батарею
16-06	Удерживающий соленоид блокировки тяги замкнут на массу
16-07	Разрыв цепи удерживающего соленоида блокировки тяги
17-05	Соленоид гидравлического запорного клапана замкнут на батарею
17-06	Соленоид гидравлического запорного клапана замкнут на массу
17-07	Разрыв цепи соленоида гидравлического запорного клапана
18-05	Соленоид золотника замкнут на батарею
18-06	Соленоид золотника замкнут на массу
18-07	Разрыв цепи соленоида золотника
19-02	Соленоид позиционирования ковша, ошибочное включение
19-03	Соленоид позиционирования ковша, ошибочное выключение
20-02	Соленоид переключения скоростей, ошибочное включение
20-03	Соленоид переключения скоростей, ошибочное выключение
21-02	Свечи накаливания, ошибочное включение
21-03	Свечи накаливания, ошибочное выключение
22-02	Стартер, ошибочное включение
22-03	Стартер, ошибочное выключение
23-02	Задний базовый соленоид, ошибочное включение
23-03	Задний базовый соленоид, ошибочное выключение
24-02	Задний штоковый соленоид, ошибочное включение
24-03	Задний штоковый соленоид, ошибочное выключение
25-02	Задний вспомогательный пропорциональный соленоид, ошибочное включение
25-03	Задний вспомогательный пропорциональный соленоид, ошибочное выключение
26-02	Ошибочное включение переднего базового соленоида
26-03	Ошибочное выключение переднего базового соленоида
27-02	Ошибочное включение переднего штокового соленоида
27-03	Ошибочное выключение переднего штокового соленоида
28-02	Ошибочное включение соленоида дивертера
28-03	Ошибочное выключение соленоида дивертера
29-02	Соленоид большой подачи, ошибочное включение
29-03	Соленоид большой подачи, ошибочное выключение
30-28	Отказ памяти контроллера
31-28	Неисправность режима восстановления
32-04	Расширенное управление (ACS) не сообщается с контроллером Bobcat
32-23	Расширенное управление ACS не откалибровано
32-31	Отказ исполнительного механизма наклона
32-32	Неисправность электропроводки исполнительного механизма наклона
32-33	Неисправность электропроводки рукоятки наклона ковша
32-34	Исполнительный механизм наклона не в нейтральном положении
32-35	Рукоятка / педаль наклона ковша не в нейтральном положении
32-36	Отказ исполнительного механизма подъема
32-37	Неисправность электропроводки исполнительного механизма подъема
32-38	Неисправность электропроводки рукоятки подъема стрелы
32-39	Исполнительный механизм подъема не в нейтральном положении
32-40	Рукоятка / педаль подъема стрелы не в нейтральном положении
32-41	Нет связи
32-49	Исполнительный механизм подъема замкнут на массу
32-50	Исполнительный механизм наклона замкнут на массу
32-51	Исполнительный механизм подъема замкнут на батарею
32-52	Исполнительный механизм наклона замкнут на батарею
32-53	Рукоятка / педаль подъема стрелы замкнута на массу
32-54	Рукоятка / педаль наклона ковша замкнута на массу
32-55	Рукоятка / педаль подъема стрелы замкнута на батарею
32-56	Рукоятка / педаль наклона ковша замкнута на батарею
32-57	Пониженная производительность исполнительного механизма подъема
32-58	Пониженная производительность исполнительного механизма наклона
32-59	Неправильное направление исполнительного механизма подъема
32-60	Неправильное направление исполнительного механизма наклона
32-61	Блокиратор рукояток замкнут на массу
32-62	Блокиратор рукояток замкнут на батарею
32-63	Цепь блокиратора педалей замкнута на массу
32-64	Цепь блокиратора педалей замкнута на батарею
32-65	Напряжение питания датчика вне допустимых пределов
32-66	Напряжение аккумуляторной батареи вне допустимых пределов
32-67	Переключатель переключился во время работы
32-68	Информационная ошибка рукоятки подъема стрелы
32-69	Переключатель режимов управления переключился во время работы
32-70	Цепь правой рукоятки движения замкнута на массу
32-71	Цепь правой рукоятки движения замкнута на батарею
33-23	Главный контроллер (контроллер Bobcat) не запрограммирован
34-04	Панель с кнопочным запуском не сообщается с контроллером Bobcat
35-02	Двухскоростной переключатель вентилятора, ошибочное включение
35-03	Двухскоростной переключатель вентилятора, ошибочное выключение
36-48	Подключено несколько контроллеров ACD
37-02	Двухскоростной дополнительный переключатель скоростей, ошибочное включение
37-03	Двухскоростной дополнительный переключатель скоростей, ошибочное выключение
38-04	Нет связи с контроллером джойстика
38-05	Ось Х левого джойстика не в нейтральном положении
38-06	Ось X правого джойстика не в нейтральном положении
38-07	Ось Y левого джойстика не в нейтральном положении
38-08	Ось Y правого джойстика не в нейтральном положении
38-09	Переключатель режимов управления — замыкание на батарею или на массу
38-11	Исполнительный механизм подъема не в нейтральном положении
38-12	Исполнительный механизм наклона не в нейтральном положении
38-13	Отказ исполнительного механизма подъема
38-14	Отказ исполнительного механизма наклона
38-15	Неисправность проводки управления скоростью правого колеса
38-16	Неисправность проводки для скорости левого колеса
38-17	Пониженная производительность исполнительного механизма наклона
38-18	Пониженная производительность исполнительного механизма подъема
38-19	Ось X левого джойстика, за верхней границей диапазона
38-20	Ось X правого джойстика, за нижней границей диапазона
38-21	Ось Y левого джойстика, за верхней границей диапазона
38-22	Ось Y правого джойстика, за верхней границей диапазона
38-23	Сигнал переднего правого датчика управления за верхней границей диапазона
38-24	Сигнал переднего левого датчика управления за верхней границей диапазона
38-25	Сигнал заднего правого датчика управления за верхней границей диапазона
38-26	Сигнал заднего левого датчика управления за верхней границей диапазона
38-27	Сигнал исполнительного механизма подъема за верхней границей диапазона
38-28	Сигнал исполнительного механизма наклона за верхней границей диапазона
38-29	Ось X левого джойстика, за нижней границей диапазона
38-30	Ось X правого джойстика, за нижней границей диапазона
38-31	Ось Y левого джойстика, за нижней границей диапазона
38-32	Ось Y правого джойстика, за нижней границей диапазона
38-33	Сигнал переднего правого датчика управления за нижней границей диапазона
38-34	Сигнал переднего левого датчика управления за нижней границей диапазона
38-35	Сигнал заднего правого датчика управления за нижней границей диапазона
38-36	Сигнал заднего левого датчика управления за нижней границей диапазона
38-37	Питание «1» 5-вольтового датчика, за нижней границей диапазона
38-38	Питание «2» 5-вольтового датчика, за нижней границей диапазона
38-39	Исполнительный механизм подъема замкнут на массу / за нижней границей диапазона
38-40	Исполнительный механизм наклона замкнут на массу / сигнал за нижней границей диапазона
38-41	Неправильное направление исполнительного механизма наклона
38-42	Неправильное направление исполнительного механизма подъема
38-43	Соленоид левого переднего привода, ошибочное включение
38-44	Соленоид левого реверсивного привода, ошибочное включение
38-45	Соленоид правого переднего привода, ошибочное включение
38-46	Соленоид правого реверсивного привода, ошибочное включение
38-47	Передний правый соленоид управления, ошибочное включение
38-48	Передний левый соленоид управления, ошибочное включение
38-49	Задний правый соленоид управления, ошибочное включение
38-50	Задний левый соленоид управления, ошибочное включение
38-51	Соленоид давления системы управления, ошибочное включение
38-52	Сигнал заднего хода, ошибочное включение
38-53	Соленоид левого переднего привода, ошибочное выключение
38-54	Соленоид левого реверсивного привода, ошибочное выключение
38-55	Соленоид правого переднего привода, ошибочное выключение
38-56	Соленоид правого реверсивного привода, ошибочное выключение
38-57	Передний правый соленоид управления выдвижением, ошибочное выключение
38-58	Передний правый соленоид управления втягиванием, ошибочное выключение
38-59	Передний левый соленоид управления выдвижением, ошибочное выключение
38-60	Передний левый соленоид управления втягиванием, ошибочное выключение
38-61	Задний правый соленоид управления выдвижением, ошибочное выключение
38-62	Задний правый соленоид управления втягиванием, ошибочное выключение
38-63	Задний левый соленоид управления выдвижением, ошибочное выключение
38-64	Задний левый соленоид управления втягиванием, ошибочное выключение
38-65	Соленоид давления системы управления, ошибочное выключение
38-66	Сигнал заднего хода, ошибочное выключение
38-67	Нет сообщений от контроллера Bobcat
38-68	Углы установки колес (выравнивание) не откалиброваны
38-69	Исполнительные механизмы подъема и наклона не откалиброваны
38-70	Отключение питания
38-71	Напряжение батареи вне допустимых пределов
38-72	Насос привода не откалиброван
38-73	Переключатель режима управления/режима движения переключился во время работы
38-74	Скорость неуправляемого правого колеса, ошибочное включение
38-75	Скорость неуправляемого левого колеса, ошибочное включение
38-76	Соленоид давления системы управления — недостаточный ток
38-77	Передний правый соленоид управления выдвижением — недостаточный ток
38-78	Передний правый соленоид управления втягиванием — недостаточный ток
38-79	Передний левый соленоид управления выдвижением — недостаточный ток
38-80	Передний левый соленоид управления втягиванием — недостаточный ток
38-81	Задний правый соленоид управления выдвижением — недостаточный ток
38-82	Задний правый соленоид управления втягиванием — недостаточный ток
38-83	Задний левый соленоид управления выдвижением — недостаточный ток
38-84	Задний левый соленоид управления втягиванием — недостаточный ток
38-85	Питание «1» 5-вольтового датчика за верхней границей диапазона
38-86	Питание «2» 5-вольтового датчика за верхней границей диапазона
38-87	Блокировка правого переднего колеса (механическая неисправность управления)
38-88	Блокировка левого переднего колеса (механическая неисправность управления)
38-89	Блокировка правого заднего колеса (механическая неисправность управления)
38-90	Ошибка заднего левого управления
38-91	Отсутствуют импульсы датчика скорости правого колеса
38-92	Отсутствуют импульсы датчика скорости левого колеса
38-93	Датчик скорости правого колеса не отвечает
38-94	Датчик скорости левого колеса не отвечает
38-98	Контроллер в режиме калибровки привода
38-99	Контроллер в режиме калибровки положения колеса
45-03	Правый указатель поворота, ошибочное выключение
46-02	Левый указатель поворота, ошибочное включение
46-03	Левый указатель поворота, ошибочное выключение
47-21	Питание 8-вольтового датчика за верхней границей диапазона
47-22	Питание 8-вольтового датчика, за нижней границей диапазона
48-02	Реле переднего света, ошибочное включение
48-03	Реле переднего света, ошибочное выключение
49-02	Реле заднего света, ошибочное включение
49-03	Реле заднего света, ошибочное выключение
60-21	Сигнал рычага управления задней доп. гидравликой за верхней границей диапазона
60-22	Сигнал рычага управления задней доп. гидравликой за нижней границей диапазона
60-23	Рычаг управления задней доп. гидравликой не возвращается в нейтральное положение
64-02	Ошибочное включение реле мощности
64-03	Ошибочное выключение реле мощности
74-72	Сбой загрузочного кода контроллера Bobcat
74-73	Левая панель, ошибка приемного устройства
80-02	ACD, выход «A», ошибочное включение
80-03	ACD, выход «A», ошибочное выключение
81-02	ACD, выход «B», ошибочное включение
81-03	ACD, выход «B», ошибочное выключение
82-02	ACD, выход «C», ошибочное включение
82-03	ACD, выход «C», ошибочное выключение
83-02	ACD, выход «D», ошибочное включение
83-03	ACD, выход «D», ошибочное выключение
84-02	ACD, выход «E», ошибочное включение
84-03	ACD, выход «E», ошибочное выключение
90-02	Сервисный выход «C», ошибочное включение
90-03	Сервисный выход «C», ошибочное выключение
91-02	Сервисный выход «D», ошибочное включение
91-03	Сервисный выход «D», ошибочное выключение
92-02	Сервисный выход «Е», ошибочное включение
92-03	Сервисный выход «Е», ошибочное выключение
93-02	Сервисный выход «F», ошибочное включение
93-03	Сервисный выход «F», ошибочное выключение

Мини-погрузчики – это отличная основа для различного навесного оборудования, разновидностей которого насчитывается около 40 приспособлений. При этом замена агрегатов составляет считанные секунды. Но любая техника нуждается в обслуживании, что и продлевает ее срок службы. Ремонт или покупка запчастей для погрузчиков Bobcat могут быть необходимы при поломках по таким причинам:

Внимание! Большая ошибка – продолжать использование техники при обнаружении проблем, появлении нехарактерных звуков.

Сервисное обслуживание

Компания Bobcat уже несколько десятилетий производит качественную, надежную и простую в эксплуатацию специализированную технику. Погрузчики сочетают в себе необходимую мощность и в то же время компактность. В таких конструкциях применяются современные системы управления, диагностики и элементы гидравлики.

Обнаружив проблемы в работе техники, необходимо воспользоваться квалифицированной помощью специалиста. При грамотном подходе можно некоторые поломки устранить самостоятельно, для этого понадобятся инструменты и необходимые запчасти для Bobcat. Компания позаботилась об ассортименте продукции и производит технику для уборки территории, погрузочных работ, для использования в сельском хозяйстве, ЖКХ и строительстве.

Важно! Для каждой модели техники предусмотрена инструкция, которую необходимо внимательно изучить.

Работа сервисных служб заключается в:

Это может быть замена технических жидкостей или вышедших из строя запчастей, ремонт отдельных узлов или навесного оборудования.

Рекомендации по эксплуатации

Одной из причин возникновения неисправностей может служить привлечение неопытного оператора, который, управляя машиной, создал неподходящий режим эксплуатации для техники. При управлении погрузчиком не может быть абсолютно всегда обеспечено выполнение четких стандартных действий. Возникают нештатные ситуации, в которых необходимо быстро принимать решения. Если они неверные, то в итоге ломаются основные узлы погрузчика или дополнительное оборудование.

Важно! Перед работой необходима проверка смазки узлов в трущихся деталях Bobcat, наличия масла, заряда АКБ, уровня охлаждающей жидкости в ДВС, давления в шинах, протяжки стяжных болтов и ступичных гаек на колесах. Каждую неделю необходима продувка радиатора и воздушного фильтра.

Поломка техники может быть связана и с плохим качеством дорог, особенно при превышении рекомендованной скорости. Возникают нежелательные вибрации, толчки, которые приводят к ускоренному износу узлов ходовой части. Не выполненная вовремя смазка может привести к деформации рулевого моста.

Замена запчастей Bobcat, узлов и деталей может понадобиться при дефектах:

Периодичность технического обслуживания позволит избежать серьезных проблем. В погрузчике каждые 250 часов работы нужно менять масло в двигателе, масляный фильтр, а каждые 1000 часов выполнять замену всех технических жидкостей и фильтров.

Ремонт и обслуживание

Согласно статистике, чаще всего неисправности происходят в топливной системе. Для того чтобы этого избежать, необходимо:

В топливную систему может попадать конденсат, это происходит в сезоны резких перепадов температур. По причине воздействия влаги могут возникнуть повреждения топливного насоса высокого давления и форсунок (в дизельном погрузчике). В бензиновом для исправления ситуации перебирают и просушивают детали карбюратора и полностью меняют топливо.

Радиатор погрузчика нуждается в продувке и промывке, особенно если эксплуатация проходит в запыленных помещениях. Возможно, могут понадобиться и дополнительные приспособления для фильтрации воздуха, которые можно приобрести в магазинах, реализующих оригинальные запчасти, например, snabavto. com.

Какие еще могут возникать проблемы:

Может подойти один из способов решения:

Возможно, неисправна система охлаждения, если постоянно высокая температура масла и образуется пена.

Важно! Запрещено работать на погрузчике без тормозов до устранения неисправностей.

Справка. Все оригинальные запчасти для Bobcat можно приобрести в различных компаниях, которые являются дистрибьюторами сертифицированной продукции, например, «Снабавто».

С чем это может быть связано:

Снижение эффективности погрузчика может быть связано с неправильной эксплуатацией АКБ, чтобы этого избежать, нужно:

Техника, в том числе погрузчики «Бобкэт», будет работать долго и исправно, если использовать ее правильно и осуществлять постоянный контроль над всеми ее системами, принимая своевременные меры по устранению дефектов.

Bobcat S650 Codes

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Коды ошибок мини погрузчиков Bobcat помогут вам идентифицировать неисправный исполнительный механизм и быстрее произвести ремонт отказавшего механизма как ДВС, так и гидравлической системы

Расшифровка кодов ошибок Bobcat

КОД	ОПИСАНИЕ
01-16	Не подсоединен воздушный фильтр
01-17	Засорен воздушный фильтр
02-16	Не подсоединен гидравлический нагнетательный фильтр
02-17	Засорен гидравлический нагнетательный фильтр
03-09	Низкое напряжение аккумуляторной батареи
03-10	Высокое напряжение аккумуляторной батареи
03-11	Предельно высокое напряжение аккумуляторной батареи
03-14	Предельно низкое напряжение аккумуляторной батареи
03-22	Напряжение аккумуляторной батареи ниже предельно допустимого
04-09	Низкий уровень давления масла в двигателе
04-14	Предельно низкий уровень давления масла в двигателе
04-15	Давление масла в двигателе на уровне экстренного выключения двигателя
04-21	Давление масла в двигателе выше предельно допустимого
04-22	Давление масла в двигателе ниже предельно допустимого
05-09	Низкое давление подпитки в гидравлической системе
05-14	Предельно низкое давление подпитки в гидравлической системе
05-15	Давление подпитки в гидравлической системе на уровне экстренного выключения двигателя
05-21	Давление подпитки в гидравлической системе выше предельно допустимого
05-22	Давление подпитки в гидравлической системе ниже предельно допустимого
06-10	Высокие обороты двигателя
06-11	Предельно высокие обороты двигателя
06-13	Отсутствует сигнал оборотов двигателя
06-15	Обороты двигателя на уровне экстренного выключения двигателя
06-18	Обороты двигателя вне допустимых пределов
07-10	Высокая температура масла в гидравлической системе
07-11	Предельно высокая температура масла в гидравлической системе
07-15	Температура масла в гидравлической системе на уровне экстренного выключения двигателя
07-21	Температура масла в гидравлической системе выше предельно допустимой
07-22	Температура масла в гидравлической системе ниже предельно допустимой
08-10	Высокая температура охлаждающей жидкости двигателя
08-11	Предельно высокая температура охлаждающей жидкости двигателя
08-15	Температура охлаждающей жидкости двигателя на уровне экстренного выключения двигателя
08-21	Температура охлаждающей жидкости двигателя выше предельно допустимой
08-22	Температура охлаждающей жидкости двигателя ниже предельно допустимой
09-09	Низкий уровень топлива
09-21	Уровень топлива выше предельно допустимого
09-22	Уровень топлива ниже предельно допустимого
11-05	Датчик рамы безопасности замкнут на батарею
11-06	Датчик рамы безопасности замкнут на массу
12-21	Сигнал ШИМ-контроллера передней доп. гидравлики за верхней границей диапазона
12-22	ШИМ-контроллер передней доп. гидравлики за нижней границей диапазона
12-23	ШИМ-контроллер передней доп. гидравлики не в нейтральном положении
13-05	Удерживающий соленоид отсечки топлива замкнут на батарею
13-06	Удерживающий соленоид отсечки топлива замкнут на массу
13-07	Разрыв цепи соленоида отсечки топлива
14-02	Втягивающий соленоид отсечки топлива, ошибочное включение
14-03	Втягивающий соленоид отсечки топлива, ошибочное выключение
15-02	Втягивающий соленоид блокировки тяги, ошибочное включение
15-03	Втягивающий соленоид блокировки тяги, ошибочное выключение
16-05	Удерживающий соленоид блокировки тяги замкнут на батарею
16-06	Удерживающий соленоид блокировки тяги замкнут на массу
16-07	Разрыв цепи удерживающего соленоида блокировки тяги
17-05	Соленоид гидравлического запорного клапана замкнут на батарею
17-06	Соленоид гидравлического запорного клапана замкнут на массу
17-07	Разрыв цепи соленоида гидравлического запорного клапана
18-05	Соленоид золотника замкнут на батарею
18-06	Соленоид золотника замкнут на массу
18-07	Разрыв цепи соленоида золотника
19-02	Соленоид позиционирования ковша, ошибочное включение
19-03	Соленоид позиционирования ковша, ошибочное выключение
20-02	Соленоид переключения скоростей, ошибочное включение
20-03	Соленоид переключения скоростей, ошибочное выключение
21-02	Свечи накаливания, ошибочное включение
21-03	Свечи накаливания, ошибочное выключение
22-02	Стартер, ошибочное включение
22-03	Стартер, ошибочное выключение
23-02	Задний базовый соленоид, ошибочное включение
23-03	Задний базовый соленоид, ошибочное выключение
24-02	Задний штоковый соленоид, ошибочное включение
24-03	Задний штоковый соленоид, ошибочное выключение
25-02	Задний вспомогательный пропорциональный соленоид, ошибочное включение
25-03	Задний вспомогательный пропорциональный соленоид, ошибочное выключение
26-02	Ошибочное включение переднего базового соленоида
26-03	Ошибочное выключение переднего базового соленоида
27-02	Ошибочное включение переднего штокового соленоида
27-03	Ошибочное выключение переднего штокового соленоида
28-02	Ошибочное включение соленоида дивертера
28-03	Ошибочное выключение соленоида дивертера
29-02	Соленоид большой подачи, ошибочное включение
29-03	Соленоид большой подачи, ошибочное выключение
30-28	Отказ памяти контроллера
31-28	Неисправность режима восстановления
32-04	Расширенное управление (ACS) не сообщается с контроллером Bobcat
32-23	Расширенное управление ACS не откалибровано
32-31	Отказ исполнительного механизма наклона
32-32	Неисправность электропроводки исполнительного механизма наклона
32-33	Неисправность электропроводки рукоятки наклона ковша
32-34	Исполнительный механизм наклона не в нейтральном положении
32-35	Рукоятка / педаль наклона ковша не в нейтральном положении
32-36	Отказ исполнительного механизма подъема
32-37	Неисправность электропроводки исполнительного механизма подъема
32-38	Неисправность электропроводки рукоятки подъема стрелы
32-39	Исполнительный механизм подъема не в нейтральном положении
32-40	Рукоятка / педаль подъема стрелы не в нейтральном положении
32-41	Нет связи
32-49	Исполнительный механизм подъема замкнут на массу
32-50	Исполнительный механизм наклона замкнут на массу
32-51	Исполнительный механизм подъема замкнут на батарею
32-52	Исполнительный механизм наклона замкнут на батарею
32-53	Рукоятка / педаль подъема стрелы замкнута на массу
32-54	Рукоятка / педаль наклона ковша замкнута на массу
32-55	Рукоятка / педаль подъема стрелы замкнута на батарею
32-56	Рукоятка / педаль наклона ковша замкнута на батарею
32-57	Пониженная производительность исполнительного механизма подъема
32-58	Пониженная производительность исполнительного механизма наклона
32-59	Неправильное направление исполнительного механизма подъема
32-60	Неправильное направление исполнительного механизма наклона
32-61	Блокиратор рукояток замкнут на массу
32-62	Блокиратор рукояток замкнут на батарею
32-63	Цепь блокиратора педалей замкнута на массу
32-64	Цепь блокиратора педалей замкнута на батарею
32-65	Напряжение питания датчика вне допустимых пределов
32-66	Напряжение аккумуляторной батареи вне допустимых пределов
32-67	Переключатель переключился во время работы
32-68	Информационная ошибка рукоятки подъема стрелы
32-69	Переключатель режимов управления переключился во время работы
32-70	Цепь правой рукоятки движения замкнута на массу
32-71	Цепь правой рукоятки движения замкнута на батарею
33-23	Главный контроллер (контроллер Bobcat) не запрограммирован
34-04	Панель с кнопочным запуском не сообщается с контроллером Bobcat
35-02	Двухскоростной переключатель вентилятора, ошибочное включение
35-03	Двухскоростной переключатель вентилятора, ошибочное выключение
36-48	Подключено несколько контроллеров ACD
37-02	Двухскоростной дополнительный переключатель скоростей, ошибочное включение
37-03	Двухскоростной дополнительный переключатель скоростей, ошибочное выключение
38-04	Нет связи с контроллером джойстика
38-05	Ось Х левого джойстика не в нейтральном положении
38-06	Ось X правого джойстика не в нейтральном положении
38-07	Ось Y левого джойстика не в нейтральном положении
38-08	Ось Y правого джойстика не в нейтральном положении
38-09	Переключатель режимов управления — замыкание на батарею или на массу
38-11	Исполнительный механизм подъема не в нейтральном положении
38-12	Исполнительный механизм наклона не в нейтральном положении
38-13	Отказ исполнительного механизма подъема
38-14	Отказ исполнительного механизма наклона
38-15	Неисправность проводки управления скоростью правого колеса
38-16	Неисправность проводки для скорости левого колеса
38-17	Пониженная производительность исполнительного механизма наклона
38-18	Пониженная производительность исполнительного механизма подъема
38-19	Ось X левого джойстика, за верхней границей диапазона
38-20	Ось X правого джойстика, за нижней границей диапазона
38-21	Ось Y левого джойстика, за верхней границей диапазона
38-22	Ось Y правого джойстика, за верхней границей диапазона
38-23	Сигнал переднего правого датчика управления за верхней границей диапазона
38-24	Сигнал переднего левого датчика управления за верхней границей диапазона
38-25	Сигнал заднего правого датчика управления за верхней границей диапазона
38-26	Сигнал заднего левого датчика управления за верхней границей диапазона
38-27	Сигнал исполнительного механизма подъема за верхней границей диапазона
38-28	Сигнал исполнительного механизма наклона за верхней границей диапазона
38-29	Ось X левого джойстика, за нижней границей диапазона
38-30	Ось X правого джойстика, за нижней границей диапазона
38-31	Ось Y левого джойстика, за нижней границей диапазона
38-32	Ось Y правого джойстика, за нижней границей диапазона
38-33	Сигнал переднего правого датчика управления за нижней границей диапазона
38-34	Сигнал переднего левого датчика управления за нижней границей диапазона
38-35	Сигнал заднего правого датчика управления за нижней границей диапазона
38-36	Сигнал заднего левого датчика управления за нижней границей диапазона
38-37	Питание «1» 5-вольтового датчика, за нижней границей диапазона
38-38	Питание «2» 5-вольтового датчика, за нижней границей диапазона
38-39	Исполнительный механизм подъема замкнут на массу / за нижней границей диапазона
38-40	Исполнительный механизм наклона замкнут на массу / сигнал за нижней границей диапазона
38-41	Неправильное направление исполнительного механизма наклона
38-42	Неправильное направление исполнительного механизма подъема
38-43	Соленоид левого переднего привода, ошибочное включение
38-44	Соленоид левого реверсивного привода, ошибочное включение
38-45	Соленоид правого переднего привода, ошибочное включение
38-46	Соленоид правого реверсивного привода, ошибочное включение
38-47	Передний правый соленоид управления, ошибочное включение
38-48	Передний левый соленоид управления, ошибочное включение
38-49	Задний правый соленоид управления, ошибочное включение
38-50	Задний левый соленоид управления, ошибочное включение
38-51	Соленоид давления системы управления, ошибочное включение
38-52	Сигнал заднего хода, ошибочное включение
38-53	Соленоид левого переднего привода, ошибочное выключение
38-54	Соленоид левого реверсивного привода, ошибочное выключение
38-55	Соленоид правого переднего привода, ошибочное выключение
38-56	Соленоид правого реверсивного привода, ошибочное выключение
38-57	Передний правый соленоид управления выдвижением, ошибочное выключение
38-58	Передний правый соленоид управления втягиванием, ошибочное выключение
38-59	Передний левый соленоид управления выдвижением, ошибочное выключение
38-60	Передний левый соленоид управления втягиванием, ошибочное выключение
38-61	Задний правый соленоид управления выдвижением, ошибочное выключение
38-62	Задний правый соленоид управления втягиванием, ошибочное выключение
38-63	Задний левый соленоид управления выдвижением, ошибочное выключение
38-64	Задний левый соленоид управления втягиванием, ошибочное выключение
38-65	Соленоид давления системы управления, ошибочное выключение
38-66	Сигнал заднего хода, ошибочное выключение
38-67	Нет сообщений от контроллера Bobcat
38-68	Углы установки колес (выравнивание) не откалиброваны
38-69	Исполнительные механизмы подъема и наклона не откалиброваны
38-70	Отключение питания
38-71	Напряжение батареи вне допустимых пределов
38-72	Насос привода не откалиброван
38-73	Переключатель режима управления/режима движения переключился во время работы
38-74	Скорость неуправляемого правого колеса, ошибочное включение
38-75	Скорость неуправляемого левого колеса, ошибочное включение
38-76	Соленоид давления системы управления — недостаточный ток
38-77	Передний правый соленоид управления выдвижением — недостаточный ток
38-78	Передний правый соленоид управления втягиванием — недостаточный ток
38-79	Передний левый соленоид управления выдвижением — недостаточный ток
38-80	Передний левый соленоид управления втягиванием — недостаточный ток
38-81	Задний правый соленоид управления выдвижением — недостаточный ток
38-82	Задний правый соленоид управления втягиванием — недостаточный ток
38-83	Задний левый соленоид управления выдвижением — недостаточный ток
38-84	Задний левый соленоид управления втягиванием — недостаточный ток
38-85	Питание «1» 5-вольтового датчика за верхней границей диапазона
38-86	Питание «2» 5-вольтового датчика за верхней границей диапазона
38-87	Блокировка правого переднего колеса (механическая неисправность управления)
38-88	Блокировка левого переднего колеса (механическая неисправность управления)
38-89	Блокировка правого заднего колеса (механическая неисправность управления)
38-90	Ошибка заднего левого управления
38-91	Отсутствуют импульсы датчика скорости правого колеса
38-92	Отсутствуют импульсы датчика скорости левого колеса
38-93	Датчик скорости правого колеса не отвечает
38-94	Датчик скорости левого колеса не отвечает
38-98	Контроллер в режиме калибровки привода
38-99	Контроллер в режиме калибровки положения колеса
45-03	Правый указатель поворота, ошибочное выключение
46-02	Левый указатель поворота, ошибочное включение
46-03	Левый указатель поворота, ошибочное выключение
47-21	Питание 8-вольтового датчика за верхней границей диапазона
47-22	Питание 8-вольтового датчика, за нижней границей диапазона
48-02	Реле переднего света, ошибочное включение
48-03	Реле переднего света, ошибочное выключение
49-02	Реле заднего света, ошибочное включение
49-03	Реле заднего света, ошибочное выключение
60-21	Сигнал рычага управления задней доп. гидравликой за верхней границей диапазона
60-22	Сигнал рычага управления задней доп. гидравликой за нижней границей диапазона
60-23	Рычаг управления задней доп. гидравликой не возвращается в нейтральное положение
64-02	Ошибочное включение реле мощности
64-03	Ошибочное выключение реле мощности
74-72	Сбой загрузочного кода контроллера Bobcat
74-73	Левая панель, ошибка приемного устройства
80-02	ACD, выход «A», ошибочное включение
80-03	ACD, выход «A», ошибочное выключение
81-02	ACD, выход «B», ошибочное включение
81-03	ACD, выход «B», ошибочное выключение
82-02	ACD, выход «C», ошибочное включение
82-03	ACD, выход «C», ошибочное выключение
83-02	ACD, выход «D», ошибочное включение
83-03	ACD, выход «D», ошибочное выключение
84-02	ACD, выход «E», ошибочное включение
84-03	ACD, выход «E», ошибочное выключение
90-02	Сервисный выход «C», ошибочное включение
90-03	Сервисный выход «C», ошибочное выключение
91-02	Сервисный выход «D», ошибочное включение
91-03	Сервисный выход «D», ошибочное выключение
92-02	Сервисный выход «Е», ошибочное включение
92-03	Сервисный выход «Е», ошибочное выключение
93-02	Сервисный выход «F», ошибочное включение
93-03	Сервисный выход «F», ошибочное выключение

ПЕРЕЧЕНЬ СЛУЖЕБНЫХ КОДОВ

Служебные коды могут представлять собой слово (3) (см. рисунок) или число (4).

REPLY (ОТВЕТ) Отсутствует связь между одной или обеими приборными панелями и контроллером.
INPUT (ВВОД) Отсутствует связь между контроллером и левой приборной панелью.
CODE (КОД) Контроллер запрашивает пароль (только для панели с кнопочным запуском).
ERROR (ОШИБКА) Введен неправильный пароль (только для панели с кнопочным запуском).

01-16 Не подсоединен воздушный фильтр

01-17 Засорен воздушный фильтр

02-16 Фильтр гидравлической / гидростатической системы не подсоединен

02-17 Фильтр гидравлической / гидростатической системы подсоединен

03-09 Низкое напряжение аккумуляторной батареи

03-10 Высокое напряжение аккумуляторной батареи

03-11 Предельно высокое напряжение аккумуляторной батареи

03-14 Предельно низкое напряжение аккумуляторной батареи

03-22 Напряжение аккумуляторной батареи ниже предельно допустимого

04-09 Низкий уровень давления масла в двигателе

04-14 Предельно низкий уровень давления масла в двигателе

04-15 Давление масла в двигателе на уровне экстренного выключения двигателя

04-21 Давление масла в двигателе выше предельно допустимого

04-22 Давление масла в двигателе ниже предельно допустимого

05-09 Низкое давление подпитки в гидравлической системе

05-10 Высокое давление подпитки в гидравлической системе

05-11 Предельно высокое давление подпитки в гидравлической системе

05-14 Предельно низкое давление подпитки в гидравлической системе

05-15 Давление подпитки в гидравлической системе на уровне экстренного выключения двигателя

05-21 Давление подпитки в гидравлической системе выше предельно допустимого

05-22 Давление подпитки в гидравлической системе ниже предельно допустимого

06-10 Высокие обороты двигателя

06-11 Предельно высокие обороты двигателя

06-13 Отсутствует сигнал оборотов двигателя

06-15 Обороты двигателя на уровне экстренного выключения двигателя

06-18 Обороты двигателя вне допустимых пределов

07-10 Высокая температура масла в гидравлической системе

07-11 Предельно высокая температура масла в гидравлической системе

07-15 Температура масла в гидравлической системе на уровне экстренного выключения двигателя

07-21 Температура масла в гидравлической системе выше предельно допустимой

07-22 Температура масла в гидравлической системе ниже предельно допустимой

08-10 Высокая температура охлаждающей жидкости двигателя

08-11 Предельно высокая температура охлаждающей жидкости двигателя

08-15 Температура охлаждающей жидкости двигателя на уровне экстренного выключения двигателя

08-21 Температура охлаждающей жидкости двигателя выше предельно допустимой

08-22 Температура охлаждающей жидкости двигателя ниже предельно допустимой

09-09 Низкий уровень топлива

09-21 Уровень топлива выше предельно допустимого

09-22 Уровень топлива ниже предельно допустимого

10-17 Засорен гидравлический нагнетательный фильтр

11-05 Датчик рамы безопасности замкнут на батарею

11-06 Датчик рамы безопасности замкнут на заземление

12-21 Сигнал ШИМконтроллера передней доп. гидравлики за верхней границей диапазона

12-22 ШИМконтроллер передней доп. гидравлики за нижней границей диапазона

12-23 ШИМконтроллер передней доп. гидравлики не в нейтральном диапазона

13-05 Удерживающий соленоид отсечки топлива замкнут на батарею

13-06 Удерживающий соленоид отсечки топлива замкнут на заземление

13-07 Разрыв цепи соленоида отсечки топлива

14-02 Втягивающий соленоид отсечки топлива, ошибочное включение

14-03 Втягивающий соленоид отсечки топлива, ошибочное выключение

15-02 Втягивающий соленоид блокировки тяги, ошибочное включение

15-03 Втягивающий соленоид блокировки тяги, ошибочное выключение

16-05 Удерживающий соленоид блокировки тяги замкнут на батарею

16-06 Удерживающий соленоид блокировки тяги замкнут на заземление

16-07 Разрыв цепи удерживающего соленоида блокировки тяги

17-05 Соленоид гидравлического запорного клапана замкнут на батарею

17-06 Соленоид гидравлического запорного клапана замкнут на заземление

17-07 Разрыв цепи соленоида гидравлического запорного клапана

18-05 Соленоид золотника замкнут на батарею

18-06 Соленоид золотника замкнут на заземление

18-07 Разрыв цепи соленоида золотника

19-02 Соленоид позиционирования ковша, ошибочное включение

19-03 Соленоид позиционирования ковша, ошибочное выключение

20-02 Соленоид переключения скоростей, ошибочное включение

20-03 Соленоид переключения скоростей, ошибочное выключение

21-02 Свечи накаливания, ошибочное включение

21-03 Свечи накаливания, ошибочное выключение

22-02 Стартер, ошибочное включение

22-03 Стартер, ошибочное выключение

23-02 Задний базовый соленоид, ошибочное включение

23-03 Задний базовый соленоид, ошибочное выключение

24-02 Задний штоковый соленоид, ошибочное включение

24-03 Задний штоковый соленоид, ошибочное выключение

25-02 Задний вспомогательный пропорциональный соленоид, ошибочное включение

25-03 Задний вспомогательный пропорциональный соленоид, ошибочное выключение

26-02 Ошибочное включение переднего базового соленоида

26-03 Ошибочное выключение переднего базового соленоида

27-02 Ошибочное включение переднего штокового соленоида

27-03 Ошибочное выключение переднего штокового соленоида

28-02 Соленоид перепускного клапана, ошибочное включение

28-03 Соленоид перепускного клапана, ошибочное выключение

29-02 Соленоид большой подачи, ошибочное включение

29-03 Соленоид большой подачи, ошибочное выключение

30-28 Отказ памяти контроллера

31-28 Неисправность режима восстановления (появляется также после обновления программного обеспечения)

32-04 Расширенное управление (ACS) не сообщается с контроллером Bobcat

32-23 Требуется калибровка ACS

32-24 Выполнена калибровка ACS

32-31 Неисправность исполнительного механизма наклона ACS

32-32 Неисправность электропроводки исполнительного механизма наклона ACS

32-33 Неисправность электропроводки ручки наклона ACS

32-34 Исполнительный механизм наклона ACS не в нейтральном положении

32-35 Рукоятка / педаль наклона ковша ACS не в нейтральном положении

32-36 Неисправность исполнительного механизма подъема ACS

32-37 Неисправность электропроводки исполнительного механизма подъема ACS

32-38 Неисправность электропроводки рукоятки подъема ACS

32-39 Исполнительный механизм подъема ACS не в нейтральном положении

32-40 Рукоятка / педаль подъема ковша ACS не в нейтральном положении

32-41 ACS: нет связи

32-49 Исполнительный механизм подъема AСS замкнут на заземление

32-50 Исполнительный механизм наклона AСS замкнут на заземление

32-51 Исполнительный механизм подъема AСS замкнут на батарею

32-52 Исполнительный механизм наклона AСS замкнут на батарею

32-53 Рукоятка / педаль подъема стрелы замкнута на заземление, AСS

32-54 Рукоятка / педаль наклона стрелы замкнута на заземление, AСS

32-55 Рукоятка / педаль подъема стрелы замкнута на батарею, ACS

32-56 Рукоятка / педаль наклона стрелы замкнута на батарею, ACS

32-57 Пониженная производительность исполнительного механизма подъема ACS

32-58 Пониженная производительность исполнительного механизма наклона ACS

32-59 Неправильное направление исполнительного механизма подъема ACS

32-60 Неправильное направление исполнительного механизма подъема ACS

32-61 Цепь блокиратора рукоятки ACS замкнута на заземление

32-62 Цепь блокиратора рукоятки ACS замкнута на батарею

32-63 Цепь блокиратора педалей ACS замкнута на заземление

32-64 Цепь блокиратора педалей ACS замкнута на батарею

32-65 Напряжение питания датчика ACS вне допустимых пределов

32-66 Напряжение аккумуляторной батареи ACS ниже предельно допустимого

32-67 Переключатель ACS переключился во время работы

32-68 Информационная ошибка рукоятки подъема стрелы, ACS

32-70 Цепь правой рукоятки движения ACS замкнута на заземление

32-71 Цепь правой рукоятки движения ACS замкнута на батарею

32-74 Ось X левого джойстика ACS вне допустимых пределов

32-75 Отключение питания неотключаемого оборудования ACS

32-76 Информационная ошибка джойстика CAN, ACS

32-77 Информационная ошибка дистанционного управления, ACS

33-23 Главный контроллер (контроллер Bobcat) не запрограммирован

34-04 Панель с кнопочным запуском не сообщается с контроллером Bobcat

35-02 Ошибочное включение вентилятора гидравлики

35-03 Ошибочное выключение вентилятора гидравлики

36-48 Подключено несколько контроллеров ACD

37-02 Двухскоростной дополнительный переключатель скоростей, ошибочное включение

37-03 Двухскоростной дополнительный переключатель скоростей, ошибочное включение

38-01 Информационная ошибка джойстика CAN

38-02 Информационная ошибка дистанционного управления

38-04 Нет связи с контроллером джойстика

38-05 Ось Х левого джойстика не в нейтральном положении

38-06 Ось X правого джойстика не в нейтральном положении

38-07 Ось Y левого джойстика не в нейтральном положении

38-08 Ось Y правого джойстика не в нейтральном положении

38-09 Переключатель режимов управления замыкание на батарею или на заземление

38-10 Выполнена калибровка исполнительного механизма

38-11 Исполнительный механизм подъема не в нейтральном положении

38-12 Исполнительный механизм наклона не в нейтральном положении

38-13 Отказ исполнительного механизма подъема

38-14 Отказ исполнительного механизма наклона

38-15 Неисправность проводки управления скоростью правого колеса

38-16 Неисправность проводки для скорости левого колеса

38-17 Пониженная производительность исполнительного механизма наклона

38-18 Пониженная производительность исполнительного механизма подъема

38-19 Ось X левого джойстика за верхней границей диапазона

38-20 Ось X правого джойстика за верхней границей диапазона

38-21 Ось Y левого джойстика за верхней границей диапазона

38-22 Ось Y правого джойстика за верхней границей диапазона

38-23 Сигнал переднего правого датчика управления за верхней границей диапазона

38-24 Сигнал переднего левого датчика управления за верхней границей диапазона

38-25 Сигнал заднего правого датчика управления за верхней границей диапазона

38-26 Сигнал заднего левого датчика управления за верхней границей диапазона

38-27 Сигнал исполнительного механизма подъема за верхней границей диапазона

38-28 Сигнал исполнительного механизма наклона за верхней границей диапазона

38-29 Ось X левого джойстика за нижней границей диапазона

38-30 Ось X правого джойстика за нижней границей диапазона

38-31 Ось Y левого джойстика за нижней границей диапазона

38-32 Ось Y правого джойстика за нижней границей диапазона

38-33 Сигнал переднего правого датчика управления за нижней границей диапазона

38-34 Сигнал переднего левого датчика управления за нижней границей диапазона

38-35 Сигнал заднего правого датчика управления за нижней границей диапазона

38-36 Сигнал заднего левого датчика управления за нижней границей диапазона

38-37 Питание «1» 5-вольтового датчика, за нижней границей диапазона

38-38 Питание «2» 5-вольтового датчика, за нижней границей диапазона

38-39 Исполнительный механизм подъема замкнут на заземление / за нижней границей диапазона

38-40 Исполнительный механизм наклона замкнут на заземление / сигнал за нижней границей диапазона

38-41 Неправильное направление исполнительного механизма наклона

38-42 Неправильное направление исполнительного механизма подъема

38-43 Соленоид левого переднего привода, ошибочное включение

38-44 Соленоид левого реверсивного привода, ошибочное включение

38-45 Соленоид правого переднего привода, ошибочное включение

38-46 Соленоид правого реверсивного привода, ошибочное включение

38-47 Передний правый соленоид управления, ошибочное включение

38-48 Передний левый соленоид управления, ошибочное включение

38-49 Задний правый соленоид управления, ошибочное включение

38-50 Задний левый соленоид управления, ошибочное выключение

38-51 Соленоид давления системы управления, ошибочное включение

38-52 Сигнал заднего хода, ошибочное включение

38-53 Соленоид левого переднего привода, ошибочное выключение

38-54 Соленоид левого реверсивного привода, ошибочное выключение

38-55 Соленоид правого переднего привода, ошибочное выключение

38-56 Соленоид правого реверсивного привода, ошибочное выключение

38-57 Передний правый соленоид управления выдвижением, ошибочное выключение

38-58 Передний правый соленоид управления втягиванием, ошибочное выключение

38-59 Передний левый соленоид управления выдвижением, ошибочное выключение

38-60 Передний левый соленоид управления втягиванием, ошибочное выключение

38-61 Задний правый соленоид управления выдвижением, ошибочное выключение

38-62 Задний правый соленоид управления втягиванием, ошибочное выключение

38-63 Задний левый соленоид управления выдвижением, ошибочное выключение

38-64 Задний левый соленоид управления втягиванием, ошибочное выключение

38-65 Соленоид давления системы управления, ошибочное выключение

38-66 Сигнал заднего хода, ошибочное выключение

38-67 Нет сообщений от контроллера Bobcat

38-68 Углы установки колес (выравнивание) не откалиброваны

38-69 Неисправность калибровки исполнительных механизмов подъема и наклона

38-70 Неисправность режима восстановления диапазона

38-71 Напряжение батареи вне допустимых пределов

38-72 Насос привода не откалиброван

38-73 Переключатель режима управления переключился во время работы

38-74 Неуправляемая скорость вращения правого колеса

38-75 Неуправляемая скорость вращения левого колеса

38-76 Соленоид давления системы управления недостаточный ток

38-77 Передний правый соленоид управления выдвижением недостаточный ток

38-78 Передний правый соленоид управления втягиванием недостаточный ток

38-79 Передний левый соленоид управления выдвижением недостаточный ток

38-80 Передний левый соленоид управления втягиванием недостаточный ток

38-81 Задний правый соленоид управления выдвижением недостаточный ток

38-82 Задний правый соленоид управления втягиванием недостаточный ток

38-83 Задний левый соленоид управления выдвижением недостаточный ток

38-84 Задний левый соленоид управления втягиванием недостаточный ток

38-85 Питание «1» 5-вольтового датчика за верхней границей диапазона

38-86 Питание «2» 5-вольтового датчика за верхней границей диапазона

38-87 Неисправность переднего правого рулевого устройства за нижней границей диапазона

38-88 Неисправность переднего левого рулевого устройства

38-89 Неисправность заднего правого рулевого устройства

38-90 Ошибка заднего левого управления

38-91 Отсутствуют импульсы датчика скорости правого колеса

38-92 Отсутствуют импульсы датчика скорости левого колеса

38-93 Датчик скорости правого колеса не отвечает

38-94 Датчик скорости левого колеса не отвечает

38-95 Изменение направления в датчике скорости левого колеса

38-96 Изменение направления в датчике скорости правого колеса

38-98 Контроллер в режиме калибровки привода

38-99 Контроллер в режиме калибровки положения колеса

39-04 Левый джойстик не имеет связи с контроллером Bobcat

39-05 Ось Х не в нейтральном положении

39-07 Ось Y не в нейтральном положении

39-12 Манипулятор переключатель левого джойстика не в нейтральном положении

39-13 Не подсоединена ручка левого джойстика выключение

39-16 Не подсоединен левый джойстик выключение

39-28 Внутренняя неисправность левого джойстика

39-48 Левый джойстик, многорежимный

40-04 Правый джойстик не имеет связи с контроллером Bobcat

40-05 Ось X правого джойстика не в нейтральном положении

40-07 Ось Y правого джойстика не в нейтральном положении

40-12 Манипулятор переключатель правого джойстика не в нейтральном положении

40-13 Не подсоединена ручка правого джойстика

40-16 Не подсоединен правый джойстик

40-28 Внутренняя неисправность правого джойстика

40-48 Правый джойстик, многорежимный

41-09 Низкое напряжение генератора

41-10 Высокое напряжение генератора

41-11 Предельно высокое напряжение генератора

44-02 Звуковой сигнал, ошибочное включение

44-03 Звуковой сигнал, ошибочное выключение

45-02 Правый указатель поворота, ошибочное включение

45-03 Правый указатель поворота, ошибочное выключение

46-02 Левый указатель поворота, ошибочное включение

46-03 Левый указатель поворота, ошибочное выключение

47-21 Питание 8вольтового датчика за верхней границей диапазона

47-22 Питание 8вольтового датчика, за нижней границей диапазона

48-02 Реле переднего света, ошибочное включение

48-03 Реле переднего света, ошибочное выключение

49-02 Реле заднего света, ошибочное включение

49-03 Реле заднего света, ошибочное выключение

60-21 Сигнал рычага управления задней доп. гидравликой за верхней границей диапазона

60-22 Сигнал рычага управления задней доп. гидравликой за нижней границей диапазона

60-23 Рычаг управления задней доп. гидравликой не в нейтральном положении

64-02 Ошибочное включение реле мощности

64-03 Ошибочное выключение реле мощности

73-04 Неисправность дистанционного управления

73-13 Дистанционное управление отсутствует сигнал

74-72 Сбой загрузочного кода контроллера Bobcat

75-01 Информационная ошибка джойстика CAN

75-04 Нет связи с контроллером привода

75-05 Ось Х левого джойстика не в нейтральном положении

75-07 Ось Y левого джойстика не в нейтральном положении

75-08 Ось Y правого джойстика не в нейтральном положении

75-09 Переключатель режимов ISO / H замыкание на батарею или на заземление

75-13 Заклинило датчик угла правого переднего колеса

75-14 Заклинило датчик угла левого переднего колеса

75-15 Заклинило датчик угла правого заднего колеса

75-16 Заклинило датчик угла левого заднего колеса

75-17 Левая наклонная пластина не в нейтральном положении

75-18 Правая наклонная пластина не в нейтральном положении

75-19 Ось X левого джойстика за верхней границей диапазона

75-21 Ось Y левого джойстика за верхней границей диапазона

75-22 Ось Y правого джойстика за верхней границей диапазона

75-23 Сигнал датчика угла правого переднего колеса за верхней границей диапазона

75-24 Сигнал датчика угла левого переднего колеса за верхней границей диапазона

75-25 Сигнал датчика угла правого заднего колеса за верхней границей диапазона

75-26 Сигнал датчика угла левого заднего колеса за верхней границей диапазона

75-27 Смещение левой наклонной пластины

75-28 Смещение правой наклонной пластины

75-29 Ось X левого джойстика за нижней границей диапазона

75-31 Ось Y левого джойстика за нижней границей диапазона

75-32 Ось Y правого джойстика за нижней границей диапазона

75-33 Сигнал датчика угла правого переднего колеса за нижней границей диапазона

75-34 Сигнал датчика угла левого переднего колеса за нижней границей диапазона

75-35 Сигнал датчика угла правого заднего колеса за нижней границей диапазона

75-36 Сигнал датчика угла левого заднего колеса за нижней границей диапазона

75-37 Питание «1» 5-вольтового датчика, за нижней границей диапазона

75-38 Питание датчика 2 за нижней границей диапазона

75-39 Сигнал датчика левой наклонной пластины за верхней границей диапазона

75-40 Сигнал датчика левой наклонной пластины за нижней границей диапазона

75-41 Сигнал датчика правой наклонной пластины за верхней границей диапазона

75-42 Сигнал датчика правой наклонной пластины за нижней границей диапазона

75-43 Соленоид левого переднего привода, ошибочное включение

75-44 Соленоид левого реверсивного привода, ошибочное включение

75-45 Соленоид правого переднего привода, ошибочное включение

75-46 Соленоид правого реверсивного привода, ошибочное включение

75-47 Передний правый соленоид управления выдвижением замкнут на батарею

75-48 Передний левый соленоид управления выдвижением замкнут на батарею

75-49 Задний правый соленоид управления выдвижением замкнут на батарею

75-50 Задний левый соленоид управления выдвижением замкнут на батарею

75-51 Соленоид давления системы управления замкнут на батарею

75-52 Сигнал заднего хода, ошибочное включение

75-53 Соленоид левого переднего привода, ошибочное выключение

75-54 Соленоид левого реверсивного привода, ошибочное выключение

75-55 Соленоид правого переднего привода, ошибочное выключение

75-56 Соленоид правого реверсивного привода, ошибочное выключение

75-57 Передний правый соленоид управления выдвижением замкнут на заземление

75-58 Передний правый соленоид управления втягиванием замкнут на заземление

75-59 Передний левый соленоид управления выдвижением замкнут на заземление

75-60 Передний левый соленоид управления втягиванием замкнут на заземление

75-61 Задний правый соленоид управления выдвижением замкнут на заземление

75-62 Задний правый соленоид управления втягиванием замкнут на заземление

75-63 Задний левый соленоид управления выдвижением замкнут на заземление

75-64 Задний левый соленоид управления втягиванием замкнут на заземление

75-65 Соленоид давления системы управления замкнут на заземление

75-66 Сигнал заднего хода, ошибочное выключение

75-67 Нет сообщений от контроллера Bobcat

75-68 Датчики угла не откалиброваны

75-69 Напряжение аккумуляторной батареи выше предельно допустимого

75-70 Неисправность режима восстановления (появляется также после обновления программного обеспечения)

75-71 Напряжение аккумуляторной батареи ниже предельно допустимого

75-72 Насос привода не откалиброван

75-73 Переключатель режимов ISO / H переключился во время работы

75-74 Неуправляемая скорость вращения правого колеса

75-75 Неуправляемая скорость вращения левого колеса

75-76 Нет сообщений от контроллера ACS

75-77 Сигнал датчика скорости левого колеса за верхней границей диапазона

75-78 Сигнал датчика скорости правого колеса за верхней границе диапазона

75-79 Сигнал датчика скорости левого колеса за нижней границей диапазона

75-80 Сигнал датчика скорости правого колеса за нижней границе диапазона

75-81 Передний правый соленоид управления втягиванием замкнут на батарею

75-82 Передний левый соленоид управления втягиванием замкнут на батарею

75-83 Задний правый соленоид управления втягиванием замкнут на батарею

75-84 Задний левый соленоид управления втягиванием замкнут на батарею

75-85 Питание «1» 5-вольтового датчика за верхней границей диапазона

75-86 Питание датчика 2 за верхней границей диапазона

75-88 Контроллер в режиме программирования

75-91 Изменение полярности датчика левой наклонной пластины

75-92 Изменение полярности датчика правой наклонной пластины

75-93 Датчик скорости правого колеса не отвечает

75-94 Датчик скорости левого колеса не отвечает

75-95 Изменение направления в датчике скорости левого колеса

75-96 Изменение направления в датчике скорости правого колеса

75-98 Контроллер в режиме калибровки

76-73 Левая панель, ошибка приемного устройства

77-48 Замок зажигания, многорежимный

78-74 Дверной / блокировочный замок открыт / включен

80-02 ACD, выход «A», ошибочное включение

80-03 ACD, выход «A», ошибочное выключение

81-02 ACD, выход «B», ошибочное включение

81-03 ACD, выход «B», ошибочное выключение

82-02 ACD, выход «C», ошибочное включение

82-03 ACD, выход «C», ошибочное выключение

83-02 ACD, выход «D», ошибочное включение

83-03 ACD, выход «D», ошибочное выключение

84-02 ACD, выход «E», ошибочное включение

84-03 ACD, выход «E», ошибочное выключение

85-02 ACD (устройство управления навесным оборудованием), выход «F», ошибочное включение

85-03 ACD, выход «F», ошибочное выключение

86-02 ACD, выход «G», ошибочное включение

86-03 ACD, выход «G», ошибочное выключение

87-02 ACD, выход «H», ошибочное включение

87-03 ACD, выход «H», ошибочное выключение

90-02 Сервисный выход «C», ошибочное включение

90-03 Сервисный выход «C», ошибочное выключение колеса

91-02 Сервисный выход «D», ошибочное включение

91-03 Сервисный выход «D», ошибочное выключение

92-02 Сервисный выход «Е», ошибочное включение

92-03 Сервисный выход «Е», ошибочное выключение

93-02 Сервисный выход «F», ошибочное включение

93-03 Сервисный выход «F», ошибочное выключение

1-1 S650 Service Manual
MAINTENANCE SAFETY
Never service the Bobcat Skid-
Steer Loader without instructions.
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.
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.
Disconnecting or loosening any
hydraulic tubeline, hose, fitting,
component or a part failure can
cause lift arms to drop. Do not go
under lift arms when raised
unless supported by an
approved lift arm support device.
Replace it if damaged.
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.
Never work on loader with lift
arms up unless lift arms are held
by an approved lift arm support
device. Replace if damaged.
Never modify equipment or add
attachments not approved by
Bobcat Company.
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.
Use the correct procedure to lift or
lower operator cab.
Cleaning and maintenance are
required daily.
MSW35-0409
WRONG
B-6589
P-90216
CORRECT
NA1204
CORREC
T
NA1193
CORRECT
NA1206
WRONGWRONG
NA1205
WRONG
NA1192
NA1200
WRONG
WRONG
NA1191
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
instructions can cause injury or death.
W-2003-0807
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.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
1-2 S650 Service Manual
1-3 S650 Service Manual
CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
1-4 S650 Service Manual
1-5 S650 Service Manual
FOREWORD
FOREWORD  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Hydraulic System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fueling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Starting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Spark Arrestor Exhaust System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SERIAL NUMBER LOCATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DELIVERY REPORT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-6 S650 Service Manual
1-7 S650 Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
FW SSL-1008 SM
1. Check that the ROPS/FOPS
(Including side screens) is in
good condition and is not
modified.
9. The parking brake must
function correctly.
2. Check that ROPS mounting
hardware is tightened and is
Bobcat approved.
10. Enclosure door latches must
open and close freely.
3. The seat belt must be
correctly installed, functional
and in good condition.
11. Bob-Tach 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 device,
replace if damaged.
13. Check for correct function of
indicator lamps.
6. Machine signs (decals) must
be legible and in the correct
location.
14. Check hydraulic fluid level,
engine oil level and fuel
supply.
7. Steering levers, hand controls
and foot pedals must return to
neutral (as applicable).
15. Inspect for fuel, oil or
hydraulic fluid leaks.
8. Check for correct function of
the work lights.
16. Lubricate the loader.
SAFETY &
ENGINE
HYDRAULIC
1-8 S650 Service Manual
FW SSL-1008 SM
17. Check the condition of the
battery and cables.
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.
22. Check for any field
modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
1-9 S650 Service Manual
FW SSL-1008 SM
1-10 S650 Service Manual
SAFETY INSTRUCTIONS
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
instructions can cause injury or death.
W-2003-0903
IMPORTANT
This notice identifies procedures which must be
followed to avoid damage to the machine.
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
The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
• 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.
• The AEM Safety Manual delivered with the machine
gives general safety information.
• The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
available through your local dealer or at
www.training.bobcat.com or www.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 www.training.bobcat.com
or  www.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 www.training.bobcat.com
or www.bobcat.com.
SI SSL-1008 SM
This symbol with a warning statement means:
“Warning, be alert! Your safety is involved!”
Carefully read the message that follows.
Safety Alert Symbol
1-11 S650 Service Manual
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.
Call Before You Dig
Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
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.
SI SSL-1008 SM
1-12 S650 Service Manual
FIRE PREVENTION
Maintenance
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.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating.
All fuels, most lubricants and some coolants mixtures are
flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire.
Operation
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material,
explosive dust or gases.
Electrical
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use
the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
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.
Always clean fluid spills. Do not use gasoline or diesel
fuel for cleaning parts. Use commercial nonflammable
solvents.
Fueling
Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
sparks. Fill the fuel tank outdoors.
Starting
Do not use ether or starting fluids on any engine that has
glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrestor Exhaust System
The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to
make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
SI SSL-1008 SM
1-13 S650 Service Manual
FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect
the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.
Have good ventilation when grinding or welding painted
parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as
hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1008 SM
1-14 S650 Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader when
requesting service information or when ordering parts.
Early 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. 
Loader Serial Number
Figure 1
The loader serial number plate (Item 1) [Figure 1] is
located on the outside of the loader frame.
Figure 2
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.
Engine Serial Number
Figure 3
The engine serial number is located on the side of the
engine (Item 1) [Figure 3] behind the alternator.
P-90537
1
P-90175
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine
Combination
P-90466
1
1-15 S650 Service Manual
DELIVERY REPORT
Figure 4
The delivery report [Figure 4] must be completed by the
dealer and signed by the owner or operator when the
Bobcat loader is delivered. An explanation of the form
must be given to the owner.
B-16315
1-16 S650 Service Manual
LOADER IDENTIFICATION
[1] Optional or Field Accessory. (Not Standard Equipment).
[2] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[3] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator cab as shown.
Extra insulated cab is available as an option (Reduced noise level).
[4] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.
FRONT
LIGHTS
GRAB
HANDLES
OPERATOR SEAT
with SEAT BELT 
AND SEAT BAR
TILT
CYLINDERS
[2] BUCKET
STEP
[1] REAR AUXILIARY 
QUICK COUPLERS
LIFT ARM
[4] TIRES
REAR
GRILLE
BUCKET
STEPS
FRONT AUXILIARY
QUICK COUPLERS
TAIL LIGHT
REAR
DOOR
REAR
LIGHT
[3] OPERATOR CAB
(ROPS AND FOPS)
NA1667
NA1668
LIFT
CYLINDER
LIFT ARM
SUPPORT DEVICE
OPERATION & 
MAINTENANCE 
MANUAL AND 
OPERATOR’S 
HANDBOOK
BACK-UP 
ALARM
10-01 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
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-1
Raising  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-2
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-3
Cab Door Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-4
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-30-4
Special Applications Kit Inspection And Maintenance  . . . . . . . . . . . . . . . . . . . . . . .  10-30-4
TRANSPORTING LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-40-1
Fastening  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-50-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-50-1
REMOTE START TOOL KIT-MEL1563  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-60-1
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-60-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-60-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . .  10-61-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-61-1
Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-61-2
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-61-3
Computer Service Tool Harness - 6689746  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-61-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-61-5
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-70-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-70-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-80-1
ENGINE COOLING SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-90-1
Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-90-1
Cleaning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-90-3
Removing And Replacing Coolant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-90-3
10-02 S650 Service Manual
FUEL SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-1
Fuel Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-2
Fuel Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-100-3
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Checking And Adding Engine Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Engine Oil Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Removing And Replacing Oil And Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . .  10-120-4
Removing And Replacing Hydraulic Charge Filter  . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-6
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-120-7
FINAL DRIVE TRANSMISSION (CHAINCASE)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-130-1
Checking And Adding Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-130-1
Removing And Replacing Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-140-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-140-1
BOB-TACH (POWER)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-141-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-141-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-150-1
Lubrication Locations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-150-1
TIRE MAINTENANCE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-160-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-170-1
Cleaning Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-180-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-180-1
LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-190-1
Storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-190-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . .  10-200-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-200-1
10-03 S650 Service Manual
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-210-1
External Access  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-210-1
Rear Window  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-210-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-210-1
SEAT BELT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-220-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-220-1
10-04 S650 Service Manual
10-10-1 S650 Service Manual
LIFTING AND BLOCKING THE LOADER
Procedure
Figure 10-10-1
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
Always park the loader on a level surface.
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
Figure 10-10-2
Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-2].
NOTE: Make sure the jackstands do not touch the
tires. Make sure tires clear floor or any
obstacles.
Figure 10-10-3
Lift the rear of the loader and install jack stands [Figure
10-10-3].
B-7023A
P-85985
P-90556
P-85425
10-10-2 S650 Service Manual
10-20-1 S650 Service Manual
LIFT ARM SUPPORT DEVICE
Installing
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
DANGER
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. (See Removal And
Installation on Page 50-40-1.) OR (See Removal And
Installation on Page 50-41-1.)
Figure 10-20-1
Put jackstands under the rear corners of the loader frame
(Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-
20-1] from the storage position.
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
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. 
P-90566
P-85463A
1
P-90567
10-20-2 S650 Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D)
Installing (Cont’d)
Figure 10-20-3
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].
Removing
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.
Start the engine and raise the lift arms all the way up.
Have a second person remove the lift arm support
device.
Lower the lift arms all the way and stop the engine.
Return the lift arm support device to the storage position
and secure with clamping knobs.
Remove the jackstands.
P100005
P100005A
10-30-1 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.
Check the ROPS / FOPS cab, mounting and hardware for
damage. Never modify the ROPS / FOPS cab. Replace
the cab and hardware if damaged. See your Bobcat
dealer for parts.
ROPS / FOPS - Roll Over Protective Structure per ISO
3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
Level I
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.
Level II
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
forestry.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
10-30-2 S650 Service Manual
OPERATOR CAB (CONT'D)
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
Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Figure 10-30-2
Remove the nuts and washers [Figure 10-30-2] (both
sides) at the front corners of the operator cab.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT 
MOVEMENT CAUSED BY CAB CONTACT WITH 
CONTROLS CAN CAUSE SERIOUS 
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3
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-85463A
Hardware Removed
P-90511A
P-90512A
Hardware Installed
P-90564A
10-30-3 S650 Service Manual
OPERATOR CAB (CONT'D)
Lowering
Always stop the engine before raising or lowering the
operator cab.
NOTE: Always use the grab handles to lower the
operator cab.
Figure 10-30-4
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.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT 
MOVEMENT CAUSED BY CAB CONTACT WITH 
CONTROLS CAN CAUSE SERIOUS 
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped 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.
WARNING
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
Install the washers and nuts (both sides) [Figure 10-30-
5].
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
P-90565A
N-20120
Hardware Installed
P-90512A
P-90511A
Hardware Removed
10-30-4 S650 Service Manual
OPERATOR CAB (CONT’D)
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
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.
A decal is located on the latch mechanism (Item 2)
[Figure 10-30-6].
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]
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.
Figure 10-30-7
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]
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.
[DOOR] will appear in the data display [Figure 10-30-7].
Special Applications Kit
WARNING
AVOID INJURY OR DEATH
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-8
Available for special applications to restrict material from
entering cab openings. Kit includes 1/2 inch thick
polycarbonate front door and polycarbonate rear window
[Figure 10-30-8].
Polycarbonate top window (standard item) must be
installed for special applications to restrict material from
entering cab openings.
See your Bobcat dealer for availability.
Special Applications Kit Inspection And Maintenance
• Inspect for cracks or damage. Replace if required.
• Pre-rinse 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.
3
P-68116
P-68115
2
1
S3999A
NA1026
10-40-1 S650 Service Manual
TRANSPORTING LOADER ON A TRAILER
Loading And Unloading
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
Be sure the transport and towing vehicles are of
adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1].
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.
Fastening
Figure 10-40-2
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.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.
P-90560A
1
P-90561A
P-85615A
Rear Tie Down
P-85616A
Front Tie Down
P-85466
P-85717A
Alternate Rear Tie Down
P-85599A
Alternate Front Tie Down
10-40-2 S650 Service Manual
10-50-1 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.
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)
10-50-2 S650 Service Manual
10-60-1 S650 Service Manual
REMOTE START TOOL KIT-MEL1563
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps
are:
MEL1563 - Remote Start Tool
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-60-1
The remote start tool (Item 1) [Figure 10-60-1] is
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics.
Figure 10-60-2
The traction lock switch (Item 1) [Figure 10-60-2] is used
to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
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 checking 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.
P16114
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P16117
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2
3
10-60-2 S650 Service Manual
REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Control - MEL1565
Figure 10-60-3
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-3] to
the electrical system on the loader.
Figure 10-60-4
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.
Figure 10-60-5
Loaders equipped with an attachment harness (Item 1)
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Connect the service tool harness to the ACD connector
and the loader harness connector.
NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool.
P16114
2
1
P-85729
1
P-85728
1
2
10-60-3 S650 Service Manual
REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566
Figure 10-60-6
The service tool harness communicator (Item 1) is
required to connect remote start tool to the Service PC
(Item 2) [Figure 10-60-6].
Remote Start Procedure
The tool listed will be needed to do the following
procedure:
MEL1563: Remote Start Tool Kit
Figure 10-60-7
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.
P16119
1
2
P16115
1
10-60-4 S650 Service Manual
REMOTE START TOOL KIT-MEL1563 (CONT’D)
Remote Start Procedure (Cont'd)
Figure 10-60-8
Figure 10-60-9
Remove the cap (Item 1) [Figure 10-60-8].
OR
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped).
Figure 10-60-10
Figure 10-60-11
Connect the remote start tool to the engine harness
connector (Item 1) [Figure 10-60-10].
OR 
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).
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.
P-85729
1
P-85728
1
P-85728
1
P-85726
1
2
10-60-5 S650 Service Manual
REMOTE START TOOL KIT-MEL1563 (CONT'D)
Remote Start Procedure (Cont'd)
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-12
The remote start tool (Item 1) [Figure 10-60-12] has
three rocker switches.
Figure 10-60-13
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 checking pressures and flow rate.
NOTE: With the engine running; pushing and holding
the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
WARNING
AVOID INJURY OR DEATH
• Use traction lock override switch for service work
with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209
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P16118
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10-60-6 S650 Service Manual
REMOTE START TOOL KIT-MEL1563 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-60-14
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].
P-85311
10-61-1 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031
Description
The Remote Start Tool (Service Tool) Kit is a
replacement tool for MEL 1563 Remote Start Tool and
MEL 1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,
can be used to service newer loaders using the supplied
harness P/N 6689747. 
A computer can be connected to the Remote Start Tool
(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.
10-61-2 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Remote Start Tool (Service Tool) - 7003030
Tools that will be needed to complete the following steps
are:
Order from Bobcat Parts P/N: 7003031 - Remote Start
Tool (Service Tool) Kit
Kit Includes:
7003030 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness 
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
Figure 10-61-1
The remote start tool (Item 1) [Figure 10-61-1] is
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics.
Figure 10-61-2
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-2] has five buttons.
The STOP button (Item 2) [Figure 10-61-2] is used to
stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine. 
The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to
indicate the service tool is active.
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine. 
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 checking pressures and flow rate.
P-76678
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5
6
4
3
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10-61-3 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Loader Service Tool Harness - 6689747
Figure 10-61-3
The loader service tool harness (Item 1) [Figure 10-61-3]
is used to connect the remote start tool (service tool)
(Item 2) [Figure 10-61-3] to the electrical system on the
loader.
Figure 10-61-4
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).
Figure 10-61-5
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].
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].
P-76678
2
1
P-85729
1
P-85725
1
2
10-61-4 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-
6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector
(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The key switch must be in the off position or
the Remote Start Tool (Service Tool) will not
operate.
WARNING
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
Computer Service Tool Harness - 6689746
Figure 10-61-7
The computer service tool harness (Item 1) [Figure 10-
61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
P-85726
1
2
3
P-76450
1
2
10-61-5 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Remote Start Procedure
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
The tool listed will be needed to do the following
procedure:
7003031: Remote Start Tool (Service Tool) Kit
Figure 10-61-8
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-8] is required when the operator cab is in the raised
position for service and the service technician needs to
turn on the loader or start the engine. Example: adjusting
the steering linkage.
Lift and block the loader. 
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device. 
Raise the operator cab (if required by the procedure). 
Open the rear door of the loader.
Figure 10-61-9
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
Loaders with an attachment control harness (7 pin or 14
pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
10-61-10].
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
harness.
P-76450
1
P-85729
1
P-85725
1
2
10-61-6 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-61-11
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 10-61-
11] 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.
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
Figure 10-61-12
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-12] has five buttons.
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 ignition power. 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 checking pressures and flow rate.
P-85726
1
2
3
P-76439
2
5
6
4
3
1
10-61-7 S650 Service Manual
REMOTE START TOOL (SERVICE TOOL) KIT - 
7003031 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-61-13
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. 
Figure 10-61-14
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
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P-85311
10-61-8 S650 Service Manual
10-70-1 S650 Service Manual
SERVICE SCHEDULE
Chart
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.
[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Perform at first 500 hours, then as scheduled.
[5] Or every 12 months.
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED
8-10 50 100
[5]
250
[5]
500
[5]
1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and 
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and 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 multi-purpose lithium based grease.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM 
pressure shown on the sidewall of the tire. 
Seat Bar, Control Interlocks, Seat 
Belt, Seat Belt Retractors
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. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or 
safety treads that are damaged or worn.
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.
Heater and A/C Filters 
(If Equipped)
Clean or replace filters as needed.
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Final Drive Trans. (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. (See TIRE 
MAINTENANCE in this manual.)
[1]
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop.
[2]
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.
[2] [3]
Hydraulic / Hydrostatic Filter, 
Charge Filter, Reservoir Breather
Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir 
breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves.
[4]
Coolant Replace the coolant Every 2 years
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
instructions can cause injury or death.
W-2003-0903
10-70-2 S650 Service Manual
10-80-1 S650 Service Manual
AIR CLEANER SERVICE
Replacing Filter Elements
Figure 10-80-1
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.
Outer Filter
Figure 10-80-2
Open the latches (Item 1) and remove the dust cover
(Item 2) [Figure 10-80-2].
Figure 10-80-3
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 new filter element. Push all the way in until it
contacts the base of the housing.
Install the dust cover and secure the latches [Figure 10-
80-2].
P-76460G
1
2
3
P100072
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1
P-90523A
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10-80-2 S650 Service Manual
AIR CLEANER SERVICE (CONT’D)
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].
Figure 10-80-4
Remove the inner filter element (Item 1) [Figure 10-80-
4].
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].
Figure 10-80-5
Install the dust cover (Item 2) and secure the latches
(Item 1) [Figure 10-80-5].
P-90524A
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P100072
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1
10-90-1 S650 Service Manual
ENGINE COOLING SYSTEM
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.
Maintenance Platform
Figure 10-90-1
A maintenance platform (Item 1) [Figure 10-90-1] is
available from your Bobcat dealer 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
Cleaning
Open the rear door. (See REAR DOOR (TAILGATE) on
Page 50-70-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.)
Loaders With Air Conditioning
Figure 10-90-2
Use low air pressure or water pressure to clean the top of
the air conditioning condenser (Item 1) [Figure 10-90-2].
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 10-90-2].
Figure 10-90-3
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. 
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 10-90-3].
Lower the air conditioning condenser (Item 1) [Figure
10-90-3]. Install the brackets (Item 3) [Figure 10-90-2]
and the bolts (Item 2) [Figure 10-90-2].
P100040A
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2
2
P100056A
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10-90-2 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Cleaning (Cont’d)
Loaders Without Air Conditioning
Figure 10-90-4
Use low air pressure or water pressure to clean the top of
the oil cooler (Item 1) [Figure 10-90-4].
All Loaders
Unhook the two rubber straps (Item 2) [Figure 10-90-4].
Figure 10-90-5
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into place to support the oil cooler. Use low air pressure
or water pressure to clean the top of the radiator (Item 3)
[Figure 10-90-5].
Raise the bar (Item 2) [Figure 10-90-5] 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.
P100181
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P100179
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10-90-3 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Checking Level
Open the rear door and raise the rear grille.
Figure 10-90-6
Check coolant level using the level markers (Item 2)
[Figure 10-90-6] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
hot.
Lower the rear grille and close the rear door.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
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.
I-2124-0497
Removing And Replacing Coolant
For the service interval for replacing the engine
coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door and remove the rear grille.
Remove the coolant fill cap (Item 1) [Figure 10-90-6].
Figure 10-90-7
Disconnect the coolant hose (Item 1) [Figure 10-90-7]
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-10-4.)
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.
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
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 10-90-6].
Use a refractometer to check the condition of propylene
glycol in your cooling system and install coolant fill cap.
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.
P-90529A
2
1
P-85606
1
10-90-4 S650 Service Manual
10-100-1 S650 Service Manual
FUEL SYSTEM
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures:
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
must be used in this machine:
The following fuels may also be used in this machine:
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
Biodiesel Blend Fuel
Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
• 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.
Apply the following guidelines if biodiesel blend fuel is
used:
• Ensure the fuel tank is as full as possible at all times
to prevent moisture from collecting in the fuel tank.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before 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 does not have long term
stability and should not be stored for more
than three months.
TEMPERATURE NO. 2 NO. 1
-9°C (+15°F) 100% 0%
Down to -29°C (-20°F) 50% 50%
Below -29°C (-20°F) 0% 100%
10-100-2 S650 Service Manual
FUEL SYSTEM (CONT’D)
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.
Figure 10-100-1
Remove the fill cap (Item 1) [Figure 10-100-1].
Figure 10-100-2
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].
Install and tighten the fuel cap (Item 1) [Figure 10-100-
1].
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
P-85367
1
NA1684
WRONG
10-100-3 S650 Service Manual
FUEL SYSTEM (CONT’D)
Fuel Filter
For the service interval for removing water from, or
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water
Figure 10-100-3
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the
filter.
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 Removing Air
From The Fuel System on Page 10-100-3.)
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
Removing Air From The Fuel System
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.
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Figure 10-100-4
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.
Close the vent (Item 2) [Figure 10-100-4].
P-85508
1
2
P-85507
2
1
10-100-4 S650 Service Manual
10-110-1 S650 Service Manual
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
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.
Engine Oil Chart
Figure 10-110-2
ENGINE OIL
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE 
CRANKCASE)
TEMPERATURE RANGE ANTICIPATED BEFORE 
NEXT OIL CHANGE (DIESEL ENGINES MUST USE API 
CLASSIFICATION CI-4 OR BETTER)
[1] Synthetic Oil - Use recommendation from Synthetic
Oil Manufacturer.
Use good quality engine oil that meets API Service
Classification of CI-4 or better [Figure 10-110-2].
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.
W-2103-0508
P-85506
1
10-110-2 S650 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter
For 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.
Figure 10-110-3
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 10-
110-3].
Loosen one cover mounting bolt (Item 2) and slide the
cover (Item 3) [Figure 10-110-3] to the rear of the loader.
Figure 10-110-4
Remove the oil drain cap (Item 1) [Figure 10-110-4] from
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
Install and tighten the oil drain cap [Figure 10-110-4].
Install the cover and the cover mounting bolts [Figure
10-110-3]. Tighten all bolts.
Figure 10-110-5
Open the rear door, remove the oil filter (Item 3) [Figure
10-110-5] and clean the filter housing surface.
Use genuine Bobcat filter only.
Put oil on the new filter gasket, install the filter and hand
tighten.
Remove the oil fill cap (Item 1) [Figure 10-110-5].
Put oil in the engine. For the correct quantity (See
Capacities on Page SPEC-10-4.) Do not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 2) [Figure 10-110-5] 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
P-90497A
P-90499A
3
2
1
P-90498A
1
P-85506
1
2
3
10-120-1 S650 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
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 Bob-
Tach fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1]. Keep the fluid level within the operating range.
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.)
Figure 10-120-2
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 (Item 1) [Figure 10-120-1].
Install the fill cap (Item 1) [Figure 10-120-2] and install
the rear grille.
Hydraulic / Hydrostatic Fluid Chart
Figure 10-120-3
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
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.)
Use only recommended fluid in the hydraulic system
[Figure 10-120-3]. (See Hydraulic System on Page
SPEC-10-3.) 
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
P-90538A
1
P100055
1
10-120-2 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE
SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after
major repair.
Always replace the hydraulic / hydrostatic filter and the
hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.)
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.)
Figure 10-120-4
Remove the hydraulic fill cap (Item 1) and unhook the
two rubber straps (Item 2) [Figure 10-120-4].
Figure 10-120-5
Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into place to support the oil cooler. This
will aid in draining the hydraulic fluid.
Figure 10-120-6
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
1
P100055
P100179
1
2
P100007
1
10-120-3 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-120-7
Pinch off and disconnect the hose (Item 1) [Figure 10-
120-7] from the cooling fan motor. Route the hose out the
side of the loader and drain the fluid into a container.
Connect the hose to the cooling fan motor when the fluid
stops draining.
Recycle or dispose of used fluid in an environmentally
safe manner.
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
Install the side access cover.
Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps.
Figure 10-120-8
Remove and clean the hydraulic fill screen (Item 1)
[Figure 10-120-8]. Use low air pressure to dry the
screen.
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-10-
4.) and (See Checking And Adding Fluid on Page 10-
120-1.)
Install the hydraulic fill cap.
Install the rear grille.
Start the engine and operate the loader hydraulic
controls.
Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
P-85721
1
P-90506
1
10-120-4 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic 
Filter
For the correct service interval. (See SERVICE
SCHEDULE on Page 10-70-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.)
The filter housing is located behind the hydraulic fluid
reservoir. 
Clean the top of the filter housing.
Figure 10-120-9
Two types of filters are used on this model loader [Figure
10-120-9]. Select the correct procedure for your
machine. 
Earlier Models
Figure 10-120-10
Remove the filter (Item 1) [Figure 10-120-10] using a
socket wrench.
Figure 10-120-11
Discard the entire filter (Item 1) [Figure 10-120-11].
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.
P-90500A
Earlier Model Later Model
P100047A
P-90500
1
P-85478
1
10-120-5 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic 
Filter (Cont’d)
Later Models
Figure 10-120-12
Remove the filter cap (Item 1) [Figure 10-120-12].
Figure 10-120-13
Remove the filter element (Item 1) [Figure 10-120-13]
and discard.
Remove the O-ring (Item 2) [Figure 10-120-13] and
discard.
Install new O-ring and lubricate with clean oil.
Install new filter element ensuring that element is fully
seated in the housing.
Install the filter cap and tighten to 25 N•m (18 ft-lb)
torque.
All Models
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
Install the rear grille.
Start the engine and operate the loader hydraulic
controls.
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.)
P100047
1
P100046
1
P100044
2
10-120-6 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Charge Filter
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.)
Figure 10-120-14
Unhook the rubber straps (Item 1) and remove the lower
fan duct (Item 2) [Figure 10-120-14].
Figure 10-120-15
Place a suitable container below the filter housing and
remove the filter housing (Item 1) [Figure 10-120-15]
using a socket wrench.
Recycle or dispose of used fluid in an environmentally
safe manner.
Figure 10-120-16
Remove and discard the filter element (Item 1) [Figure
10-120-16].
Clean the surface of the filter housing and the filter base
where they contact the filter element seal. 
Put clean oil on the seal of the new filter element. Install
the element on the filter base. Install and tighten the filter
housing to 47 - 54 N•m (35 - 40 ft-lb) torque.
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
Install the lower fan duct [Figure 10-120-14].
NOTE: Failure to install the lower fan duct correctly
may result in decreased cooling.
Lower the operator cab. (See Lowering on Page 10-30-
3.)
Start the engine and operate the loader hydraulic
controls.
P-85470
2
1
P-85489
1
P-85489A
1
10-120-7 S650 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Charge Filter 
(Cont’d)
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.)
Breather Cap
See the SERVICE SCHEDULE for the correct
replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-
60-1.)
Figure 10-120-17
Remove the breather cap (Item 1) [Figure 10-120-17]
and discard.
Install new breather cap.
Install the rear grille.
P100055
1
10-120-8 S650 Service Manual
10-130-1 S650 Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the hydraulic /
hydrostatic system. (See Hydraulic System on Page
SPEC-10-3.)
Stop the loader on a level surface and stop the engine.
Figure 10-130-1
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing. (Lift arms shown
raised for clarity.)
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole.
Install and tighten the plug.
Removing And Replacing Oil
Figure 10-130-2
Remove the check plug (Item 1) [Figure 10-130-2] from
the front of the chaincase housing.
Figure 10-130-3
Pump the oil out of the chaincase [Figure 10-130-3].
Recycle or dispose of the used oil in an environmentally
safe manner.
Add oil through the check plug hole until the oil flows from
the hole.
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
1
P-85744
1
P-85745
P-85742
10-130-2 S650 Service Manual
10-140-1 S650 Service Manual
BOB-TACH (HAND LEVER)
Inspection And Maintenance
Figure 10-140-1
Move the Bob-Tach levers down to engage the wedges
[Figure 10-140-1].
The levers and wedges must move freely.
WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-140-2
The wedges (Item 1) [Figure 10-140-2] must extend
through the holes in the attachment mounting frame.
The spring loaded wedges (Item 1) must contact the
lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-140-2].
If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
Inspect the mounting frame on the attachment and Bob-
Tach, linkages and wedges for excessive wear or
damage  [Figure 10-140-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) (See LUBRICATING THE LOADER on
Page 10-150-1.)
P-85513A
P-31233A P-31233
2
1
Wedge must contact lowe
r
edge of hole in th
e
attachment mountin
g
frame.
B-17460
10-140-2 S650 Service Manual
10-141-1 S650 Service Manual
BOB-TACH (POWER)
This machine may be equipped with a Power Bob-Tach.
Inspection And Maintenance
Figure 10-141-1
Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down.
The levers and wedges must move freely.
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Figure 10-141-2
The wedges (Item 1) [Figure 10-141-2] must extend
through the holes in the attachment mounting frame.
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].
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.
Figure 10-141-3
Inspect the mounting frame on the attachment and Bob-
Tach, linkages and wedges for excessive wear or
damage  [Figure 10-141-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
P-85320A
1
2
P-31233A P-31233
2
1
Wedge must contact lowe
r
edge of hole in th
e
attachment mountin
g
frame.
B-17460
10-141-2 S650 Service Manual
10-150-1 S650 Service Manual
LUBRICATING THE LOADER
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.
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. 
Tilt the Bob-Tach forward until it contacts the ground.
Stop the engine.
Lubricate the following:
Figure 10-150-1
1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-
150-1].
Figure 10-150-2
2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-
150-2].
Figure 10-150-3
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-3].
Figure 10-150-4
4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-4].
P-90540
1
P-90572A
2
P-90543A
3
P-90542A
4
10-150-2 S650 Service Manual
LUBRICATING THE LOADER (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-150-5
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-
150-5].
Figure 10-150-6
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-
150-6].
Figure 10-150-7
7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-
7].
Figure 10-150-8
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8].
P-85484
5
P-85720
6
P-85719
7
P-85487
8
10-150-3 S650 Service Manual
LUBRICATING THE LOADER (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-150-9
9. Rear Control Link (Both Sides) (2) [Figure 10-150-9].
Figure 10-150-10
10. Front Control Link (Both Sides) (2) [Figure 10-150-
10].
P-90570A
9
P-90544A
10
10-150-4 S650 Service Manual
10-160-1 S650 Service Manual
TIRE MAINTENANCE
Wheel Nuts
Figure 10-160-1
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.)
When installing
wheel nuts, tighten to 217 N•m (160 ft-lb)
torque.
When checking
wheel nut torque, set the torque wrench
to 190 N•m (140 ft-lb) to prevent over-tightening.
Rotating
Check the tires regularly for wear, damage and pressure.
Figure 10-160-2
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].
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.
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.
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.
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 loader.
I-2057-0794
P-85479
NA1023A
10-160-2 S650 Service Manual
10-170-1 S650 Service Manual
SPARK ARRESTOR MUFFLER
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrestor muffler. (See SERVICE
SCHEDULE on Page 10-70-1.)
Do not operate the loader with a defective exhaust
system.
IMPORTANT
This machine is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor exhaust
system.
The spark arrestor muffler, if equipped, must be
cleaned to keep it in working condition. The spark
arrestor muffler must be serviced by dumping the
spark chamber every 100 hours of operation.
On some models, the turbocharger functions as the
spark arrestor and must operate correctly for proper
spark arrestor function.
If this machine is operated on flammable forest,
brush, or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
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
arrestor requirements.
I-2284-0409
Stop the engine and open the rear door.
Figure 10-170-1
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
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
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.
W-2068-1285
P-85509
1
10-170-2 S650 Service Manual
10-180-1 S650 Service Manual
PIVOT PINS
Inspection And Maintenance
Figure 10-180-1
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].
Check that the lock nuts are tightened to 48 - 54 N•m (35
- 40 ft-lb) torque.
P-90536A
1
10-180-2 S650 Service Manual
10-190-1 S650 Service Manual
LOADER STORAGE AND RETURN TO SERVICE
Storage
Sometimes it may be necessary to store your Bobcat
loader for an extend period of time. Below is a list of items
to perform before storage.
• Thoroughly clean the loader including the engine
compartment.
• Lubricate the loader.
• Replace worn or damaged parts.
• Park the loader in a dry protected shelter.
• Lower the lift arms all the way and put the bucket flat
on the ground.
• Put blocks under the frame to remove weight from the
tires.
• 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.
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.
Return To Service 
After the Bobcat loader has been in storage, it is
necessary to follow a list of items to return the loader to
service. 
• Check the engine and hydraulic oil levels; check
coolant level.
• Install a fully charged battery.
• Remove grease from exposed cylinder rods.
• Check all belt tensions.
• Be sure all shields and guards are in place.
• Lubricate the loader.
• Check tire inflation and remove blocks from under
frame.
• Remove cover from exhaust pipe opening.
• 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.
10-190-2 S650 Service Manual
10-200-1 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.
Figure 10-200-1
Push the engine speed control fully down [Figure 10-
200-1] to decrease the engine speed.
Engage the parking brake.
Figure 10-200-2
Turn the key switch to the STOP position (Item 1) or
press the STOP button (Item 2) [Figure 10-200-2].
NOTE: If the loader lights are ON, they will remain ON
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
personnel.
NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Deluxe Instrumentation Panel allows
operation of the loader without using a
password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-200-3
Exit the loader using grab handles, safety tread and
steps (maintaining a 3-point contact) [Figure 10-200-3].
WARNING
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.
The seat bar system must deactivate these functions
when the seat bar is up. Service the system if
controls do not deactivate.
W-2463-0610
P-90525A
P-90688A
1
P-90214A
2
P-85737A
P-85735A
10-200-2 S650 Service Manual
10-210-1 S650 Service Manual
EMERGENCY EXIT
The front opening on the operator cab and rear window
provide exits.
External Access
Figure 10-210-1
The rear window can be removed from outside the loader
using a T40 TORX® driver. Turn both screws (Item 1)
[Figure 10-210-1] in until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.
Rear Window
NOTE: Use this procedure to remove the rear window
only under emergency conditions. Damage to
machine may occur.
Figure 10-210-2
Turn both latches (Item 1) [Figure 10-210-2] in until they
disengage from the window frame.
Push the rear window out of the rear of the operator cab.
Figure 10-210-3
Exit through the rear of the operator cab [Figure 10-210-
3].
Front Door
This machine may be equipped with a front door.
NOTE: Use this procedure to remove the front door
only under emergency conditions. Damage to
machine may occur.
Figure 10-210-4
Turn both latches (Item 1) [Figure 10-210-4] down until
they disengage from the door frame.
Push the door out of the operator cab door frame.
Exit through the opening.
P-85724
1
P-85309A
1
P-90563A
P-90725
1
10-210-2 S650 Service Manual
EMERGENCY EXIT (CONT’D)
Front Door (Cont’d)
Front Door Reassembly
Figure 10-210-5
Disconnect electrical connector (Item 2) and washer fluid
hose (Item 1) [Figure 10-210-5].
Figure 10-210-6
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 10-210-6].
Remove the door hinges from the loader.
Figure 10-210-7
Orient the latches as shown (Item 1) and install the door
hinges (Item 2) [Figure 10-210-7] on the door. (Bottom
hinge shown)
Figure 10-210-8
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 10-210-8]
up to lock cast washer into place. (Bottom hinge shown)
(Plastic cap shown removed for clarity)
Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
the clip into the hole in the gas spring socket. Rotate the
clip to lock into place [Figure 10-210-6].
Connect electrical connector (Item 2) and washer fluid
hose (Item 1) [Figure 10-210-5].
P-85781A
1
2
P-85588A
1
P-85589A
2
3
P-90685
1
2
P-90686A
1
2
10-220-1 S650 Service Manual
SEAT BELT
Inspection And Maintenance
WARNING
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.
Inspect the seat belt system thoroughly at least once
each year or more often if the machine is exposed to
severe environmental conditions or applications.
Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware or any other obvious
problem should be replaced immediately.
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 Bobcat dealer for seat belt system replacement
parts for your machine.
Figure 10-220-1
B-22283
1
2
3
4
10-220-2 S650 Service Manual
20-01 S650 Service Manual
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-10-1
Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-10-1
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-10-5
CYLINDER (LIFT)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-2
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-6
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-7
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-20-8
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-2
Base End Pivot Pin Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-4
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-5
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-6
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-21-8
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-2
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-3
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-4
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-22-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-30-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-30-4
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-30-5
20-02 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-2
Mount Bracket Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-5
Identification Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-40-7
Load Check Valve Removal And Installation (Tilt & 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
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-5
Actuator Removal And Installation (Out Of Loader)  . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-7
Identification Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-10
Mount Bracket Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Load Check Valve Removal And Installation (Tilt & Auxiliary)  . . . . . . . . . . . . . . . .  20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)  . . . . . . . . . . . . . . .  20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . .  20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . .  20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)  . . . . .  20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-15
Plug Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-17
Lift Spool Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-22
Auxiliary Spool Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-26
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-27
Lock Valve Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-28
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-29
Main Relief Valve Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-41-30
20-03 S650 Service Manual
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-2
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-3
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-1
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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-7
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-8
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-60-9
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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-11
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-61-12
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-61-13
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-70-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-70-1
Housing Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-80-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-80-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-80-1
Hydraulic Fluid Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-90-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-90-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-90-1
BUCKET POSITION VALVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-1
Solenoid Testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-2
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-100-4
20-04 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Solenoid Testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-2
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-120-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-120-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-120-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-120-3
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK  . . . . . . . . . . . . . . . . . . . . . . . .  20-130-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-130-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-130-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20-130-1
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
V-1348legend
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE:    25 PSI (1,7 bar)
RESERVOIR:
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
System Capacity . . . . . . .  10.5 Gal. (39,7 L)
1
2
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
14
LOAD CHECK VALVE
9
RELIEF VALVE - MAIN:
3500 PSI (241 bar)
at Front Quick Couplers
11
12
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
10
5
6
24
25
26
27
28
29
V-1348legend (6-8-09)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
LEGEND
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
DIFFERENTIAL PRESSURE SWITCH:
15 PSI (1,07 bar)
Normally Closed                      
3
22
38
21
20
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
8
HYDRAULIC PUMP   . . . . . . .  Gear Type 
23.0 GPM (87,1 L/min.) at High Engine Idle
23
35
36
4
7
FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
13
LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
37
CHARGE PUMP -
13.5 GPM (51,1 L/min) at High Engine Idle
RELIEF/ANTICAVITATION VALVE -
PORT                4000 PSI (276 bar)
FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
ANTICAVITATION VALVE
PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
SENSOR – HYD. TEMPERATURE
SENSOR – CHARGE PRESSURE –
Fan Filter
15
SIGHT GUAGE
DIAGNOSTIC COUPLER
RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL)  4000 PSI (276 bar)
SPRING LOADED FILTER BY-PASS
VALVE:  75 - 83 PSI (5,2 - 5,7 bar)
FILTER - HYDRAULIC (CANISTER)
30
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
FILTER - BICS CONTROL VALVE
(SCREEN)
17
16
CHECK VALVE - With 14.5 PSI (1,0 bar) 
Spring
18
RESTRICTION . . . . . . . 0.079 in. (2,0 mm)
32
31
33
34
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:    5294 PSI (365 bar)
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
RELIEF VALVE - CHARGE INLET:
465 PSI (32, bar) 
at High Engine Idle 
With 140 degrees F. (60 degrees C.) Fluid
ANTICAVITATION VALVE
RESTRICTION - 0.06 inch (1,5 mm)
CHECK VALVE - With 200 PSI (13,8 bar) 
Spring
CHECK VALVE – COLD WEATHER BY-PASS 
With 50 PSI (3,45 bar) Spring
DRIVE MOTOR SHUTTLE VALVE
HYDROSTATIC PUMP
19
IN
OUT
16
18
20
15
?
13
14
9
10
8
17
16
Tilt Spool
Lift Spool
Auxiliary Spool
8
HYDRAULIC CONTROL VALVE
BICS CONTROL VALVE
DRAIN / RETURN  MANIFOLD
33
12
12
INTEGRATED COUPLER BLOCK
Male
Male
Female
28
34
8
10
7
27
11
11
11
6
37
35
35
T
Charge
Inlet
36
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
24
25
26
23
21
DR
P 22
1
2
38
36
36
36
B
A
L
29
31
30
32
A
B
L
31
30
29
32
A
C
D
B
M1
M
3
M4
M
2
RESERVOIR (VENTED)
HYDRAULIC FILTER
4
5
1
2
PRINTED IN U.S.A.
Oil Cooler
LIFT
CYLINDERS
TILT
CYLINDERS
DRIVE MOTOR
DRIVE MOTOR
PUMP 
SUPPLY
DRAIN / 
RETURN
PILOT 
PRESSURE
WORKING 
CIRCUIT
3
(PRINTED JUNE 2009)
7170812
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
S650 (S/N A3NV11001 & ABOVE)
(S/N A3NW11001 & ABOVE)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
V-1349legend
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE:    25 PSI (1,7 bar)
RESERVOIR:
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
System Capacity . . . . . . .  10.5 Gal. (39,7 L)
1
2
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
14
LOAD CHECK VALVE
9
RELIEF VALVE - MAIN:
3500 PSI (241 bar)
at Front Quick Couplers
11
44
39
CHECK VALVE - With 80 PSI (5,5 bar) Spring
12
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
10
5
6
24
25
26
27
28
29
42
V-1349legend (6-8-09)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
LEGEND
FLOW DIVIDER ADJUSTMENT VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
CHECK VALVE - BUCKET POSITION
VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
DIFFERENTIAL PRESSURE SWITCH:
15 PSI (1,07 bar)
Normally Closed                      
3
22
38
21
20
43
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
8
HYDRAULIC PUMP   . . . . . . .  Gear Type 
23.0 GPM (87,1 L/min.) at High Engine Idle
23
41
35
36
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 2000 PSI (137 bar)
46
4
7
FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
13
LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
37
45
RESTRICTION - 0.025 inch (0,6 mm)
RELIEF VALVE - 1200 PSI (83 bar)
CHARGE PUMP -
13.5 GPM (51,1 L/min) at High Engine Idle
CHECK VALVE - With 300 PSI (20,7 bar) 
Spring And With  0.016 inch (0,40 mm) Orifice
RELIEF/ANTICAVITATION VALVE -
PORT                4000 PSI (276 bar)
FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
ANTICAVITATION VALVE
PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
SENSOR – HYD. TEMPERATURE
SENSOR – CHARGE PRESSURE –
Fan Filter
15
SIGHT GUAGE
DIAGNOSTIC COUPLER
RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL)  4000 PSI (276 bar)
SPRING LOADED FILTER BY-PASS
VALVE:  75 - 83 PSI (5,2 - 5,7 bar)
FILTER - HYDRAULIC (CANISTER)
30
LOAD SHUTTLE VALVE - BLEED OFF
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY 
RESTRICTOR - 0.031 inch (0,8 mm)
FILTER - BRAKE
HYDRAULIC BRAKE – SPRING APPLIED –
PRESSURE RELEASE (SAPR)
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR – 2 SPEED
HIGH PRESSURE SHUTTLE
RELIEF VALVE:    3300 PSI (228 bar)
57
58
59
60
61
62
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – 2 SPEED
CHECK VALVE
63
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – MAKE-UP
65
64
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – BRAKE
FILTER - BICS CONTROL VALVE
(SCREEN)
17
16
CHECK VALVE - With 14.5 PSI (1,0 bar) 
Spring
18
RESTRICTION . . . . . . . 0.079 in. (2,0 mm)
32
31
33
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
34
RESTRICTION - 0.089 inch (2,26 mm)
FILTER - BOB-TACH VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:    5294 PSI (365 bar)
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
49
50
51
52
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BASE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD
RELIEF VALVE - CHARGE INLET:
465 PSI (32, bar) 
at High Engine Idle 
With 140 degrees F. (60 degrees C.) Fluid
53
66
67
69
68
HIGH FLOW HYDRAULIC PUMP  Gear Type 
7.5 GPM (28,4 L/min.) at High Engine Idle
RELIEF VALVE - 3500 PSI (241 bar)
DUMP VALVE – ON / OFF
CHECK VALVE - With 5.0 PSI (0,34 bar) 
Spring
70
ANTICAVITATION VALVE
54
RESTRICTION - 0.06 inch (1,5 mm)
55
CHECK VALVE - With 200 PSI (13,8 bar) 
Spring
71
RIDE CONTROL VALVE
72
HIGH PRESSURE CHAMBER
73
LOW PRESSURE CHAMBER
FILTER – BOB-TACH VALVE
74
75
CHECK VALVE – COLD WEATHER BY-PASS 
With 50 PSI (3,45 bar) Spring
56 DRIVE MOTOR SHUTTLE VALVE
HYDROSTATIC PUMP
19
IN
OUT
16
18
20
15
?
13
14
9
10
8
17
16
Tilt Spool
Lift Spool
Auxiliary Spool
8
HYDRAULIC CONTROL VALVE
BICS CONTROL VALVE
DRAIN / RETURN  MANIFOLD
43
66
12
12
INTEGRATED COUPLER BLOCK
Male
Male
Female
41
42
8
10
7
70
11
11
11
6
P1
P2
37
38
36
39
34 40
33
35
??
32
BOBTACH VALVE 
(OPTIONAL)
DR
PP
53
51
51
T
Charge
Inlet
52
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
24
25
26
23
21
DR
P 22
1
2
REAR AUXILIARY 
VALVE (OPTIONAL)
46
??
Base
49
?
Rod
50
?
48
FEMALE
MALE
47
45
44
T
P - outP - in
BUCKET POSITIONING VALVE (OPTIONAL)
B
A
31
29
27
?
30
C
D
28
HIGH FLOW VALVE (OPTIONAL)
67
68
?
75
52
52
52
P
63
61
?
65
62
62
64
64
2-SPEED & SAPR BRAKE 
VALVE (OPTIONAL)
T
A
D
C
B
B1
A1
B
A
Z
L
X
W
54
60
56
55
59
57
58
Z
A
B
L
X
W
60
56
55
54
59
57
58
A
C
D
B
M1
M
3
M4
M
2
RESERVOIR (VENTED)
HYDRAULIC FILTER
4
5
1
2
69
74
74
6
PRINTED IN U.S.A.
PUMP 
SUPPLY
DRAIN / 
RETURN
PILOT 
PRESSURE
WORKING 
CIRCUIT
Oil Cooler
BOB-TACH CYLINDER
(OPTIONAL)
RIDE CONTROL  
(OPTIONAL)
71
73
72
DUAL STAGE 
ACCUMULATOR
LIFT
CYLINDERS
TILT
CYLINDERS
TWO SPEED DRIVE MOTOR (OPTIONAL)
TWO SPEED DRIVE MOTOR (OPTIONAL)
REAR AUXILIARY COUPLERS (OPTIONAL)
3
(PRINTED JUNE 2009)
7170812
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS   
S650 (S/N A3NV11001 & ABOVE)
(S/N A3NW11001 & ABOVE)
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
V-1350legend
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE:    25 PSI (1,7 bar)
RESERVOIR:
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
System Capacity . . . . . . .  10.5 Gal. (39,7 L)
1
2
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
LOAD CHECK VALVE
9
RELIEF VALVE - MAIN:
3500 PSI (241 bar)
at Front Quick Couplers
11
37
12
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
10
5
6
24
25
26
27
40
V-1350legend (6-8-09)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
LEGEND
DIFFERENTIAL PRESSURE SWITCH:
15 PSI (1,07 bar)
Normally Closed                      
3
22
21
20
38
Printed in U.S.A.
8
23
39
4
7
FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
13
RELIEF/ANTICAVITATION VALVE -
PORT                4000 PSI (276 bar)
FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
ANTICAVITATION VALVE
PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
SENSOR – HYD. TEMPERATURE
SIGHT GUAGE
DIAGNOSTIC COUPLER
RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL)  4000 PSI (276 bar)
SPRING LOADED FILTER BY-PASS
VALVE:  75 - 83 PSI (5,2 - 5,7 bar)
FILTER - HYDRAULIC (CANISTER)
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
RESTRICTION . . . . . . . 0.079 in. (2,0 mm)
ANTICAVITATION VALVE
RESTRICTION - 0.06 inch (1,5 mm)
CHECK VALVE - With 200 PSI (13,8 bar) 
Spring
DRIVE MOTOR SHUTTLE VALVE
CHECK VALVE – COLD WEATHER BY-PASS 
With 50 PSI (3,45 bar) Spring
35
32
33
34
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:    5294 PSI (365 bar)
RELIEF VALVE - CHARGE INLET:
385 PSI (26,5 bar) at High Engine Idle 
With 140 degrees F. (60 degrees C.) Fluid
36
SERVO PISTON – Swash Plate
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
FILTER
19
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
FILTER - BICS CONTROL VALVE
(SCREEN)
17
16
CHECK VALVE - With 14.5 PSI (1,0 bar) 
Spring
18
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
15
28
29
41
HYDRAULIC PUMP   . . . . . . .  Gear Type 
23.0 GPM (87,1 L/min.) at High Engine Idle
CHARGE PUMP -
13.5 GPM (51,1 L/min) at High Engine Idle
SENSOR – CHARGE PRESSURE –
Fan Filter
30
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
31
TANDEM 
HYDROSTATIC 
DRIVE PUMP
R
IN
OUT
18
20
14
8
17
?
15
16
10
19
18
13
HYDRAULIC CONTROL VALVE (SPOOL 
VALVE)
BICS CONTROL VALVE
DRAIN/RETURN  
MANIFOLD
30
12
12
INTEGRATED COUPLER BLOCK
Male
Male
Female
22
29
10
7
11
11
11
6
33
35
?
?
34
31
35
34
31
M
M
M
A
A
X
X
X
X
M
G
R
M
B
B
T
T
Charge
Inlet
32
32
32
32
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
26
27
28
25
23
DR
P
24
1
2
9
37
LIFT CYLINDERS
8
8
TWO SPEED DRIVE MOTOR (OPTIONAL)
A
B
L
40
39
38
41
B
A
L
38
40
39
41
DRIVE MOTOR
36
36
36
36
RESERVOIR (VENTED)
HYDRAULIC FILTER
3
4
5
21
1
2
6
PUMP 
SUPPLY
DRAIN / 
RETURN
PILOT 
PRESSURE
WORKING 
CIRCUIT
OIL COOLER
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTION
S650 (S/N A3NV11001 & ABOVE)
(S/N A3NW11001 & ABOVE)
(PRINTED JUNE 2009)
7170813
PRINTED IN U.S.A.
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
V-1351legend
FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY-PASS
VALVE:    25 PSI (1,7 bar)
RESERVOIR:
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
System Capacity . . . . . . .  10.5 Gal. (39,7 L)
1
2
19
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
14
LOAD CHECK VALVE
9
RELIEF VALVE - MAIN:
3500 PSI (241 bar)
at Front Quick Couplers
11
44
39
CHECK VALVE - With 80 PSI (5,5 bar) Spring
12
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
10
5
6
24
25
26
27
28
29
42
V-1351legend (6-8-09)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
LEGEND
FLOW DIVIDER ADJUSTMENT VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
CHECK VALVE - BUCKET POSITION
VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
DIFFERENTIAL PRESSURE SWITCH:
15 PSI (1,07 bar)
Normally Closed                      
3
22
21
20
43
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
8
HYDRAULIC PUMP   . . . . . . .  Gear Type 
23.0 GPM (87,1 L/min.) at High Engine Idle
23
41
35
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 2000 PSI (137 bar)
46
4
7
FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
13
LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
45
RESTRICTION - 0.025 inch (0,6 mm)
CHARGE PUMP -
13.5 GPM (51,1 L/min) at High Engine Idle
CHECK VALVE - With 300 PSI (20,7 bar) 
Spring And With  0.016 inch (0,40 mm) Orifice
RELIEF/ANTICAVITATION VALVE -
PORT                4000 PSI (276 bar)
FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
ANTICAVITATION VALVE
PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
SENSOR – HYD. TEMPERATURE
SENSOR – CHARGE PRESSURE –
Fan Filter
15
SIGHT GUAGE
DIAGNOSTIC COUPLER
RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL)  4000 PSI (276 bar)
SPRING LOADED FILTER BY-PASS
VALVE:  75 - 83 PSI (5,2 - 5,7 bar)
FILTER - HYDRAULIC (CANISTER)
30
LOAD SHUTTLE VALVE - BLEED OFF
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY 
RESTRICTOR - 0.031 inch (0,8 mm)
FILTER - BRAKE
HYDRAULIC BRAKE – SPRING APPLIED –
PRESSURE RELEASE (SAPR)
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR – 2 SPEED
HIGH PRESSURE SHUTTLE
RELIEF VALVE:    3300 PSI (228 bar)
61
62
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – 2 SPEED
CHECK VALVE
63
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – MAKE-UP
65
64
SOLENOID ACTIVATED DIRECECTIONAL 
CONTROL VALVE – BRAKE
FILTER - BICS CONTROL VALVE
(SCREEN)
17
16
CHECK VALVE - With 14.5 PSI (1,0 bar) 
Spring
18
RESTRICTION . . . . . . . 0.079 in. (2,0 mm)
32
31
33
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
34
RESTRICTION - 0.089 inch (2,26 mm)
FILTER - BOB-TACH VALVE
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:    5294 PSI (365 bar)
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
49
50
51
52
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BASE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD
RELIEF VALVE - CHARGE INLET:
385 PSI (26,5 bar) at High Engine Idle 
With 140 degrees F. (60 degrees C.) Fluid
53
66
67
69
68
HIGH FLOW HYDRAULIC PUMP  Gear Type 
7.5 GPM (28,4 L/min.) at High Engine Idle
RELIEF VALVE - 3500 PSI (241 bar)
DUMP VALVE – ON / OFF
CHECK VALVE - With 5.0 PSI (0,34 bar) 
Spring
70
ANTICAVITATION VALVE
54
55
71
RIDE CONTROL VALVE
72
HIGH PRESSURE CHAMBER
73
LOW PRESSURE CHAMBER
FILTER – BOB-TACH VALVE
74
75
56
38
36
37
RELIEF VALVE - 1200 PSI (83 bar)
57
58
59
SERVO PISTON – Swash Plate
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – FORWARD/REVERSE
FILTER
RESTRICTION - 0.06 inch (1,5 mm)
CHECK VALVE - With 200 PSI (13,8 bar) 
Spring
DRIVE MOTOR SHUTTLE VALVE
76
77
78
CHECK VALVE – COLD WEATHER BY-PASS 
With 50 PSI (3,45 bar) Spring
60
TANDEM 
HYDROSTATIC 
R
IN
OUT
18
20
14
8
17
?
15
16
10
19
18
13
HYDRAULIC CONTROL VALVE (SPOOL 
VALVE)
BICS CONTROL VALVE
DRAIN/RETURN  MANIFOLD
46
73
12
12
INTEGRATED COUPLER BLOCK
Male
Male
Female
44
45
10
7
11
11
11
6
P1
P2
39
4138
36 43
35
42
37
??
34
POWER BOBTACH 
VALVE (OPTIONAL)
DR
PP
BOBTACH CYLINDER (OPTIONAL)
56
58
?
?
57
54
58
57
54
M
M
M
A
A
X
X
X
X
M
G
R
M
B
B
T
T
Charge
Inlet
55
55
55
55
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
26
27
28
25
23
DR
P
24
1
2
9
REAR AUXILIARY 
VALVE (OPTIONAL)
49
??
52
?
53
?
51
FEMALE
MALE
50
48
47
T
P outP in
REAR QUICK COUPLERS
BUCKET POSITIONING VALVE 
(OPTIONAL)
B
A
33
31
29
?
32
C
D
30
HIGH FLOW VALVE (OPTIONAL)
74
75
?
60
LIFT CYLINDERS
8
8
TWO SPEED DRIVE MOTOR (OPTIONAL)
Z
A
B
L
X
W
67
63
62
61
66
64
65
B
A
Z
L
X
W
61
67
63
62
66
64
65
TWO SPEED DRIVE MOTOR (OPTIONAL)
P
70
68
?
72
69
69
71
71
2-SPEED & SAPR 
BRAKE VALVE 
T
A
D
C
B
B1
A1
59
59
59
59
RESERVOIR (VENTED)
HYDRAULIC FILTER
3
4
5
21
1
2
76
40
40
6
22
78
77
PUMP 
SUPPLY
DRAIN / 
RETURN
PILOT 
PRESSURE
WORKING 
CIRCUIT
OIL COOLER
TILT CYLINDERS
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTION
S650 (S/N A3NV11001 & ABOVE)
(S/N A3NW11001 & ABOVE)
(PRINTED JUNE 2009)
7170813
PRINTED IN U.S.A.
20-10-1 S650 Service Manual
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
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).
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.
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection).
OIL LINES CROSSING (NOT
Connected).
COUPLER - Quick - Acting Coupling
(uncoupled, closed by non-return
valve).
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit.
SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS
SYMBOL DESCRIPTION
BASIC and MISCELLANEOUS SYMBOLS
RESTRICTION - Line with Fixe
d
Restriction - Affected by Viscosit
y
(property of resistance to flowin
g
fluid).
VARIABLE ADJUSTMEN
T
RESTRICTION - Regulated o
r
Variable Restriction.
TEMPERATURE CONTROL 
-
(Indication of temperature).
TEMPERATURE INDICATOR 
-
(temperature measurement 
-
thermometer).
FILTER (strainer or screen) - For fluid
conditioning.
VENTED AND FILTERED
RESERVOIR (reservoir open t
o
atmosphere).
PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoi
r
uses a pressured cap).
OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
PRESSURE SENSOR - Varies
electric signal with pressure.
DIFFERENTIAL PRESSURE
SWITCH - Switch activates when
pressure difference reaches specified
level.
PRESSURE SWITCH - Switch
activates when pressure reaches
specified level.
MUFFLER (silencer) - Reduces
noise.
20-10-2 S650 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
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.
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two
directions of flow (bidirectional).
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDRAULIC
MOTOR - With two directions of flow
(bidirectional.
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
SYMBOL DESCRIPTION
C
YLINDER: Equipment to convert hydraulic energy into
l
inear energy and in which the fluid pressure operates
a
lternately in both directions (forward and backward
s
trokes).
SYMBOL DESCRIPTION
CONTROL MECHANISMS
CONTROL VALVE WITH DETEN
T
(Holds Valve in Position) - device fo
r
maintaining a given positio
n
(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).
CONTROL VALVE WITH SPRING
RETURN (mechanical).
CONTROL VALVE ACTIVATED BY
AN ELECTRIC SOLENOID
(electrical).
CONTROL VALVE ACTIVATED BY A
PROPORTIONAL ELECTRICAL
SOLENOID (electrical).
CONTROL VALVE ACTIVATED BY
DUAL ELECTRICAL SOLENOID
(electrical).
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).
P
UMP: To convert mechanical energy into hydraulic
e
nergy.
M
OTOR: To convert hydraulic energy into rotary
m
echanical energy.
20-10-3 S650 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
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.
SPRING LOADED VALVE (bypass
Valve) - Opens if the Inlet pressure is
greater than the Outlet pressure plus
the spring pressure.
SHUTTLE VALVE - The Inlet port
connected to the higher pressure is
automatically connected to the Outlet
port while the other Inlet port is
closed.
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to
open the valve by pilot pressure.
O
UT
IN
OUT IN
OUT I N
SYMBOL DESCRIPTION
N
ON-RETURN VALVE, SHUTTLE VALVE: Valve which
a
llows free flow in one direction only.
SYMBOL DESCRIPTION
DIRECTIONAL CONTROL VALVE: Valve providing for th
e
opening (fully or restricted) or the closing of one or mo
re
flow paths (represented by several squares).
TWO PORTS and CLOSED FLOW
PATHS
SOLENOID ACTIVATE
D
DIRECTIONAL CONTROL VALV
E
(Two Position) - controlled by a
n
electric solenoid (with return spring).
PILOT ACTIVATED DIRECTIONA
L
CONTROL VALVE (Two Position) 
-
controlled by pressure (with retur
n
spring).
MANUALLY ACTIVATED DIRECTIO
N
CONTROL VALVE (Variable Position
)
Joystick Controlled, variable pressur
e
to shift the pilot activated directiona
l
control valve spool.
T
P
OUT
I
N
IN
MANUALLY ACTIVATED FLOW
CONTROL VALVE (Two Position
)
allows for changing pilot flow t
o
control switching joystick functions fo
r
STD / ISO Control (Excavators Only
).
BACK
FRONT
STD
ISO
STEERING CONTROL VALV
E
(Variable Position) - Used fo
r
controlling the hydraulic flow for th
e
steering cylinders in relationship t
o
the amount the steering wheel 
is
rotated.
20-10-4 S650 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
RELIEF VALVE - When the Inlet
pressure overcomes the opposing
force of the spring, the valve opens
permitting flow from the Outlet port.
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.
LOCK VALVE - hydraulic pressure is
applied to open the valve to allow the
hydraulic cylinder to move.
ONE WAY RESTRICTOR VALVE
(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
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.
OUT
IN
OUT
IN
OU
T
I
N
SYMBOL DESCRIPTION
P
RESSURE CONTROL VALVE: Valve ensuring the
c
ontrol of pressure.
SYMBOL DESCRIPTION
MISCELLANEOUS
ACCUMULATOR - Supplie
s
temporary reserve pressure to th
e
hydraulic system when the engin
e
has been stopped.
F
LOW CONTROL VALVE: Valve controlling the flow in
o
ne or both directions.
TOW VALVE - Normally in closed
position.
LOAD SENSE BLEED VALVE -
Regulates small amount of fluid flow
(leakage).
20-10-5 S650 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)
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.
If a service code appears in the left instrument panel.
(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate.  1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 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 when the pedal is in neutral position 4, 9, 10, 11
Lift arm bypass control valve stuck 12
Lift arm bypass control valve stem bent or broken 13
KEY TO CORRECT CAUSE
1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid.
(See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-40-1.)
8. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace lift arm bypass control valve assembly.
20-10-6 S650 Service Manual
20-20-1 S650 Service Manual
CYLINDER (LIFT)
Testing
Figure 20-20-1
Lower the lift arms. Stop the engine. Raise the seat bar.
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
Check only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.
Figure 20-20-2
Install a cap (Item 1) [Figure 20-20-2] on the hose and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair. Repeat the procedure to check the other lift
cylinder.
P-90616
1
P-90617
1
2
20-20-2 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Removal And Installation
Lift and block the loader. (See Procedure on Page 10-10-
1.)
NOTE: Remove only one cylinder at a time.
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
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 20-20-3
Mark and disconnect the two hydraulic hoses (Item 1)
[Figure 20-20-3].
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
Figure 20-20-4
Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
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 oil as the lift arms are
raised.
Recycle or dispose of used fluid in an environmentally
safe manner.
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
P-90616
1
P-90824
1
2
2
20-20-3 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Removal And Installation (Cont’d)
Figure 20-20-5
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-5] from the pin 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
With a slide hammer, remove the pin (Item 1) [Figure 20-
20-6] from the rod end of the cylinder.
P-90602A
1
2
P-90611
1
20-20-4 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Removal And Installation (Cont’d)
DANGER
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
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
Figure 20-20-7
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
Install a bolt (Item 1) [Figure 20-20-8] through the eyelet
of the cylinder and install a strap (Item 2) [Figure 20-20-
8] to secure the cylinder.
P-90605
1
P-90823
1
2
20-20-5 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Removal And Installation (Cont’d)
Open the rear door.
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
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-9] from the pin on the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 20-20-10
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 ft-
lb) torque.
Figure 20-20-11
With a slide hammer, remove the pin (Item 1) [Figure 20-
20-11] from the base end of the lift cylinder.
Figure 20-20-12
Using a chain hoist remove the lift cylinder (Item 1)
[Figure 20-20-12] from the loader.
P-90834
1
1
P-90825
1
P-90827
1
P-90823
1
20-20-6 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Parts Identification
1. Seal
2. Hydraulic Tubeline
3. Cylinder Case Tube
4. Plug
5. Clamp
6. Nut
7. Back-up Ring
8.   O-ring
9. Piston Assembly
10. Spacer
11. O-ring
12. Back-up Ring
13. O-ring
14. Head
15. Rod Seal
16. Wiper Seal
17. Rod
18. Grease Fitting
NA1413S
2
3
4
4
5
6
7
8
9
10
12
1
13
14
15
16
17
18
11
20-20-7 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Disassembly
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Figure 20-20-13
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-20-13] from the cylinder case.
Figure 20-20-14
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].
Figure 20-20-15
Remove the back-up ring (Item 1) and O-ring (Item 2)
[Figure 20-20-15] from the piston.
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
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-48033
1
P-48036
1
2
3
4
P-48038
1
2
3
P-48039
1
3
2
20-20-8 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Disassembly (Cont'd)
Figure 20-20-17
Remove the wiper seal (Item 1) [Figure 20-20-17] from
the cylinder head.
Figure 20-20-18
Remove the rod seal (Item 1) [Figure 20-20-18] from the
cylinder head.
Assembly
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Figure 20-20-19
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
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.
P-48040
1
P-48042
1
P7424
20-20-9 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Assembly (Cont’d)
Figure 20-20-20
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
20-20] on the cylinder piston.
Figure 20-20-21
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 20-
20-21].
Figure 20-20-22
Install the rod seal in the head [Figure 20-20-22].
Figure 20-20-23
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
23].
P-48038
1
2
P7427
P-48043
1
P7425
P-48042
P-4804
1
1
2
20-20-10 S650 Service Manual
CYLINDER (LIFT) (CONT'D)
Assembly (Cont'd)
Figure 20-20-24
Install the O-ring (Item 1) and the seal (Item 2) [Figure
20-20-24] on the cylinder head.
Figure 20-20-25
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
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 1152 N•m
(850 ft-lb) torque.
Figure 20-20-26
Put the base end of the hydraulic cylinder in a vise.
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-20-26] until the head is flush with the end of
the cylinder tube assembly.
P101716
1
2
P-48036
1
2
3
4
P-48035
1
20-21-1 S650 Service Manual
CYLINDER (TILT)
Testing
Figure 20-21-1
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
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
Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the rod end of the tilt cylinder.
Figure 20-21-2
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
Operate the controls that rolls the Bob-Tach forward.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-21-2]. Remove the cylinder for repair.
Repeat procedure to check the other cylinder.
P-85553
1
P100721
2
1
20-21-2 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Removal And Installation
Figure 20-21-3
Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward
Stop the engine. Raise the seat bar.
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
3] from the rod end pivot pin.
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.
Figure 20-21-4
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].
Figure 20-21-5
Disconnect the two hydraulic hoses (Items 1 & 2) [Figure
20-21-5] from the cylinder.
Cap the hoses and plug the fittings on the cylinder.
Figure 20-21-6
Remove the base end pivot bolt and washer (Item 3)
[Figure 20-21-5].
Remove the retainer nut and washer (Item 1) [Figure 20-
21-6] from the base end pivot pin.
Installation: Tighten the retainer nut to 257,6 N•m (190
ft-lb) torque.
P-85554
1
P-85649
1
P-85562
3
2
1
P-85648
1
20-21-3 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Removal And Installation (Cont'd)
Figure 20-21-7
Slide the cylinder from the base pin and remove the
cylinder from the loader [Figure 20-21-7].
P-85564
20-21-4 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Base End Pivot Pin Removal And Installation
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Figure 20-21-8
Figure 20-21-9
Remove the cylinder from the cylinder base pin (Item 1)
[Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a shaft (Item 1) [Figure 20-21-9] and a hammer to
remove the cylinder base pin from the lift arms.
Figure 20-21-10
Check pivot pin and replace as needed [Figure 20-21-
10].
P-85565
1
P-85566
1
P-85567
20-21-5 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Parts Identification
NA1210S
1. Tubeline
2. Case
3. Plug
4. Grease Fitting
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring
9. Piston
10. O-ring
11. Back-up Ring
12. O-ring
13. Head
14. Seal
15. Wiper
16. Rod
17. Bushing
18. Seal
4
5
6
7
8
9
3
3
1
10
11
18
12
13
14
15
16
17
4
2
20-21-6 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Disassembly
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-11
Remove the seals (Item 1) [Figure 20-21-11] on both
sides of the pivot bushing.
Remove and replace bushing (Item 2) with a driver tool
and hammer [Figure 20-21-11].
Figure 20-21-12
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-21-12] from the cylinder case.
Figure 20-21-13
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].
P-85651
1
1
2
P-48035
1
P-48071
1
2
3
20-21-7 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Disassembly (Cont'd)
Figure 20-21-14
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.
Figure 20-21-15
Remove the O-ring (Item 1). Remove the O-ring (Item 2)
and back-up washer (Item 3) [Figure 20-21-15].
NOTE: The O-ring (Item 2) and back-up ring (Item 3)
[Figure 20-21-15] 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.
Figure 20-21-16
Remove the wiper seal (Item 1) [Figure 20-21-16] from
the cylinder head.
Figure 20-21-17
Remove the rod seal (Item 1) [Figure 20-21-17] from the
cylinder head.
P-48073
1
2
P-48039
3
1
2
P-48040
1
P-48042
1
20-21-8 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Assembly
Use the following tools to assemble 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.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
Figure 20-21-18
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-18].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
Figure 20-21-19
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
21-19] on the cylinder piston.
Figure 20-21-20
Install the rod seal on the rod seal tool [Figure 20-21-20].
NOTE: During installation the spring side of the seal
(Item 1) [Figure 20-21-20] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-
21-20].
P7424
P-48073
1
2
P7427
P-48043
1
20-21-9 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Assembly (Cont'd)
Figure 20-21-21
Install the rod seal in the head [Figure 20-21-21].
Figure 20-21-22
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
22].
Figure 20-21-23
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
21-16] on the cylinder head.
Figure 20-21-24
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-24].
Tighten the nut (Item 3) [Figure 20-21-24] to 1152 N•m
(850 ft-lb) torque.
Put the base end of the hydraulic cylinder in a vise.
P7425
P-48042
P-4804
1
1
2
P101716
1
2
P-48071
1
2
3
20-21-10 S650 Service Manual
CYLINDER (TILT) (CONT'D)
Assembly (Cont'd)
Figure 20-21-25
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-21-25] until the head is flush with the end of
the cylinder tube assembly.
Figure 20-21-26
Install the bushing (Item 1) and seals (Item 2) [Figure 20-
21-26] using a driver tool and hammer.
P-48035
1
P-85650
1
2
2
20-22-1 S650 Service Manual
CYLINDER (BOB-TACH)
Testing
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
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
Figure 20-22-1
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1].
Push and hold BOB-TACH “WEDGES UP” switch until
levers are in the unlocked position (Wedges fully raised).
Figure 20-22-2
Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
Figure 20-22-3
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).
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the cylinder for repair.
P-85570
P-85570
1
P-85568
1
20-22-2 S650 Service Manual
CYLINDER (BOB-TACH) (CONT’D)
Removal And Installation
Figure 20-22-4
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
Remove the bolts and washers (Item 1) [Figure 20-22-
5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.
Remove the cylinder from the lever pivots.
P-85570
1
P-85569
1
1
20-22-3 S650 Service Manual
CYLINDER (BOB-TACH) (CONT’D)
Parts Identification
PE3954S
1. Tube
2. Nut
3. Piston
4. O-ring
5. Ring
6. Spacer
7. O-ring
8. Ring
9. O-ring
10. Head
11. Seal
12. Seal
13. Rod
1
2
3
4
5
6
7
8
9
10
11
12
13
20-22-4 S650 Service Manual
CYLINDER (BOB-TACH) (CONT’D)
Disassembly
Figure 20-22-6
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [Figure 20-22-
6].
Figure 20-22-7
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.
Figure 20-22-8
Piston: Remove the O-ring (Item 1), and seal (Item 2)
from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9
Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P-85647
P16294
1
2
3
4
P16295
1
2
3
N-20611
1
2
4
3
5
20-22-5 S650 Service Manual
CYLINDER (BOB-TACH) (CONT’D)
Assembly
Figure 20-22-10
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.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
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.
Figure 20-22-11
Piston: Install the O-ring (Item 1) and seal (Item 2) on the
piston (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
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.
P7424
P16295
1
2
3
4
N-20612
20-22-6 S650 Service Manual
CYLINDER (BOB-TACH) (CONT’D)
Assembly (Cont’d)
Figure 20-22-13
Rotate the handles to collapse the rod seal [Figure 20-
22-13].
Figure 20-22-14
Install the rod seal in the head [Figure 20-22-14].
Install the wiper seal with the wiper toward the outside of
the head.
Figure 20-22-15
Install the thin O-ring (Item 1) [Figure 20-22-15].
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Figure 20-22-16
Install the head (Item 1), and spacer (Item 2) [Figure 20-
22-16].
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 122 N•m (90 ft-lb) torque.
N-20613
P7425
P7422
1
2
3
P16294
1
2
3
4
20-22-7 S650 Service Manual
CYLINDER (BOB-TACH) (CONT'D)
Assembly (Cont'd)
Figure 20-22-17
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [Figure 20-22-
17].
P-85647
20-22-8 S650 Service Manual
20-30-1 S650 Service Manual
MAIN RELIEF VALVE
Description
The main relief valve limits the hydraulic system pressure
by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
The main relief valve is adjustable and is located on the
hydraulic control valve near the bottom, facing the front of
the loader.
20-30-2 S650 Service Manual
MAIN RELIEF VALVE (CONT’D)
Testing
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.
W-2006-1209
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
The tools listed will be needed to do the following
procedure:
TWX-RFIK200-S-6 54 U.S. gpm FLOW METER
MEL10006 - Hydraulic Test Kit
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.
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 20-30-1
Connect the IN port (Item 1) [Figure 20-30-1] of the
hydraulic tester to the bottom (female) quick coupler on
the loader.
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
Figure 20-30-2
Start the engine and run at low idle.
• 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.
P-85571
2
1
P-76460C
1
2
20-30-3 S650 Service Manual
MAIN RELIEF VALVE (CONT’D)
Testing (Cont’d)
Figure 20-30-3
Figure 20-30-4
• 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 20-30-
4] a second time.
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full
RPM.
Refer to (See Hydraulic System on Page SPEC-10-3.) for
both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.
With the engine at high idle and hydraulic oil at 140 °F
turn the restrictor control on the tester until the flow
through the tester drops to zero. Check the relief
pressure.
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.
P-85572
Right
Steering
Lever
Control
1
P-26697
1
Right
Steering
Lever 
Control
Joystick Option Only
20-30-4 S650 Service Manual
MAIN RELIEF VALVE (CONT’D)
Adjusting
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5
If the pressure is not correct, adjust the main relief valve.
Loosen the lock nut (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. Check the
pressure setting of the new relief valve.
P-85573
1
2
20-30-5 S650 Service Manual
MAIN RELIEF VALVE (CONT’D)
Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the operator cab. (See Raising on Page 10-30-2.)
Clean the area around the control 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.
Figure 20-30-6
If the pressure is not correct, adjust the main relief valve.
Loosen the lock nut (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. Check the
pressure setting of the new relief valve.
Figure 20-30-7
Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-7].
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-7].
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Check the pressure again. (See Testing on Page 20-30-
2.)
P-85573
1
2
P-37689
20-30-6 S650 Service Manual
20-40-1 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
The hydraulic control valve is located inside the main
frame on the right hand side, below the operators 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 oil 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.
P-90327
20-40-2 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT’D)
Removal And Installation
DANGER
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
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
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
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.)
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.
Open rear door.
Figure 20-40-2
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.
P-90187
2
3
1
20-40-3 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-40-3
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].
Figure 20-40-4
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.
Figure 20-40-5
Disconnect the hose (Item 1) [Figure 20-40-5] that
routes from the control valve to the brake valve.
Disconnect the hose (Item 2) [Figure 20-40-5] that
routes from the control valve to the fan motor.
Figure 20-40-6
Disconnect the hose (Item 1) [Figure 20-40-6] that
routes from the top of the control valve to the hydraulic
filter.
P-90267
1
P-90269
2
3
1
1
P-90270
2
1
P-90271
1
20-40-4 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-40-7
Remove the tubeline clamp (Item 1) [Figure 20-40-7].
Disconnect the two tubelines (Item 2) [Figure 20-40-7]
that route from the control valve to the front auxiliary
hydraulics.
Figure 20-40-8
Remove the tubeline clamp (Item 1) [Figure 20-40-8].
Figure 20-40-9
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.
Figure 20-40-10
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.
Disconnect the lift arm bypass drain hose (Item 2)
[Figure 20-40-10] from the control valve.
P-90272
1
2
2
P-90273
1
P-90274
1
1
1
P-90275
1
2
20-40-5 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-40-11
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 20-40-12
Support the control valve and remove the two bolts (Item
1) [Figure 20-40-12].
Remove the control valve from the loader.
Mount Bracket Removal And Installation
Figure 20-40-13
Support the mounting bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14
Remove the two control valve mount bolts (Item 1)
[Figure 20-40-14].
Remove the two frame bolts (Item 2) [Figure 20-40-14]
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 bracket from the loader.
P-90276
1
P-90278
1
P-90280
1
P-90279
1
2
20-40-6 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-15
P-90307
A2
A3
B2
B3
D1
C2
C3
J2
E1
E2
E3
E3
D5
D2
D3
C1
B1
A1
F1
F2
H1
H3
G1
G2
J3
F3
F4
MR
J1
J4
D4
H2
C4
ITEM S650 LOADER
A1 Lift Cylinder Base End
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulic Rod End
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics Base End
C1 Load Check
C2 Load Check Valve Tilt Function
C3 Load Check Valve Auxiliary Function
C4 Check Valve
D1 Anti-Cavitation Valve
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Lift (Base End)
D3 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Tilt (Base End)
D4 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) 
27,6 MPa (275,8 bar) (4000 psi) (Optional)
ITEM S650 LOADER
E1 Lift Spool Detent
E2 Tilt Spool Centering Spring
E3 Auxiliary Spool/Centering Springs
F1 Lift Spool
F2 Tilt Spool
F3 Lift Spool Lock Solenoid
F4 Tilt Spool Lock Solenoid
G1 Auxiliary Solenoid Stem
G2 Auxiliary Solenoid Stem
H1
BICS Solenoid
H2
BICS Lock Valve (Tilt)
H3
BICS Lock Valve (Lift)
J1 Inlet Fluid Flow (From Pump)
J2 Outlet Fluid Flow (Return to Tank)
J3 Lift Arm Bypass Orifice
J4 Drain (Case)
MR Main Relief Valve – 24,1 MPa (241,3 bar) 
(3500 psi)
20-40-7 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Load Check Valve Removal And Installation
Figure 20-40-16
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS valve fitting on the top of the lift load check
valve.
Figure 20-40-17
Remove the lift load check valve (Item 1) [Figure 20-40-
17] 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.
Figure 20-40-18
Remove and install new O-rings (Item 1) and back-up
ring (Item 2) [Figure 20-40-18].
Check the free movement load check valve and spring
(Item 3) [Figure 20-40-18].
P-90308
1
P-90310
1
P-90309
1
2
3
20-40-8 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Load Check Valve Removal And Installation (Tilt & 
Auxiliary)
Figure 20-40-19
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].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
Figure 20-40-20
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-20].
Check the orifice (Item 3) [Figure 20-40-20] in the
poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-40-
20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-90311
1
2
P-90312
2
3
4
1
20-40-9 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Anti-Cavitation Valve Removal And Installation (Lift, 
Rod End)
Figure 20-40-21
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-22].
Check 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 20-40-
22] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Lift, Base End)
Figure 20-40-23
Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-40-23].
Figure 20-40-24
Replace the O-ring (Item 1) [Figure 20-40-24] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90312
2
3
4
1
P-90314
1
P-90315
1
20-40-10 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Tilt, Base End)
Figure 20-40-25
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
Replace the O-ring (Item 1) [Figure 20-40-26] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Tilt, Rod End)
Figure 20-40-27
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-27] from the rod end of the tilt section.
Figure 20-40-28
Replace the O-ring (Item 1) [Figure 20-40-28] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90316
1
P-90314
1
P-90319
1
20-40-11 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Port Relief Valve Removal And Installation
Figure 20-40-29
Remove the port relief plug (Item 1) [Figure 20-40-29]
from the auxiliary circuit of the control valve.
Figure 20-40-30
Installation: Always use new O-rings (Item 1) [Figure
20-40-30]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-31
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-40-31]. 
Remove the auxiliary port relief valve.
Figure 20-40-32
Installation: Always use new O-rings (Item 1) [Figure
20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90318
1
2
P-90318A
1
P-51640
1
20-40-12 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Plug Removal And Installation
Figure 20-40-33
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-33].
Figure 20-40-34
Installation: Always use new O-rings (Item 1) [Figure
20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.
Figure 20-40-35
At the bottom side of the control valve remove the plug
(Item 1) [Figure 20-40-35]. 
Figure 20-40-36
Installation: Always use new O-rings (Item 1) [Figure
20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.
P-68016
1
P-51460A
1
P-51461
1
P-51462
1
20-40-13 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Rubber Boot Removal And Installation
Figure 20-40-37
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
Remove the rubber boots (Item 1) from the retainer plate
(Item 2) [Figure 20-40-38].
P-51506
1
1
1
P-51701
1
1
2
20-40-14 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
End Cap Block Removal And Installation
Figure 20-40-39
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.
Figure 20-40-40
Disconnect the tube line (Item 1) [Figure 20-40-40] from
the end cap / spool lock block.
Figure 20-40-41
Figure 20-40-42
Remove the four end cap / spool lock block mount
screws (Item 1) [Figure 20-40-41] and [Figure 20-40-
42].
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.
Remove the end cap / spool lock block (Item 4) [Figure
20-40-42] from the control valve.
P-51697
2
1
P-90320
1
P-51699A
1
1
1
1
P-51701
4
2
1
1
20-40-15 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation
The tool listed will be needed to do the following
procedure:
MEL1278 - Detent Tool
MEL1285 - Detent Spring Tool
Remove the end cap / spool lock block from the control
valve. 
Figure 20-40-43
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
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-44] from the lift spool.
Figure 20-40-45
Remove the end cap (Item 1) [Figure 20-40-45].
Figure 20-40-46
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-46].
Remove the washer (Item 2) [Figure 20-40-46].
P-51511A
1
P-51512
1
2
P-90321
1
P-51514
1
2
20-40-16 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-47
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.
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-48
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.
Figure 20-40-49
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-49].
P-51515
1
2
1
P-51516
P-51517
1
2
3
2
20-40-17 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-50
Remove the lift spool assembly and seal (Item 1) [Figure
20-40-50] from the control valve.
Figure 20-40-51
Remove the lift spool seal (Item 1) [Figure 20-40-51]
from the linkage end of the valve.
Figure 20-40-52
Clamp the linkage end of the spool in a vise [Figure 20-
40-52].
NOTE: Protect spool before clamping in vise.
Figure 20-40-53
Install the spring tool (Item 1) [Figure 20-40-53] over the
centering spring.
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-53] from the centering
spring, as it is under spring pressure.
P-51518
1
P-51519
1
P-8988
N-18915
2
1
3
20-40-18 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-54
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.
Remove the detent adapter with an Alan wrench.
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-54].
Figure 20-40-55
Remove the detent adapter (Item 1) [Figure 20-40-55]
from the spring assembly.
Figure 20-40-56
Remove spring tool (Item 1) [Figure 20-40-56] from the
spring assembly.
Figure 20-40-57
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-18916
1
2
N-19004
1
N-19009
1
N-18919A
4
3
2
1
20-40-19 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-58
Remove the stud from the end of the spool [Figure 20-
40-58].
Figure 20-40-59
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in)
drill.
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.
Figure 20-40-60
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-60].
NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
recheck the lift spool before the control valve
is replaced.
Figure 20-40-61
Install the plastic plug and O-ring in the spool [Figure 20-
40-61].
N-18918
N-18920
1
N-18961
2
1
N-18963
20-40-20 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-62
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].
Figure 20-40-63
Clamp the collar (Item 1) [Figure 20-40-63] in a vice.
Figure 20-40-64
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-64].
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
Install the detent adapter to the collar [Figure 20-40-65].
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.
B-14712
Plastic
Plug
O-ring
15,2 mm
(0.60 inch)
N-18967
1
N-18958
3
2
1
2
N-18968
1
20-40-21 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-66
Install the spring tool (Item 1) [Figure 20-40-66] over the
washer, spring, collar and detent adapter.
Figure 20-40-67
Install the spool seal (Item 1) and back-up washer (Item
2) [Figure 20-40-67].
Figure 20-40-68
Install the spring assembly to the lift spool hand tight
[Figure 20-40-68].
Remove the spring tool.
Check the alignment of the detent adapter and the
washer.
Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-68].
Figure 20-40-69
Install the detent balls and spring [Figure 20-40-69].
N-19004
1
N-18917
1
2
N-19005
1
CD-15051
20-40-22 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-70
Hold the detent balls in place with the detent pliers
[Figure 20-40-70].
Figure 20-40-71
Install the detent sleeve (Item 1) [Figure 20-40-71] to the
detent adapter.
Figure 20-40-72
Install the lift spool assembly in the spool bore [Figure
20-40-72].
Install the detent bonnet (Item 1) [Figure 20-40-72].
Install the mounting screws (Item 2) [Figure 20-40-72].
Installation: Lubricate the screws and tighten to 10,2 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-73
Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-73].
N-19007
N-19008
1
P-51515
2
2
1
P-51514
2
1
20-40-23 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-74
Install the end cap (Item 1) [Figure 20-40-74].
Figure 20-40-75
Install the spool seal (Item 1) [Figure 20-40-75] on the
linkage end of the valve.
Figure 20-40-76
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-40-76] on the lift spool.
Figure 20-40-77
Install the O-ring (Item 1) [Figure 20-40-77] on the
control valve.
P-90321
1
P-51520
1
P-51512
2
1
P-51511A
1
20-40-24 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Spool And Detent Removal And Installation 
(Cont'd)
Figure 20-40-78
Install the end cap / spool lock block (Item 1) and the
mount bolt (Item 2) [Figure 20-40-78].
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
Connect the tubeline (Item 1) [Figure 20-40-79].
Figure 20-40-80
Use an ohmmeter to measure the lock solenoid coils
resistance.
The correct resistance for the coil is 16.02 - 19.58 ohm.
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].
P-51701
1
3
4
2
P-90320
1
P-51697
2
1
20-40-25 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap Block Removal And Installation on Page 20-40-
14.)
Figure 20-40-81
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-81] from the tilt spool.
Figure 20-40-82
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.
Figure 20-40-83
Remove the spool centering block (Item 1) [Figure 20-
40-83] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-
83] and lubricate the O-ring lightly with grease or oil
before installation of the end cap / spool lock block.
Figure 20-40-84
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-40-84].
Assembly: Always use a new spool seal.
P-51521
1
2
P-90321
2
1
1
2
P-90323
1
2
P-51544
20-40-26 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-85
Put the linkage end of the spool in the vice [Figure 20-
40-85].
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
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.
Figure 20-40-87
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-87].
Figure 20-40-88
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-18942
1
N-19014
1
N-18944A
4
3
2
1
N-18943
P-51545
1
2
1
20-40-27 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-89
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.
Remove the spool centering block (Item 3) [Figure 20-
40-89] from the control valve.
Figure 20-40-90
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.
Figure 20-40-91
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-91] from the auxiliary spool.
Figure 20-40-92
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.
P-90321
2
1
1
2
3
P-51546A
2
1
P-51547
1
2
P-51549A
1
2
20-40-28 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-93
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-93] from the auxiliary spool.
Figure 20-40-94
Remove the spool (Item 1) [Figure 20-40-94].
P-51550
1
2
P-51551
1
20-40-29 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-95
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
Check and 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.
P-85528
1
1
2
2
P-85556
1
20-40-30 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Solenoid Removal And Installation
Figure 20-40-97
Remove the nut (Item 1) [Figure 20-40-97] from the
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-97].
Figure 20-40-98
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.
Figure 20-40-99
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.
Figure 20-40-100
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.
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.
P-90310
2
1
N-18693A
1
1
P-85528
1
N-18694
2
1
3
20-40-31 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-101
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 20-40-102
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.
Figure 20-40-103
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.
Figure 20-40-104
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-
104].
P-90310
2
1
P-90321
1
P-51564
1
2
2
2
1
1
1
P-51705
1
20-40-32 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105
Remove the lift spool lock solenoid (Item 1) [Figure 20-
40-105].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-
40-105].
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
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.
Figure 20-40-107
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
1
2
P-90324
1
P-51564
1
2
2
2
1
1
1
20-40-33 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-108
Remove the fitting (Item 1) [Figure 20-40-108] from the
valve.
Figure 20-40-109
Check the lift arm bypass orifice (Item 1) [Figure 20-40-
109].
NOTE: This orifice is not removable from the valve
casting.
Main Relief Valve Removal And Installation
Figure 20-40-110
Remove the main relief valve (Item 1) [Figure 20-40-
110].
Figure 20-40-111
Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Installation: Always use new O-rings. Tighten to 52 - 61
N•m (38 - 45 ft-lb) torque.
P-90308
1
P-51437
1
P-51707
1
P-51463
1
20-40-34 S650 Service Manual
HYDRAULIC CONTROL VALVE (STANDARD) 
(CONT'D)
Check Valve Removal And Installation
Figure 20-40-112
Remove the tubeline (Item 1) [Figure 20-40-112].
Figure 20-40-113
Remove the check valve fitting (Item 1) [Figure 20-40-
113] from the hydraulic control valve.
Figure 20-40-114
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-
114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
torque.
Figure 20-40-115
Inspect the screen (Item 1) [Figure 20-40-115].
P-90308
1
P-90310
1
P-68869
1
P-90326
1
20-41-1 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
Description
Figure 20-41-1
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 oil 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.
Removal And Installation
DANGER
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
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
P-90337
20-41-2 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
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.)
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: 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.
Open rear door.
Figure 20-41-2
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-41-2] off to the side.
Figure 20-41-3
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].
P-90187
2
3
1
P-90267
1
20-41-3 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-41-4
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.
Figure 20-41-5
Disconnect the hose (Item 1) [Figure 20-41-5] that
routes from the control valve to the brake valve.
Disconnect the hose (Item 2) [Figure 20-41-5] that
routes from the control valve to the fan motor.
Figure 20-41-6
Disconnect the hose (Item 1) [Figure 20-41-6] that
routes from the top of the control valve to the hydraulic
filter.
Figure 20-41-7
Remove the tubeline clamp (Item 1) [Figure 20-41-7].
Disconnect the two tubelines (Item 2) [Figure 20-41-7]
that route from the control valve to the front auxiliary
hydraulics.
P-90269
2
3
1
1
P-90270
2
1
P-90271
1
P-90272
1
2
2
20-41-4 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-41-8
Remove the tubeline clamp (Item 1) [Figure 20-41-8].
Figure 20-41-9
Disconnect the three tubelines (Item 1) [Figure 20-41-9]
that route from the control valve to the junction block at
the rear of the loader.
Figure 20-41-10
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.
Figure 20-41-11
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.
P-90273
1
P-90274
1
1
1
P-90275
1
2
P-90276
1
20-41-5 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-41-12
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-12].
Remove the control valve from the loader.
Actuator Removal And Installation (In Loader)
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.)
Stop the engine. Raise the seat bar.
Mark the actuator wiring harness connectors for proper
installation.
Figure 20-41-13
Unplug the actuator connectors (Item 1) [Figure 20-41-
13] from the loader harness.
P-90278
1
P-90330
1
20-41-6 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Actuator Removal And Installation (In Loader) 
(Cont’d)
Figure 20-41-14
Remove the two screws (Item 1) [Figure 20-41-14] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
Figure 20-41-15
Pull the actuator (Item 1) [Figure 20-41-15] away from
the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure
20-41-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed
when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)
Figure 20-41-16
Inspect the O-ring (Item 1) [Figure 20-41-16] on the face
of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-16] and
replace as needed.
P-54587
1
P-54566
1
2
P-54568
1
2
20-41-7 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Actuator Removal And Installation (Out Of Loader)
Remove the control valve from the loader.
Figure 20-41-17
Remove the two mount bolts (Item 1) [Figure 20-41-17]
from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Figure 20-41-18
Slide the actuator mount bracket (Item 1) [Figure 20-41-
18] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-18].
Figure 20-41-19
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-41-19] from the actuator
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-20
Inspect the O-ring (Item 1) [Figure 20-41-20] on the face
of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-20] and
replace as needed.
P-54337
1
1
P-54338
1
P-54339
1
P-54340
1
2
20-41-8 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Actuator Removal And Installation (Out of Loader) 
(Cont’d)
Figure 20-41-21
Remove the two mount bolts (Item 1) [Figure 20-41-21]
from the lift actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Figure 20-41-22
Slide the actuator mount bracket (Item 1) [Figure 20-41-
22] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-22].
Figure 20-41-23
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-41-23] from the actuator
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-24
Inspect the O-ring (Item 1) [Figure 20-41-24] on the face
of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-24] and
replace as needed.
P-54341
1
1
P-54342
1
P-54343
1
P-54340
1
2
20-41-9 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Actuator Removal And Installation (Out Of Loader) 
(Cont’d)
Figure 20-41-25
NOTE: The two longer bolts (Item 1) are used to
mount the lift actuator and end cap (Item 2)
[Figure 20-41-25] 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 20-41-25].
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-41-25]
P-90329
3
1
2
4
3
20-41-10 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Identification Chart 
Figure 20-41-26
P-90307
A2
A3
B2
B3
D1
C2
C3
J2
E1
E2
E3
E3
D5
D2
D3
C1
B1
A1
F1
F2
H1
H3
G1
G2
J3
F3
F4
MR
J1
J4
D4
H2
C4
ITEM S650 LOADER
A1 Lift Cylinder Base End
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulic Rod End
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics Base End
C1 Load Check
C2 Load Check Valve Tilt Function
C3 Load Check Valve Auxiliary Function
C4 Check Valve
D1 Anti-Cavitation Valve
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Lift (Base End)
D3 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Tilt (Base End)
D4 Port Relief/Anti-Cavitation Valve – 27,6 MPa 
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) 
27,6 MPa (275,8 bar) (4000 psi) (Optional)
ITEM S650 LOADER
E1 Lift Spool Detent
E2 Tilt Spool Centering Spring
E3 Auxiliary Spool/Centering Springs
F1 Lift Spool
F2 Tilt Spool
F3 Lift Spool Lock Solenoid
F4 Tilt Spool Lock Solenoid
G1 Auxiliary Solenoid Stem
G2 Auxiliary Solenoid Stem
H1
BICS Solenoid
H2
BICS Lock Valve (Tilt)
H3
BICS Lock Valve (Lift)
J1 Inlet Fluid Flow (From Pump)
J2 Outlet Fluid Flow (Return to Tank)
J3 Lift Arm Bypass Orifice
J4 Drain (Case)
MR Main Relief Valve – 24,1 MPa (241,3 bar) 
(3500 psi)
20-41-11 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-27
Support the mounting bracket (Item 1) [Figure 20-41-27].
Figure 20-41-28
Remove the two control valve mount bolts (Item 1)
[Figure 20-41-28].
Remove the two frame bolts (Item 2) [Figure 20-41-28]
Installation: Torque the two frame bolts (Item 2) [Figure
20-41-28] to 406 - 447 N•m (300 - 330 ft lb).
Remove the control valve bracket from the loader.
Lift Load Check Valve Removal And Installation
Figure 20-41-29
Remove the charge tubeline (Item 1) [Figure 20-41-29]
from the BICS valve fitting on the top of the lift load check
valve.
Figure 20-41-30
Remove the lift load check valve (Item 1) [Figure 20-41-
30] 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.
P-90280
1
P-90279
1
2
P-90308
1
P-90310
1
20-41-12 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Load Check Valve Removal And Installation 
(Cont’d)
Figure 20-41-31
Remove and install new O-rings (Item 1) and back-up
ring (Item 2) [Figure 20-41-31].
Check the free movement load check valve and spring
(Item 3) [Figure 20-41-31].
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
Load Check Valve Removal And Installation (Tilt & 
Auxiliary)
Figure 20-41-32
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-32].
NOTE: The tilt and auxiliary load check valves are
interchangeable.
Figure 20-41-33
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-33].
Check the orifice (Item 3) [Figure 20-41-33] in the
poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-41-
33] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.
P-90309
1
2
3
P-90311
1
2
P-90312
2
3
4
1
20-41-13 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Anti-Cavitation Valve Removal And Installation (Lift, 
Rod End)
Figure 20-41-34
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-34].
Figure 20-41-35
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-35].
Check the orifice (Item 3) [Figure 20-41-35] in the
poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-41-
35] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Lift, Base End)
Figure 20-41-36
Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-41-36].
Figure 20-41-37
Replace the O-ring (Item 1) [Figure 20-41-37] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90312
2
3
4
1
P-90314
1
P-90315
1
20-41-14 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Tilt, Base End)
Figure 20-41-38
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-38] from the base end of the tilt section.
Figure 20-41-39
Replace the O-ring (Item 1) [Figure 20-41-39] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Port Relief / Anti-Cavitation Valve Removal And 
Installation (Tilt, Rod End)
Figure 20-41-40
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-40] from the rod end of the tilt section.
Figure 20-41-41
Replace the O-ring (Item 1) [Figure 20-41-41] before
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90316
1
P-90314
1
P-90319
1
20-41-15 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-41-42
Remove the port relief plug (Item 1) [Figure 20-41-42]
from the auxiliary circuit of the control valve.
Figure 20-41-43
Installation: Always use new O-rings (Item 1) [Figure
20-41-43]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-41-44
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-41-44]. 
Remove the auxiliary port relief valve.
Figure 20-41-45
Installation: Always use new O-rings (Item 1) [Figure
20-41-45]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
P-90314
1
P-90318
1
P-90318A
1
P-51640
1
20-41-16 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Plug Removal And Installation
Figure 20-41-46
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-46].
Figure 20-41-47
Installation: Always use new O-rings (Item 1) [Figure
20-41-47]. Tighten to 81,3 N•m (60 ft-lb) torque.
Figure 20-41-48
At the bottom side of the control valve remove the plug
(Item 1) [Figure 20-41-48]. 
Figure 20-41-49
Installation: Always use new O-rings (Item 1) [Figure
20-41-49]. Tighten to 81,3 N•m (60 ft-lb) torque.
P-68016
1
P-51460A
1
P-51461
1
P-51462
1
20-41-17 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
End Cap Block Removal And Installation
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on
Page 20-41-5.)
Figure 20-41-50
Disconnect the tube line (Item 1) [Figure 20-41-50] from
the end cap block.
Remove the two end cap block mount screws (Item 2)
[Figure 20-41-50].
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
Figure 20-41-51
Remove the end cap block (Item 1) [Figure 20-41-51]
from the control valve.
Lift Spool Removal And Installation
The tool listed will be needed to do the following
procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve. 
Figure 20-41-52
Remove the O-ring (Item 1) [Figure 20-41-52].
Installation: Replace the O-ring, and lubricate lightly
with oil before installation of the end cap block.
Figure 20-41-53
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-53] from the lift spool.
P-90338
1
2
P-90339
1
P-68042
1
P-68047
1
2
20-41-18 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-54
Remove the two screws (Item 1) [Figure 20-41-54] 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 20-41-55
Remove the lift spool end cap (Item 1) [Figure 20-41-55]
from the control valve.
Figure 20-41-56
Remove the lift spool assembly and seal (Item 1) [Figure
20-41-56] from the control valve.
Figure 20-41-57
Remove the lift spool seal (Item 1) [Figure 20-41-57]
from the linkage end of the valve.
P-68043
1
1
P-68044
1
P-68045
1
P-68046
1
20-41-19 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-58
Clamp the linkage end of the spool in a vise [Figure 20-
41-58].
NOTE: Protect spool before clamping in vise.
Figure 20-41-59
Install the spring tool (Item 1) [Figure 20-41-59] over the
centering spring.
Figure 20-41-60
Remove the bolt (Item 1) [Figure 20-41-60] 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.
Figure 20-41-61
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-61].
P-51772
P-51773
1
N-190146
1
P-51776
4
3
2
1
20-41-20 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-62
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in)
drill.
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 20-41-62] 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.
Figure 20-41-63
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-41-63].
NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
recheck the lift spool before the control valve
is replaced.
Figure 20-41-64
Install the plastic plug and O-ring in the spool [Figure 20-
41-64].
Figure 20-41-65
Remove the spool seal(s) (Item 1) and the back-up
washer (Item 2) [Figure 20-41-65].
Assembly: Always use a new spool seal.
N-18920
1
P-74183
2
1
P-74184
P-51775
P-68046
1
2
1
20-41-21 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-66
Install the lift spool assembly (Item 1) [Figure 20-41-66]
in the spool bore.
Install the end cap (Item 2) [Figure 20-41-66].
Install the mounting screws (Item 3) [Figure 20-41-66].
Installation: Lubricate the screws and tighten to 10,2 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-67
Install the spool seal (Item 1) [Figure 20-41-67] on the
linkage end of the valve.
Figure 20-41-68
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-41-68] on the lift spool.
Figure 20-41-69
Install the O-ring (Item 1) [Figure 20-41-69] on the
control valve.
Installation: Replace the O-ring, lubricate lightly with oil
or grease before installation of the end cap block.
P-68044
2
3
1
3
P-68048
1
P-68047
2
1
P-68042
1
20-41-22 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-70
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-41-70].
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
Connect the tubeline (Item 3) [Figure 20-41-70] to the
end cap block.
Install the lift and tilt actuators to the control valve.
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block
Removal And Installation on Page 20-41-17.)
Figure 20-41-71
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-71] from the tilt spool.
Figure 20-41-72
Disconnect the two tubelines (Item 1) [Figure 20-41-72].
Remove the three screws (Item 2) [Figure 20-41-72]
from the spool centering block.
Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100
in-lb) torque.
P-68040
2
1
3
P-68049
1
2
P-90321
1
1
2
2
20-41-23 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-41-73
Remove the spool centering block (Item 1) [Figure 20-
41-73] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-41-
73] and lubricate lightly with oil / grease before
installation of the end cap block.
Figure 20-41-74
Remove the tilt spool, centering spring, back-up washer
and spool seal (Item 1) [Figure 20-41-74].
Assembly: Always use a new spool seal.
Figure 20-41-75
Put the linkage end of the spool in the vice [Figure 20-
41-75].
Install the spring tool (Item 1) [Figure 20-41-75] over the
centering spring.
Figure 20-41-76
Remove the bolt (Item 1) [Figure 20-41-76] 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.
P-90342
1
2
P-68052
1
N-18942
1
N-19014
1
20-41-24 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-41-77
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-77].
Figure 20-41-78
Remove the spool seal(s) (Item 1) and the back-up
washer (Item 2) [Figure 20-41-78].
Assembly: Always use a new spool seal.
Auxiliary Spool Removal And Installation
Figure 20-41-79
Disconnect the two tubelines (Item 1) [Figure 20-41-79]
from the spool centering block.
Remove the three screws (Item 2) [Figure 20-41-79]
from the spool centering block.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
Remove the spool centering block from the control valve.
Figure 20-41-80
Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-41-80] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure
20-41-80] must be replaced, replace the
retainer on the opposite end also.
N-18944A
4
3
2
1
N-18943
P-51545
1
2
1
P-90321
1
1
2
2
P-68053
2
1
20-41-25 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-81
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-81] from the auxiliary spool.
Figure 20-41-82
Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-41-82] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure
20-41-82] must be replaced, replace the
retainer on the opposite end also.
Figure 20-41-83
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-83] from the auxiliary spool.
Figure 20-41-84
Remove the auxiliary spool (Item 1) [Figure 20-41-84].
P-68054
2
1
P-68076
1
2
P-68077
1
2
P-68078
1
20-41-26 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Auxiliary Solenoid Removal And Installation
Figure 20-41-85
Remove the screws (Item 1) [Figure 20-41-85] from both
solenoids.
Remove the solenoids (Item 2) [Figure 20-41-85].
Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6
- 26.4 in-lb) torque.
Figure 20-41-86
Check and remove the O-rings (Item 1) [Figure 20-41-
86] 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.
P-90337
1
1
2
2
P-85556
1
20-41-27 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Solenoid Removal And Installation
Figure 20-41-87
Remove the nut (Item 1) [Figure 20-41-87] from the
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-87].
Figure 20-41-88
Remove the O-rings (Item 1) [Figure 20-41-88] 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.
Figure 20-41-89
Remove the solenoid stem (Item 1) [Figure 20-41-89].
Installation: Lubricate the O-rings and tighten the stem
to 27 - 33 N•m (20 - 24 ft-lb) torque.
Figure 20-41-90
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-90] from the stem.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing
excessive wear.
NOTE: The screen (Item 3) [Figure 20-41-90] may be
cleaned with solvent. If it is torn or worn the
solenoid 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 20-41-88] and
[Figure 20-41-90] and new back-up rings (Item 2)
[Figure 20-41-90] on the solenoid stem.
P-90337
1
2
N-18693A
1
1
P-90346
1
N-18694
2
1
3
20-41-28 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-91
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-41-91] is for the lift circuit.
Figure 20-41-92
Remove the lift lock valve (Item 1) [Figure 20-41-92]
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.
Figure 20-41-93
Remove the tilt lock valve (Item 1) [Figure 20-41-93]
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.
Figure 20-41-94
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-94] from the valve, and replace with new.
P-90310
2
1
P-90321
1
P-51792
1
P-51564
1
2
2
2
1
1
1
20-41-29 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-95
Remove the fitting (Item 1) [Figure 20-41-95] from the
valve.
Figure 20-41-96
Check the lift arm bypass orifice (Item 1) [Figure 20-41-
96].
NOTE: This orifice is not removable from the valve
casting.
Main Relief Valve Removal And Installation
Figure 20-41-97
Remove the main relief valve (Item 1) [Figure 20-41-97].
Figure 20-41-98
Remove the O-rings from the main relief valve (Item 1)
[Figure 20-41-98].
Installation: Always use new O-rings. Tighten to 52 - 61
N•m (38 - 45 ft-lb) torque.
P-90308
1
P-51437
1
P-51794
1
P-90344
1
20-41-30 S650 Service Manual
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 
(CONT’D)
Check Valve Removal And Installation
Figure 20-41-99
Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100
Remove the check valve fitting (Item 1) [Figure 20-41-
100] from the hydraulic control valve.
Figure 20-41-101
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-
101] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
torque.
Figure 20-41-102
Inspect the screen (Item 1) [Figure 20-41-102].
P-90308
1
P-90310
1
P-68869
1
P-90326
1
20-50-1 S650 Service Manual
LIFT ARM BYPASS CONTROL VALVE
Description
The lift arm bypass control valve is located on the right
side of the machine.
The lift arm bypass control valve is manually operated by
pulling on the valve (Item 1) [Figure 20-50-1] and turning
the knob 90° clockwise. The valve releases the hydraulic
fluid from the base end of the lift cylinder(s) which allows
the lift arm to slowly come down to the transport position. 
Testing
Figure 20-50-1
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob should return to its normal position.
P-85290B
1
P-85290A
20-50-2 S650 Service Manual
LIFT ARM BYPASS CONTROL VALVE (CONT’D)
Removal And Installation
DANGER
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
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
Lower the lift arms.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 20-50-2
Hold the lift arm bypass control knob (Item 1) [Figure 20-
50-2] 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
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.
P-85670
2
3
1
P-85671
1
2
20-50-3 S650 Service Manual
LIFT ARM BYPASS CONTROL VALVE (CONT'D)
Bracket Removal And Installation 
Figure 20-50-4
Remove the two bolts (Item 1) [Figure 20-50-4] to
replace the bypass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm
bypass valve in the loader.
Disassembly And Assembly
Figure 20-50-5
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
damage and replace if necessary.
Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
lb) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.
P-85672
1
P-85673
1
2
20-50-4 S650 Service Manual
20-60-1 S650 Service Manual
HYDRAULIC PUMP
Description
The hydraulic pump is attached to the end of the
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that
provide hydraulic flow to several hydraulic systems. 
The hydraulic pump has a dedicated charge pump. This
supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
A seal kit is available to service the hydraulic pump. If any
of the main components of the pump are damaged, the
entire pump must be replaced.
Pump Test At Quick Couplers
The tools listed will be needed to do the following
procedure:
TWX-RFIK200-S-6 54 U.S. gpm Flow Meter
MEL10006 - Fitting Kit
Figure 20-60-1
NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19,1 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. 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.
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 6,9 MPa
(69 bar) (1000 psi).
NOTE: DO NOT EXCEED 25,5 MPa (255 bar) (3700
psi).
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 gpm should drop off slightly
until the pressure reaches approximately 21,4 MPa
(213,7 bar) (3100 psi). At approximately 21,4 MPa (213,7
bar) (3100 psi) the flow should start decreasing rapidly
until the pressure reaches 23,8 - 24,1 MPa (237,9 - 241,3
bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9 - 241,3
bar) (3450 - 3500 psi) the flow should be at zero 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.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)
for system relief pressure and full RPM.
P-90171
11
2
20-60-2 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following
procedure:
MEL1563 or 7003031 - Remote Start Tool
TWX-RFIK200-S-6 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 Procedure 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.
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 -
7003031 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo
clarity.
Figure 20-60-2
Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
that comes from the gear pump, and connects to the
control valve. 
Figure 20-60-3
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.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-90176
1
P-90178
2
1
2
P-90580
1
2
20-60-3 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (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*.
Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 6,9 MPa (69 bar) (1000 psi).
DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the remote start tool engage the auxiliary hydraulics,
the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (gpm). The high pressure flow
must be at least 80% of free flow.
A low percentage may indicate a failed pump.
*Refer to (See Hydraulic System on Page SPEC-10-3.)
for system relief pressure and full RPM.
HIGH PRESSURE FLOW (U.S. gpm)
FREE FLOW (U.S. gpm)
% =     X 100
20-60-4 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Charge Section)
The tools listed will be needed to do the following
procedure:
MEL1563 or 7003031 - Remote Start Tool
TWX-RFIK200-S-6 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 Procedure 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.
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 -
7003031 on Page 10-61-1.)
Figure 20-60-4
Disconnect the inlet hose (Item 1) [Figure 20-60-4].
Figure 20-60-5
Connect the INLET hose (Item 1) [Figure 20-60-5] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-4]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-60-4].
P-85897A
1
P-90580
1
2
20-60-5 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Charge 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*.
Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 4,1 MPa (41,4 bar) (600
psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.
Turn the restrictor down to system operating pressure
approximately 6,9 MPa (69 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
A low percentage may indicate a failed pump.
*Refer to the Hydraulic Schematics for pump flow and
rpm.
HIGH PRESSURE FLOW (U.S. gpm)
FREE FLOW (U.S. gpm)
% =     X 100
20-60-6 S650 Service Manual
HYDRAULIC PUMP (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.
W-2059-0598
DANGER
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
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
Open the rear door of the loader.
Figure 20-60-6
Disconnect and cap the four hoses (Item 1) [Figure 20-
60-6] from the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See
Removal And Installation on Page 20-130-1.)
Figure 20-60-7
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
60-7] from the hydraulic pump.
Remove the two mounting bolts (Item 2) [Figure 20-60-
7] 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 20-60-7]
from the loader.
P-90180
1
1
1
1
P-90509
1
1
3
2
2
20-60-7 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Removal And Installation (Cont’d)
Figure 20-60-8
Replace the O-ring (Item 1) [Figure 20-60-8] on the
hydraulic pump.
Reverse the removal procedure to install the hydraulic
pump.
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 20-60-9
To crank the engine without starting, the machine key
switch can be bypassed. Obtain a starter bypass tool
from a local source which can be used as a universal
connection to remotely crank the engine without starting.
The starter bypass tool consists of two wires, each with a
clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Connect the starter bypass tool to the starter solenoid
battery terminal and S terminal. 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.
Start the loader from the operators 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.
P-43938AP-43940
1
P-59354
Momentary Switch
Starter Bypass Tool
20-60-8 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Parts Identification
Figure 20-60-10
P-66540
6
5
4
3
2
6
8
7
9
1
10
2
3
12
13
14
6
6
15
16
5
11
4
17
2
2
5
5
18
20-60-9 S650 Service Manual
HYDRAULIC PUMP (CONT'D)
Parts Identification (Cont’d)
The items listed below refer to Page 20-60-8 [Figure 20-
60-10].
1. Auxiliary Pump End Section
2. Section Seal
3. Pre-Load Seal
4. Load Seal
5. Wear Plate
6. Alignment Pins
7. Drive Gear (Auxiliary Pump)
8. Idler Gear (Auxiliary Pump)
9. Auxiliary Pump Center Section
10. Auxiliary Pump End Section
11. Spline Shaft
12. Drive Gear (Charge Pump)
13. Idler Gear (Charge Pump)
14. Charge Pump Center Section
15. Charge Pump End Section
16. Shaft Seal
17. Bolts (4)
18. Bolts (4)
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 20-60-8.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service
Parts. 
Assembly: Tighten the eight pump housing bolts (Item
19) [Figure 20-60-10] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plate (Item 5) [Figure 20-60-
10] 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.
20-60-10 S650 Service Manual
20-61-1 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW)
Description
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.
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 54 U.S. gpm Flow Meter
MEL10006 - Fitting Kit
Figure 20-61-1
NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19,1 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. 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 20-61-1] onto
the front auxiliary quick couplers.
This procedure will require one operator in the cab and
one operator running the tester.
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 6,9 MPa
(69 bar) (1000 psi).
NOTE: DO NOT EXCEED 25,5 MPa (255 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 gpm should drop off slightly
until the pressure reaches approximately 21,4 MPa
(213,7 bar) (3100 psi). At approximately 21,4 MPa (213,7
bar) (3100 psi) the flow should start decreasing rapidly
until the pressure reaches 23,8 - 24,1 MPa (237,9 - 241,3
bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9 - 241,3
bar) (3450 - 3500 psi) the flow should be at zero 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.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)
for system relief pressure and full RPM.
P-90171
11
2
20-61-2 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following
procedure:
MEL1563 or 7003031 - Remote Start Tool
TWX-RFIK200-S-6 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 Procedure 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.
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 -
7003031 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo
clarity.
Figure 20-61-2
Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
that comes from the gear pump, and connects to the
control valve. 
Figure 20-61-3
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.
P-90176
1
P-90178
2
1
2
P-90580
1
2
20-61-3 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (Standard Section) (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*.
Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 6,9 MPa (69 bar) (1000 psi).
DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the remote start tool engage the auxiliary hydraulics,
the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (gpm). The high pressure flow
must be at least 80% of free flow.
A low percentage may indicate a failed pump.
*Refer to (See Hydraulic System on Page SPEC-10-3.)
for system relief pressure and full RPM.
Direct Pump Test (Charge Section)
The tools listed will be needed to do the following
procedure:
MEL1563 or 7003031 - Remote Start Tool
TWX-RFIK200-S-6 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 Procedure 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.
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 -
7003031 on Page 10-61-1.)
HIGH PRESSURE FLOW (U.S. gpm)
FREE FLOW (U.S. gpm)
% =     X 100
20-61-4 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-61-4
Disconnect the inlet hose (Item 1) [Figure 20-61-4].
Figure 20-61-5
Connect the INLET hose (Item 1) [Figure 20-61-5] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-4]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-61-4].
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*.
Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 4,1 MPa (41,4 bar) (600
psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.
Turn the restrictor down to system operating pressure
approximately 6,9 MPa (69 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
A low percentage may indicate a failed pump.
*Refer to the Hydraulic Schematics for pump flow and
rpm.
P-85897A
1
P-90580
1
2
HIGH PRESSURE FLOW (U.S. gpm)
FREE FLOW (U.S. gpm)
% =      X 100
20-61-5 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (High Flow Section)
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
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
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 7003031 - Remote Start Tool
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure 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 -
7003031 on Page 10-61-1.)
Figure 20-61-6
Install a jumper hose (Item 1) [Figure 20-61-6] 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.)
P-90186
1
20-61-6 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (High Flow Section) (Cont'd)
Figure 20-61-7
Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow check valve INLET fitting (Item 2)
[Figure 20-61-7].
Figure 20-61-8
Connect the INLET hose (Item 1) [Figure 20-61-8] from
the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.
Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 6,9 MPa (69 bar) (1000 psi).
NOTE: DO NOT EXCEED 3700 PSI.
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm. Increase the restriction and the flow
should drop to zero U.S. gpm between 24,1 MPa (241,3
bar) (3500 psi) and 25,5 MPa (255,1 bar) (3700 psi).
If pressure readings are not obtained go to the High Flow
Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)
Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.
A low percentage may indicate a failed pump.
*Refer to Hydraulic Schematics for system relief pressure
and full rpm.
P-90183
1
2
P-90580
1
2
%= HIGH PRESSURE FLOW (U.S. gpm) X100
FREE FLOW (U.S. gpm)
20-61-7 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
High Flow Relief Valve Adjustment
If the pump is unable to reach 3500 PSI stop the engine.
The relief screw (Item 1) [Figure 20-61-11] will need to
be turned clockwise 90° and retested with the procedure
above. (90° equals approximately 1,4 MPa (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 checked and is OK, go to the
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-13.)
Remove right rear wheel. (See Wheel Nuts on Page 10-
160-1.)
Figure 20-61-9
Remove the mounting bolts (Item 1) [Figure 20-61-9]
from the access cover and remove the cover from the
loader.
Figure 20-61-10
Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove the plug (Item 2) [Figure 20-61-10] located on
the bottom of the high flow relief valve. 
Figure 20-61-11
NOTE: [Figure 20-61-11] shows adjusting the relief
screw.
If the pump reaches 25,5 MPa (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.
P-90577
1
P-45443
1
2
P-45445
1
20-61-8 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
High Flow Relief Valve 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.
W-2017-0286
Remove right rear wheel. (See Wheel Nuts on Page 10-
160-1.)
Figure 20-61-12
Remove the mounting bolts (Item 1) [Figure 20-61-12]
from the access cover and remove the cover from the
loader.
Figure 20-61-13
Locate the high flow relief valve through rear door along
the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-13] from
the pump.
Installation: Tighten the relief valve to 41 - 47 N•m (30 -
35 ft-lb) torque.
Figure 20-61-14
Inspect the relief valve and replace the two O-rings (Item
1) and washer (Item 2) [Figure 20-61-14].
If the relief valve is bad, it must be replaced as a
complete unit.
Remove the plug (Item 3) and inspect the O-ring [Figure
20-61-14] damage and replace as needed.
P-90577
1
P-45444
1
P-45459
1
1
2
3
20-61-9 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Solenoid Removal And Installation 
Figure 20-61-15
At the right side access hole, disconnect the electrical
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid.
Figure 20-61-16
Remove the solenoid nut (Item 1) [Figure 20-61-16].
Remove the solenoid (Item 2) [Figure 20-61-16].
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -
72 in-lb)
Figure 20-61-17
NOTE: Mark the pump housing (Item 1) [Figure 20-61-
17] for proper installation of the solenoid
valve cartridge.
Remove the valve cartridge (Item 1) [Figure 20-61-17].
Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-18
Inspect the O-ring (Item 1) [Figure 20-61-18] and
replace as needed.
Inspect the O-ring and back-up washer (Item 2) [Figure
20-61-18] and replace as needed.
P-43958
1
P-45460
1
2
P-45461
2
1
P-45462
2
1
20-61-10 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (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.
W-2059-0598
DANGER
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
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
120-2.) 
Open the rear door of the loader.
Figure 20-61-19
Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-19] from the front of the hydraulic pump.
Figure 20-61-20
Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
from the back of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See
Removal And Installation on Page 20-61-10.)
P-90184
1
1
1
1
P-90185
1
20-61-11 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Removal And Installation (Cont’d)
Figure 20-61-21
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
61-21] from the hydraulic pump.
Remove the two mounting bolts (Item 2) [Figure 20-61-
21] 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 20-61-21]
from the loader.
Figure 20-61-22
Replace the O-ring (Item 1) [Figure 20-61-22] on the
hydraulic pump.
Reverse the removal procedure to install the hydraulic
pump.
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 20-61-23
To crank the engine without starting, the machine key
switch can be bypassed. Obtain a starter bypass tool
from a local source which can be used as a universal
connection to remotely crank the engine without starting.
The starter bypass tool consists of two wires, each with a
clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Connect the starter bypass tool to the starter solenoid
battery terminal and S terminal. 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.
Start the loader from the operators 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.
P-90509A
1
1
2
2
3
P-43938AP-43940
1
P-59354
Momentary Switch
Starter Bypass Tool
20-61-12 S650 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Parts Identification
Figure 20-61-24
6
MS1456S
22
1. Stem
2. Valve
3. Wear Plate
4. Seal Section
5. Rear Housing
6. Bolt
7. Pre-load Seal
8. Load Seal
9. Spline Connector
10. Pin
11. Gear Set
12. Gear Housing
13. Gear Housing
14. Gear Set
15. Gear Housing
16. Gear Set
17. Center Housing
18. Center Housing
19. Front Housing
20. Shaft Seal
21. High Flow Relief
22. Seal
23. Nut
24. Coil
5
1
21
22
4
3
3
3
3
3
4
4
7
8
9
8
7
4
4
4
7
8
4
2
10
10
11
12
17
10
10
10
10
16
15
13
14
18
19
20
24
23
9
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 20-61-12.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service
Parts. 
Assembly: Tighten the eight pump housing bolts (Item 6)
[Figure 20-61-24] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plate (Item 3) [Figure 20-61-
19] 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
washers.
20-61-14 S650 Service Manual
20-70-1 S650 Service Manual
HYDRAULIC / HYDROSTATIC FILTERS
Description
The hydraulic / hydrostatic filters help to remove
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one
main filter and one charge flow filter.
The main filter removes contaminants before entering
gear pumps including oil returning from the main valve.
The charge flow filter removes contaminants after the
charge pump.
Housing Removal And Installation
DANGER
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
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
Figure 20-70-1
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 fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Disconnect the electrical connector (Item 1) [Figure 20-
70-1] from the hydraulic / hydrostatic filter sender.
Disconnect and plug the three hoses (Item 2) [Figure 20-
70-1] from the hydraulic / hydrostatic filter housing.
P-90010
1
2
2
2
20-70-2 S650 Service Manual
HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
Remove and plug the two hoses (Item 1) [Figure 20-70-
2] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-70-3
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the
loader.
P-90011
1
P-90537
1
1
20-80-1 S650 Service Manual
HYDRAULIC FLUID RESERVOIR
Description
The hydraulic fluid reservoir is a storage container for the
loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
The hydraulic fluid reservoir is located behind the
operator’s cab under the rear grille on the right side of the
loader. 
Removal And Installation
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 fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the Hydraulic / Hydrostatic Filter Housing (See
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille (See Removal And Installation on
Page 50-60-1.)
Figure 20-80-1
Remove the clamp and the hose (Item 1) [Figure 20-80-
1].
Figure 20-80-2
Remove the two bolts (Item 1) [Figure 20-80-2].
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.
P-90013
1
P-90579
1
20-80-2 S650 Service Manual
HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen
Remove the rear grille (See Removal And Installation on
Page 50-60-1.)
Figure 20-80-3
Remove the hydraulic fluid reservoir breather cap
[Figure 20-80-3] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-
80-3] from the reservoir.
Wash the screen in clean solvent and air dry, before
replacing.
P-90506
1
20-90-1 S650 Service Manual
OIL COOLER
Description
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.
Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Remove the rear grille from the loader. (See Removal
And Installation on Page 50-60-1.)
Figure 20-90-1
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.
Figure 20-90-2
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
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.
NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
P-85938
1
2
3
P-90589
1
2
3
P-90501
1
2
2
4
4
3
5
20-90-2 S650 Service Manual
20-100-1 S650 Service Manual
BUCKET POSITION VALVE
Description
The Bucket Position Valve is an option that allows the
operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower
right rear side of the loader frame.
See Hydraulic Schematic for more circuit information.
Solenoid Removal And Installation
DANGER
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) 
Figure 20-100-1
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.
Cover the fuel tank inlet.
Figure 20-100-2
Disconnect the wire harness connector (Item 1) [Figure
20-100-2] from the bucket position shut-off solenoid.
Disconnect the cap the two tubelines (Item 2) [Figure 20-
100-2].
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 washers and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
torque. Overtightening may cause valve failure.
NOTE: The engine is shown removed for photo
clarity.
Figure 20-100-3
Inspect the solenoid stem and replace the O-rings (Item
1) and the back-up washer (Item 2) [Figure 20-100-3].
P-90187
2
3
1
P-90197
1
2
3
N-18191
1
2
20-100-2 S650 Service Manual
BUCKET POSITION VALVE (CONT'D)
Solenoid Testing
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
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) 
Figure 20-100-4
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.
Cover the fuel tank inlet.
Figure 20-100-5
NOTE: The engine is shown removed for photo
clarity.
NOTE: Mark all hoses and tubelines for correct
installation.
Disconnect the electric solenoid connector (Item 1)
[Figure 20-100-5].
Figure 20-100-6
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.
P-90187
2
3
1
P-90197
1
P-90188
1
2
3
4
20-100-3 S650 Service Manual
BUCKET POSITION VALVE (CONT'D)
Removal And Installation (Cont'd)
Figure 20-100-7
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
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.
Figure 20-100-9
Remove the mounting screws (Item 1) [Figure 20-100-
9].
Remove the bucket position valve from the loader.
P-90189A
1
2
P-90197A
1
2
2
1
P-90190A
1
20-100-4 S650 Service Manual
BUCKET POSITION VALVE (CONT'D)
Disassembly And Assembly
Figure 20-100-10
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-10].
Assembly: Tighten the nut to a maximum of 8 N•m (6 ft-
lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Figure 20-100-11
Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-100-11].
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.
Figure 20-100-12
Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear, inspect the O-ring and replace as needed.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
ft-lb) torque.
Figure 20-100-13
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 O-
ring on the plug before installing.
Assembly: Tighten the plug to torque.
P-90192
1
2
3
P-90195
1
P-90194
3
1
2
P-90193
1
2
3
20-110-1 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE
Description
The rear auxiliary diverter valve is an optional valve that
diverts oil 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
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
P9137
20-110-2 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Removal And Installation
DANGER
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
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.)
Figure 20-110-2
Disconnect and cap the tubelines (Item 1) [Figure 20-
110-2]
Figure 20-110-3
Disconnect and cap the tubelines (Item 1) [Figure 20-
110-3]
Figure 20-110-4
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-4] from the main harness.
P-90583
1
P-93303
1
1
P-93312
1
20-110-3 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Removal And Installation (Cont’d)
Figure 20-110-5
Remove the two bolts (Item 1) and remove the valve
(Item 2) [Figure 20-110-5]
Disassembly And Assembly
Figure 20-110-6
Figure 20-110-7
Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-6] and [Figure 20-
110-7] are located all over the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up washers.
Tighten to 13,6 N•m (10 ft-lb) torque.
P-90581
1
2
P-48751
1
1
P-48752
1
20-110-4 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
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.
I-2003-0888
Figure 20-110-8
Figure 20-110-9
Remove the shuttle valve (Item 1) [Figure 20-110-8] and
[Figure 20-110-9] from diverter valve and inspect the O-
rings and back-up washers (Item 2) [Figure 20-110-9] for
damage.
Assembly: Put oil on the O-rings and back-up washers.
Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.
Figure 20-110-10
Figure 20-110-11
Remove the differential sensing valve (Item 1) [Figure
20-110-10] and [Figure 20-110-11] from diverter valve
and inspect the O-rings and back-up washers (Item 2)
[Figure 20-110-11] for damage.
Assembly: Put oil on O-ring and back-up washers.
Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.
P-48755
1
P-48756
2
2
2
1
P-48755
1
P-48757
1
2
2
20-110-5 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-110-12
Figure 20-110-13
Remove the relief valve (Item 1) [Figure 20-110-12] and
[Figure 20-110-13] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
110-13] for damage.
Assembly: Put oil on O-ring and back-up washers.
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-110-14
Figure 20-110-15
NOTE: Before removing the solenoid coils mark the
coils for proper alignment. 
Remove the nut (Item 1) [Figure 20-110-14] and [Figure
20-110-15] from the solenoid valve stem.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
torque.
Remove the spacer (Item 2) and solenoid valve coils
(Item 3) [Figure 20-110-15].
P-48753
1
P-48754
1
2
P-48759
1
P-48760
1
2
3
20-110-6 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-110-16
NOTE: Before removing the solenoid coils mark the
coils for proper alignment. 
Remove the nuts (Item 1) [Figure 20-110-16] from the
solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
torque.
Figure 20-110-17
Figure 20-110-18
Remove the solenoid valve stem (Item 1) [Figure 20-
110-17] and [Figure 20-110-18] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-18] for
damage.
Assembly: Put oil on O-rings and back-up washers.
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.
P-48761
1
P-48762
1
P-48763
1
1
2
2
20-110-7 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-110-19
Figure 20-110-20
Remove the solenoid valve stem (Item 1) [Figure 20-
110-19] & [Figure 20-110-20] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-20] for
damage.
Assembly: Put oil on O-rings and back-up washers.
Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.
Figure 20-110-21
Remove the plug (Item 1) [Figure 20-110-21].
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-22
Remove and inspect the orifice (Item 1) [Figure 20-110-
22] for dirt and debris.
Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.
P-48763A
1
P-48764
1
2
P-48765
1
P-48766
1
20-110-8 S650 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-110-23
Remove the plug (Item 1) [Figure 20-110-23].
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque.
Figure 20-110-24
Remove the orifice (Item 1) [Figure 20-110-24].
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)
torque.
Figure 20-110-25
Remove the plugs (Item 1) [Figure 20-110-25].
Assembly: Tighten the plug to 19 N•m (14 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 washers.
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48765
1
P-48786
1
P-48758
1
20-120-1 S650 Service Manual
BOB-TACH (POWER) BLOCK
Description
The power Bob-Tach is an option that allows the operator
to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right
switch panel.
The power Bob-Tach block is mounted on the right side of
the machine in front of the engine on the back side of the
hydraulic pump.
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.
W-2059-0598
DANGER
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
20-120-2 S650 Service Manual
BOB-TACH (POWER) BLOCK (CONT'D)
Removal And Installation (Cont'd)
Figure 20-120-1
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
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.)
Disconnect and cap the two electrical solenoid
connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness.
Figure 20-120-2
Mark the hydraulic hoses for proper installation.
Disconnect and cap the outlet hose (Item 1) [Figure 20-
120-2] from block.
Remove the hydraulic muffler (if equipped) (Item 2)
[Figure 20-120-2] from block.
Disconnect and cap the hoses (Item 3) [Figure 20-120-2]
from block.
Remove the four mounting bolts (Item 4) [Figure 20-120-
2] from block.
Installation: Tighten the mounting bolts to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Remove the power Bob-Tach block.
P-90968
1
P-90969
3
2
1
3
3
4
20-120-3 S650 Service Manual
BOB-TACH (POWER) BLOCK (CONT'D)
Disassembly And Assembly
Figure 20-120-3
Clean the block (Item 1) [Figure 20-120-3] to remove dirt
before disassembly. Block ports are labeled for correct
assembly.
Remove the plug (Item 2) [Figure 20-120-3].
Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-
lb) torque.
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 20-120-4
Remove the spring guide (Item 1), spring (Item 2) and the
spool (Item 3) [Figure 20-120-4].
Inspect the O-ring (Item 4) [Figure 20-120-4] on the plug
and replace as needed.
Figure 20-120-5
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 ft-
lb) torque.
P-48115
1
2
P-48120
1
2
4
3
P-48116
1
20-120-4 S650 Service Manual
BOB-TACH (POWER) BLOCK (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-120-6
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.
Figure 20-120-7
Inspect the check valve (Item 1) and piston assembly
(Item 2) [Figure 20-120-7].
Inspect the O-rings and back-up washers (Item 3)
[Figure 20-120-7] on the check valve and piston
assembly and replace as needed.
Figure 20-120-8
Do not remove the plugs (Item 1) [Figure 20-120-8].
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
will be altered. 
Figure 20-120-9
Remove the plug (Item 1) [Figure 20-120-9], inspect the
O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-120-9]
to 16,3 - 19 N•m (12 - 14 ft-lb) torque.
P-48382
1
P-48119
1
2
3
P-48122
1
P-48384
1
20-120-5 S650 Service Manual
BOB-TACH (POWER) BLOCK (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-120-10
Remove the orifice screw (Item 2) located behind the
plug (Item 1) [Figure 20-120-10].
Installation: Tighten the orifice screw (Item 2) [Figure
20-120-10] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.
Figure 20-120-11
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.
Figure 20-120-12
Remove the first solenoid coil (Item 1) and the second
solenoid coil (Item 2) [Figure 20-120-12].
NOTE: Remember the solenoid coil orientation for
ease of installation.
Figure 20-120-13
Remove the solenoid stem (Item 1) [Figure 20-120-13].
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
(20 - 25 ft-lb) torque.
P-48664
2
1
P-48127
1
2
P-48106A
1
2
P-48386
1
20-120-6 S650 Service Manual
BOB-TACH (POWER) BLOCK (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-120-14
Remove the armature assembly (Item 1) [Figure 20-120-
14].
Figure 20-120-15
Inspect the solenoid stem (Item 1), armature assembly
(Item 2) and the spool (Item 3) for damage [Figure 20-
120-15]. 
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 20-120-
15].
Figure 20-120-16
Remove the screened orifice plug (Item 1) [Figure 20-
120-16].
Installation: Tighten the screened orifice plug to 14,9 -
16,3 N•m (11 - 12 ft-lb) torque.
Figure 20-120-17
Inspect the screened orifice plug (Item 1) [Figure 20-
120-17] for damage replace as needed. If the screened
orifice plug is blocked replace with a new plug.
Inspect the O-ring (Item 2) [Figure 20-120-17] and
replace as needed.
P-48175
1
P-48173
1
3
2
P-48174
1
P-48138
1
2
20-130-1 S650 Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
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.
The front auxiliary coupler block is located at the front of
the left side lift arm.
Removal And Installation 
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-130-1
Remove the two mounting bolts (Item 1) [Figure 20-130-
1].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-1].
Disassembly And Assembly 
Figure 20-130-2
Figure 20-130-3
P-85281
1
1
P-90002
2
3
1
P-90003
2
3
1
20-130-2 S650 Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 
(CONT’D)
Disassembly And Assembly (Cont’d)
Figure 20-130-4
Remove the male coupler, spring, and fitting (Item 1)
[Figure 20-130-2],  [Figure 20-130-4] and [Figure 20-
130-4]
Assembly: Tighten the male coupler (Item 1) [Figure 20-
130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Remove the drain coupler, spring, and fitting (Item 2)
[Figure 20-130-2],  [Figure 20-130-4] and [Figure 20-
130-4].
Assembly: Tighten the drain coupler (Item 2) [Figure
20-130-3] and [Figure 20-130-4] to 50 N•m (37 ft-lb)
Remove the female coupler, spring, and fitting (Item 3)
[Figure 20-130-2],  [Figure 20-130-4] and [Figure 20-
130-4].
Assembly: Tighten the female coupler (Item 3) [Figure
20-130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Check the O-rings (Item 4) [Figure 20-130-4] and
replace as needed.
.
Figure 20-130-5
Check the O-rings (Item 1) back-up O-rings (Item 2) for
damage and replace as needed [Figure 20-130-5].
Figure 20-130-6
Check the O-rings (Item 1) back-up O-rings (Item 2) for
damage and replace as needed [Figure 20-130-6].
P-90001
2
4
4
4
1
3
4
P-34665
1
2
P-34664
2
1
30-01 S650 Service Manual
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-10-1
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-10-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-10-2
HYDROSTATIC DRIVE MOTOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-20-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-20-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-20-2
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-20-4
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-20-5
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  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 MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-2
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-3
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-4
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-30-5
HYDROSTATIC MOTOR CARRIER (SJC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-2
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-3
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-4
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-31-6
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-40-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-40-1
Sender Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-40-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-40-4
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
30-02 S650 Service Manual
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 Start Up  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-1
Belt Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-1
Stop Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-3
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-4
Tensioner Pulley Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-60-4
TWO-SPEED / BRAKE VALVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-70-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-70-2
Valve Block Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-70-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-80-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-80-1
Drain Manifold Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30-80-1
30-10-1 S650 Service Manual
HYDROSTATIC SYSTEM INFORMATION
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.
If a service code appears in the left instrument panel.
(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE
1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and/or incorrect steering drift compensation setting.
30-10-2 S650 Service Manual
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Description
The hydrostatic system consists of a tandem hydrostatic
pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader. 
The hydrostatic pump is connected to the engine by a
drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.
30-20-1 S650 Service Manual
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 endcap of the hydrostatic motor, there is a
shuttle valve. The shuttle valve helps to keep the motor
cool by mixing case drain oil with cooled low pressure oil
from the charge circuit. The shuttle valve is shifted by the
high pressure oil 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. 
30-20-2 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
Removal And Installation
DANGER
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
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 Procedure 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 Removal And
Installation on Page 20-90-1.)
Figure 30-20-1
Remove the motor cover.
Mark the hoses for correct installation.
Disconnect the case drain hose (Item 1) [Figure 30-20-
1].
Disconnect the high pressure hoses (Item 2) [Figure 30-
20-1].
Figure 30-20-2
Remove the ten mounting bolts (Item 1) [Figure 30-20-
2].
Installation: Tighten the mounting bolts to 149,2 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.
P-90510
1
2
P-90495
1
1
1
1
1
1
2
30-20-3 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
Removal And Installation (Cont’d)
Figure 30-20-3
Remove the piston / roller section (Item 1) [Figure 30-20-
3] from the loader, if it was not removed with the motor/
cam ring.
To remove the motor carrier. (See Removal And
Installation on Page 30-30-2.)
P5405
1
30-20-4 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
Parts Identification
B-17125
5
2
25
3
19
23
6
9
15
17
16
4
16
20
26
14
1
21
1. Distributor
2. Spring
3. Seal
4. O-ring
5. Plug
6. O-ring
7. Spring
8. Washer
9. Spool
10. Spring
11. Rear Housing
12. Plug
13. O-ring
14. O-ring
15. Stop Pin
16. Bolt
17. Plug
18. O-ring
19. Spring
20. Shim
21. Poppet
22. O-ring
23. Seal
24. O-ring
25. Seal
26. O-ring
27. Cam
28. Roller
29. Piston
30. Block
18
27
30
3
4
7
8
10
11
13
12
29
28
24
22
30-20-5 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (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
Figure 30-20-4
Remove the piston / roller section (Item 1) [Figure 30-20-
4] from the motor.
Assembly: Install the motor on the loader and tighten the
mount bolts to 149,2 N•m (110 ft-lb) torque.
NOTE: Before operating the hydrostatic motor, make
sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS] brake locked,
engine running, stroke the steering lever until
oil comes out of the case drain port.
Figure 30-20-5
Apply low air pressure to each port in the cylinder block
to remove the roller (Item 1) and piston/ring assembly
(Item 2) [Figure 30-20-5].
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 30-20-5].
Assembly: Dip the roller / piston assembly into oil and
install into the bore in the cylinder.
Repeat for each roller / piston assembly.
N-17861
1
P5765
1
2
30-20-6 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-20-6
Remove the two cam ring mounting bolts (Item 1)
[Figure 30-20-6].
Assembly: Install the two cam ring mounting bolts (Item
1)  [Figure 30-20-6] and tighten to 67,8 N•m (50 ft-lb)
torque.
Figure 30-20-7
Remove the cam ring (Item 1) [Figure 30-20-7] from the
motor housing.
Inspect the cam ring for surface scratches or wear.
Assembly: Install the cam ring (Item 1) [Figure 30-20-7]
and align the mounting bolt holes.
Figure 30-20-8
Remove the stop pin (Item 1) [Figure 30-20-8] from the
rear motor housing.
Assembly: Install the stop pin (Item 1) [Figure 30-20-8]
and tighten to 10-12 N•m (7-9 ft-lb) torque.
Figure 30-20-9
NOTE: The distributor removal, is best accomplished
by lifting the housing (Item 2) [Figure 30-20-8]
50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing.
Assembly: Install the stop pin (Item 1) [Figure 30-20-8]
and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.
Assembly: Install the distributor (Item 2) [Figure 30-20-
9] into the housing.
Assembly: Align the distributor hole (Item 3) [Figure 30-
20-9] 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 30-20-9].
N-17860
1
1
N-17863
1
N-17864
1
2
N-17868
2
4
1
3
30-20-7 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-20-10
Remove and replace the two seals and back-up O-rings
(Item 1) [Figure 30-20-10] on the distributor.
Inspect the distributor and springs (Item 2) [Figure 30-
20-10] for damage or surface scratches.
Assembly: Put grease on the springs to hold them in
place.
Assembly: Install the springs into the distributor.
Figure 30-20-11
Remove the two seals (Item 1) [Figure 30-20-11] 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: Lightly smear grease over the seals.
Figure 30-20-12
Remove, inspect and install the plug (Item 1), spring
(Item 2), shim (Item 3) and poppet (Item 4) [Figure 30-
20-12].
Assembly: Remove and replace the O-ring (Item 5)
[Figure 30-20-12].
Assembly: Tighten the plug to 12 - 15 N•m (9 - 11 ft-lb)
torque.
Figure 30-20-13
Remove, inspect and install the plug (Item 1), springs
(Item 2), spool (Item 3) and washer (Item 4) [Figure 30-
20-13].
Assembly: Remove and replace the O-ring (Item 5)
[Figure 30-20-13].
Assembly: Tighten the plug to 25 - 30 N•m (18 - 22 ft-lb)
torque.
N-17869
2
1
N-17866
1
N-17872
1
2
3
4
5
N-17871
1
2
3
4
2
5
30-20-8 S650 Service Manual
30-21-1 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps. 
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 oil with cooled low pressure oil from the charge
circuit. The shuttle valve is shifted by the high pressure
oil 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. 
Removal And Installation
DANGER
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
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 Procedure 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 Removal And
Installation on Page 20-90-1.)
30-21-2 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Removal And Installation (Cont'd)
Figure 30-21-1
Remove the motor cover mount bolts (Item 1) [Figure
30-21-1].
Remove the motor cover from the loader.
Mark the hoses for correct installation.
Figure 30-21-2
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.
Disconnect the hydraulic hose (Item 3) [Figure 30-21-2]
that goes to the make-up port on the two-speed / brake
block.
Figure 30-21-3
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]
that goes to the drain manifold.
Figure 30-21-4
Remove the eight flange bolts (Item 1) [Figure 30-21-4]
from the high pressure hoses on the motor.
Installation: Install the lower collar to the motor and
connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 34 N•m (25
ft-lb) torque.
P-90256
1
P-90258
3
2
1
P-90257
1
P-90257
1
1
30-21-3 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Removal And Installation (Cont'd)
Figure 30-21-5
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-
21-5] 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.
Figure 30-21-6
Installation: Replace the O-ring (Item 1) [Figure 30-21-
6] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 149 N•m (110 ft-
lb) torque.
P-90496
1
N-22535
1
30-21-4 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Parts Identification
1
2
8
5
4
6
9
13
12
11
7
3
16
14
15
10
21
19
20
22
23
24
34
35
37
33
36
32
38
30
39
40
41
42
43
44
45
46
47
48
29
28
50
27
26
25
31
49
17
18
4
5
13
24
51
MS1467S
Ref. Description
1. Roller
2. Piston
3. Ring
4. Clamp
5. Ring
6. Block
7. Cam
8. Quad Ring
9. Distributor
10. Spring
11. Seal/O-ring
12. Seal/O-ring
13. Seal/O-ring
14. Seal/O-ring
15. Seal/O-ring
16. Poppet
17. Spool
18. Spring
19. O-ring
20. Plug
21. Pin
22. Plug
23. Housing
24. Spring
25. Spool
26. Washer
27. O-ring
28. Plug
29. Quad Ring
30. Bushing
31. Shaft
32. Dowel
33. Housing
34. Bolt
35. Shim
36. Brake Disc
37. O-ring
38. Snap Ring
39. Washer
40. Spring
41. Spool
42. Bolt
43. Seal
44. O-ring
45. Clamp
46. Piston
47. O-ring
48 Spring
49. Gasket
50. Cover
51. Bolt
Ref. Description
1. Roller
2. Piston
3. Ring
4. Clamp
5. Ring
6. Block
7. Cam
8. Quad Ring
9. Distributor
10. Spring
11. Seal/O-ring
12. Seal/O-ring
13. Seal/O-ring
14. Seal/O-ring
15. Seal/O-ring
16. Poppet
17. Spool
18. Spring
19. O-ring
20. Plug
21. Pin
22. Plug
23. Housing
24. Spring
25. Spool
26. Washer
27. O-ring
28. Plug
29. Quad Ring
30. Bushing
31. Shaft
32. Dowel
33. Housing
34. Bolt
35. Shim
36. Brake Disc
37. O-ring
38. Snap Ring
39. Washer
40. Spring
41. Spool
42. Bolt
43. Seal
44. O-ring
45. Clamp
46. Piston
47. O-ring
48 Spring
49. Gasket
50. Cover
51. Bolt
30-21-5 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly
Figure 30-21-7
NOTE: Install a mark on the motor, brake, and motor
carrier housings for correct assembly [Figure
30-21-7].
NOTE: Always protect any sealing surfaces. Any
scratches or marks will cause premature
failure.
Place the cam sealing surface (Item 1) [Figure 30-21-7]
on a protective material.
Drain the oil from the motor casing.
Figure 30-21-8
Remove the twelve mounting bolts (Item 1) [Figure 30-
21-8] from the brake cover plate.
NOTE: Remove and / or tightened the bolts one turn
at a time to maintain equal preload on the end
cap and the brake spring.
Figure 30-21-9
Remove the cover plate from the brake housing.
Remove the cover plate gasket (Item 1) [Figure 30-21-
9].
Remove the brake spring (Item 2) [Figure 30-21-9] from
the brake housing.
NOTE: Mark the top side of the brake spring for
proper installation.
Figure 30-21-10
Remove the piston from the brake housing (Item 1)
[Figure 30-21-10].
NOTE: The use of air pressure through the brake line
connection (Item 2) [Figure 30-21-10] will aid
in piston removal.
Check the brake piston for damage and replace the seal.
N-22489
1
N-22490
1
N-22492
1
2
N-22493
1
2
30-21-6 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly (Cont'd)
Figure 30-21-11
Remove the five mounting bolts (Item 1) [Figure 30-21-
11] from the brake housing.
Remove the brake housing (Item 2) [Figure 30-21-11]
from the rear housing.
Figure 30-21-12
Protect the sealing surface. Remove the snap ring (Item
1) [Figure 30-21-12] to remove the seal from the brake
housing.
Figure 30-21-13
Remove the brake disks (Item 1) [Figure 30-21-13] from
the brake shaft. Mark the position of the brake disks and
the shims.
Figure 30-21-14
Remove the two-speed spool (Item 1) [Figure 30-21-14]
from the housing assembly.
Remove and discard the o-rings (Item 2) [Figure 30-21-
14] on the housing.
P-69973
1
2
P-73062
1
P-69985
1
P-69978
1
2
2
30-21-7 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly (Cont'd)
Figure 30-21-15
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-15].
NOTE: The spool (Item 1) [Figure 30-21-15] is marked
with either an A or B. The spool must be
replaced with a spool with the same mark.
Figure 30-21-16
Remove the flushing spool plug (Item 1) [Figure 30-21-
16] from the housing.
Installation: Tighten the plug to 30 Nm (22 ft-lb) torque.
NOTE: Current motor housings are provided with
break off plugs (Item 2) [Figure 30-21-16] on
the side of the flushing spool housing. Earlier
motors were equipped with threaded plugs.
Figure 30-21-17
Remove the flushing spool assembly (Item 1) [Figure 30-
21-17] from the housing.
Figure 30-21-18
Remove the spring (Item 1), washer (Item 2) and rear
spring (Item 3) from the spool (Item 4) [Figure 30-21-18].
Inspect all parts and replace as needed.
N-22501
1
4
3
2
P-69979
1
2
P-73057
1
N-22504
1
2
4
3
30-21-8 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly (Cont'd)
Figure 30-21-19
Remove the plug (Item 1) [Figure 30-21-19] from the
housing.
Installation: Tighten the plug to 22 N•m (18 ft-lb) torque.
Figure 30-21-20
Remove the poppet assembly (Item 1) [Figure 30-21-20]
from the housing.
Figure 30-21-21
Inspect the poppet (Item 1), shim (Item 2) and spring
(Item 3) for wear and replace as needed [Figure 30-21-
21].
Figure 30-21-22
Remove the two (8 mm) cam ring mount bolts (Item 1)
[Figure 30-21-22].
Turn the housing, cam ring, and rotating group assembly
over and place on a stand. Remove the cam ring from the
housing.
P-69981
1
P-69982
1
N-22507
1
3
2
P-73058
1
1
30-21-9 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly (Cont'd)
Figure 30-21-23
Protect the sealing surfaces. Check the cam ring inside
surface for wear and scratches [Figure 30-21-23].
Figure 30-21-24
Remove the cylinder block (Item 1) [Figure 30-21-24]
from the housing.
Remove the O-ring (Item 2) [Figure 30-21-24] from the
housing.
Figure 30-21-25
Protect the sealing surfaces. Remove the roller/piston
assembly (Item 1) [Figure 30-21-25] from the cylinder
block.
Check all roller and piston assemblies for wear and
replace as needed.
NOTE: Put all roller/piston assembles back in the
original bore.
Figure 30-21-26
Remove the shaft from the distributor [Figure 30-21-26].
NOTE: The end of the shaft with the snap ring (Item 1)
[Figure 30-21-26] must be toward the brake
housing during assembly.
Remove the distributor from the housing.
N-22510
N-22509
1
2
N-22511
1
P-73059
1
30-21-10 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Disassembly (Cont'd)
Figure 30-21-27
NOTE: The distributor removal is best accomplished
by lifting the housing (Item 1) [Figure 30-21-
27] 2-3 inches above a wooden surface, and
dropping the housing [Figure 30-21-27].
Figure 30-21-28
Protect the sealing surfaces. Remove the locating pin
(Item 1) [Figure 30-21-28] from the distributor.
Remove the springs (Item 1) [Figure 30-21-28] from the
distributor.
Inspect the springs, distributor surface and bushing for
damage or wear and replace as needed.
Figure 30-21-29
Remove the bushing (Item 1) [Figure 30-21-29] from the
distributor, if worn or scratched.
Figure 30-21-30
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-21-30].
P-69984
1
N-22521
1
2
N-22523
1
N-22519
1
30-21-11 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Assembly
NOTE: Always use new O-rings and seals during
motor and brake assembly. 
Figure 30-21-31
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
30-21-31] in oil and replace back its original bore.
Figure 30-21-32
Apply a small amount of grease to the locating pin (Item
1)  [Figure 30-21-32] and install the locating pin in the
housing
Figure 30-21-33
Install a new bushing (Item 1) [Figure 30-21-33] in the
distributor if the old bushing was removed.
Install new O-rings and seals on the distributor [Figure
30-21-34].
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 30-21-34
Using a small amount of grease, install the springs into
the distributor valve (Item 1) [Figure 30-21-34].
N-22511
1
N-22518
1
N-22525
1
P-73060
1
30-21-12 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Assembly (Cont'd)
Figure 30-21-35
Install the distributor (Item 1) [Figure 30-21-35] in the
housing. Protect the sealing surface of the distributor.
Figure 30-21-36
The pin in the distributor must align with the hole in the
housing (Item 1) [Figure 30-21-36]. 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.
Figure 30-21-37
Install the cylinder block assembly (Item 1) [Figure 30-
21-37].
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 30-21-38
Turn the motor so that it sets on the cam ring, and
cylinder block [Figure 30-21-38].
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 to 35 - 39 N•m
(26 - 29 ft-lb) torque.
N-22515
1
P-73061
1
N-22509
1
P-69983
1
1
30-21-13 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Assembly (Cont'd)
Figure 30-21-39
Install new o-rings (Item 1) [Figure 30-21-39] on the
housing assembly and apply grease to the o-rings.
Install the two speed spool (Item 2) [Figure 30-21-39].
Install the shaft into the distributor [Figure 30-21-39].
Figure 30-21-40
Clamp the disc pack in a vise and measure the height
[Figure 30-21-40]. The height must be 31,1 mm (1.22
in).
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.
Figure 30-21-41
Install the brake housing (Item 1) [Figure 30-21-41] on
the motor housing.
Apply liquid adhesive (Loctite® 243) to the five mounting
bolts. Install the bolts (Item 2) [Figure 30-21-41] and
tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque.
Figure 30-21-42
If needed, install the shims first, then install the brake
disc pack starting with an outer disc (Item 1) [Figure 30-
21-42] and alternating with an inner disc, throughout the
pack.
End the disc pack with an outer disc.
P-69978
1
2
N-18347
P-69986
2
1
P-73064
1
30-21-14 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Assembly (Cont'd)
Figure 30-21-43
Install the brake seal (Item 1) [Figure 30-21-43].
NOTE: Install the seal with the metal case end
towards the brake pack.
Install the snap ring (Item 2) [Figure 30-21-43] to secure
the seal in the brake housing.
Install a new o-ring (Item 3) [Figure 30-21-43] in the
seal.
Figure 30-21-44
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-44].
Figure 30-21-45
Install the piston (Item 1) [Figure 30-21-45] in the brake
housing.
Figure 30-21-46
Install the brake spring (Item 1) [Figure 30-21-46].
Install the end plate gasket (Item 2) [Figure 30-21-46].
P-73055
1
3
2
N-22498
1
N-22493
1
N-22492
1
2
30-21-15 S650 Service Manual
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 
(CONT'D)
Assembly (Cont'd)
Figure 30-21-47
Install the brake end cover (Item 1) [Figure 30-21-47].
Install the twelve end cover mount bolts and tighten
evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.
N-22490
1
30-21-16 S650 Service Manual
30-30-1 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 oil from the hydrostatic motor case drain
oil.
The hydrostatic motor carriers are made to fit on both the
right and left hand side of the loader.
30-30-2 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Removal And Installation
DANGER
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
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
Lift and block the loader. (See Procedure on Page 10-10-
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.)
Remove the fluid from the chain case. (See CHAINCASE
on Page 40-30-1.)
Remove the center chain case cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the front axle sprocket. (See Chain Removal
And Installation on Page 40-20-9.)
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.)
Remove the control pedal linkages. (See Linkage
Removal And Installation on Page 50-90-2.)
Figure 30-30-1
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.
Figure 30-30-2
NOTE: For easier access for the motor carrier
coming out and going into the chain case, tie
the front drive chain to the chain case with a
wire [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 [Figure 30-
30-2].
Pull the motor carrier away from the chain case and out
of the loader. [Figure 30-30-2].
P5467A
1
1
P5489A
30-30-3 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT'D)
Parts Identification
TS-1227B
1
2
8
5
4
6
7
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring
3
30-30-4 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT'D)
Disassembly
Figure 30-30-3
Remove the large O-ring from the groove (Item 1)
[Figure 30-30-3] in the housing.
Figure 30-30-4
Put the motor carrier in a hydraulic press [Figure 30-30-
4].
Put a small amount of pressure on the shaft to release
the pre-load on the snap ring.
Figure 30-30-5
Remove the snap ring (Item 1) [Figure 30-30-5] from the
shaft.
Figure 30-30-6
Use a hydraulic press to remove the shaft from the
housing [Figure 30-30-6].
P5760
1
P5768
P-76544
1
P5766
30-30-5 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT'D)
Disassembly (Cont’d)
Figure 30-30-7
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
Remove the two seals (Item 1) [Figure 30-30-8] from the
housing.
Check the bearing cup (Item 2) [Figure 30-30-8] (both
sides) and replace as needed.
Assembly
Figure 30-30-9
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool
Install the first seal (Item 1) [Figure 30-30-9] into the
housing with the seal lip facing away from you.
Use the tool (Item 2) [Figure 30-30-9] as shown in the
figure.
Figure 30-30-10
Install the second seal (Item 1) [Figure 30-30-10] into the
housing with the seal lip facing toward you.
Use the tool (Item 2) [Figure 30-30-10] as shown in the
figure.
P5761
P5763
1
2
P5764
1
2
P5762
2
1
30-30-6 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT'D)
Assembly (Cont’d)
Figure 30-30-11
Install the bearing on the shaft [Figure 30-30-11].
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
install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) using the tool (Item 2) [Figure
30-30-12] (MEL1431).
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.
P5767
1
P5769
1
2
30-31-1 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 oil from the hydrostatic motor case drain
oil.
The hydrostatic motor carrier with (SJC) uses a speed
sensor installed in the motor carrier housing. The speed
sensor senses a disk that is fixed to the shaft in the motor
carrier.
A brake disk is installed on each hydrostatic motor
carrier. The brake disk 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.
30-31-2 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Removal And Installation
DANGER
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
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
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
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
Axle, Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
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
Shock Removal And Installation on Page 50-100-18.)
Figure 30-31-1
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
Slide the motor carrier toward the rear and remove the
rear drive chain.
NOTE: For easier access for the motor carrier
coming out and going into the chaincase, tie
the front drive chain to the chaincase with a
wire [Figure 30-31-2].
Slide the motor carrier out of the chaincase far enough to
install a chain and chain hoist to the carrier [Figure 30-
31-2].
NOTE: When installing the motor carrier into the
loader, use caution to protect the wheel speed
washer from damage.
P5467A
1
1
P5489A
30-31-3 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Parts Identification
PE3328SA
7
6
2
3
5
4
3
2
8
Ref. Description
1. Snap Ring
2. Bearing
3. Race
4. Seal
5. Housing
6. Speed Washer
7. Shaft
8. Cover
1
30-31-4 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Disassembly 
Figure 30-31-3
Remove the large O-ring from the groove (Item 1)
[Figure 30-31-3] in the housing.
Figure 30-31-4
Put the motor carrier in a hydraulic press [Figure 30-31-
4].
Put a small amount of pressure on the shaft to release
the pre-load on the snap ring.
Figure 30-31-5
Remove the snap ring (Item 1) [Figure 30-31-5] from the
shaft.
Figure 30-31-6
Use a hydraulic press, remove the shaft from the housing
[Figure 30-31-6].
P5760
1
P-76540
P-28155
1
P5766
30-31-5 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Disassembly (Cont’d)
Figure 30-31-7
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.
Figure 30-31-8
Install the bearing puller tool (Item 1) [Figure 30-31-8]
under the bearing flange, between the bearing and the
speed washer.
Figure 30-31-9
Use the hydraulic press to remove the bearing from the
shaft [Figure 30-31-9].
Figure 30-31-10
Remove the wheel speed washer (Item 1) [Figure 30-31-
10] from the shaft.
P-76462
1
2
P-28157
1
P-28158
P-76464
1
30-31-6 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Disassembly (Cont’d)
Figure 30-31-11
Remove the two seals (Item 1) [Figure 30-31-11] from
the housing.
Check the bearing cup (Item 2) [Figure 30-31-11] (both
sides) and replace as needed.
Assembly
Figure 30-31-12
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool
Install the first seal (Item 1) [Figure 30-31-12] into the
housing with the seal lip facing away from you.
Use the tool (Item 2) [Figure 30-31-12] as shown in the
figure.
Figure 30-31-13
Install the second seal (Item 1) [Figure 30-31-13] into the
housing with the seal lip facing toward you.
Use the tool (Item 2) [Figure 30-31-13] as shown in the
figure.
P-28164
1
2
P5764
2
1
P5762
2
1
30-31-7 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Assembly (Cont'd)
Figure 30-31-14
The wheel speed washer, has one alignment pin (Item 1)
[Figure 30-31-14].
Check the new wheel speed washer with a straight edge,
to be sure it is square   [Figure 30-31-14].
If the washer is more than 0.080 (2,03 mm) out of square,
it must be replaced.
Figure 30-31-15
Inspect the wheel speed washer for damage to the
magnetic surface (Item 1) [Figure 30-31-15].
NOTE: Do not contact the magnetic surface of the
wheel speed washer (Item 1) [Figure 30-31-
15], with a magnet. This may cause damage to
the magnetic surface.
Install the wheel speed washer on the shaft [Figure 30-
31-15].
Align the one pin (Item 2) [Figure 30-31-15] in the
sprocket.
P-76541
1
P-76542
1
2
30-31-8 S650 Service Manual
HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Assembly (Cont'd)
Figure 30-31-16
Install the bearing on the shaft [Figure 30-31-16].
Use a pipe (Item 1) [Figure 30-31-16] 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 30-31-17
Install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) using the tool (MEL1431)
(Item 2) [Figure 30-31-17].
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.
P-76539
1
P-5769
1
2
30-40-1 S650 Service Manual
CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve. 
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary spool, and to pilot
open the BICS system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender is located on the hydraulic
fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed. 
Testing
Figure 30-40-1
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6,9 MPa (69,0 bar) (1000 psi) (Item 3) and adapter
fitting (P/N 93F-5) (Item 4) [Figure 30-40-1].
Figure 30-40-2
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.
P-43196
1
2
3
4
P-43197
1
2
3
30-40-2 S650 Service Manual
CHARGE PRESSURE (CONT’D)
Testing (Cont’d)
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 Procedure on Page
10-10-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 30-40-3
Disconnect the hydraulic hose (Item 1) [Figure 30-40-3].
Figure 30-40-4
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].
Install the hose (Item 2) [Figure 30-40-4], that was
disconnected from the motor, to the T fitting.
Install the hose (Item 3) [Figure 30-40-4], that is
attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings.
Connect the remote start tool. (See REMOTE START
TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)
Start the loader and warm the hydraulic fluid to 140° F.
On non-SJC equipped loaders the charge pressure at
high idle, with the fluid temperature of 60°C (140°F) is 3,0
- 3,4 MPa (30,0 - 34,1 bar) (435 - 495 psi) with the pump
in neutral.
NOTE: If the machine is equipped with SJC option
the charge pressure should be set at 2,5 - 2,8
MPa (24,8 - 28,2 bar) (360 - 410 psi) at 60°C
(140°F) fluid @ High idle.
P-90302
1
P-90301
1
2
3
30-40-3 S650 Service Manual
CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-40-5
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: Inspect the O-ring on the sender before
installation.
P-90302
2
1
30-40-4 S650 Service Manual
CHARGE PRESSURE (CONT’D)
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.
I-2003-0888
Figure 30-40-6
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-40-6].
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
(30 - 50 ft-lb) torque.
Figure 30-40-7
Remove the plug, spring and poppet [Figure 30-40-7].
Check the poppet, spring and poppet seat for wear or
damage.
Figure 30-40-8
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
(0,6 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 3,0
- 3,4 MPa (30,0 - 34,1 bar) (435 - 495 psi) with the pump
in neutral.
P-43856
1
N-17231
N-19568
1
30-40-5 S650 Service Manual
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.
I-2003-0888
Figure 30-40-9
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.
Figure 30-40-10
Check the poppet and spring for wear or damage. 
Inspect the seat inside the hydrostatic pump case for
wear or damage.
There are several different thickness of shims (Item 1)
[Figure 30-40-10] used to adjust the charge pressure. 
NOTE:  1,0 mm shim (Item 1) [Figure 30-40-10] = 300,0
kPa (3 bar) (43.5 PSI) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure. 
The charge pressure should be set at 2,5 - 2,8 MPa (24,8
- 28,2 bar) (360 - 410 psi).
P-64431
1
P-64435
1
30-40-6 S650 Service Manual
30-50-1 S650 Service Manual
HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump. 
The hydrostatic pump contains replenishing valves. The
function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the
mainframe mounted to the engine flywheel housing. 
30-50-2 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
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 30-
60-1.)
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
Figure 30-50-1
Loosen the nut (Item 1) [Figure 30-50-1] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque
Figure 30-50-2
Use a puller (Item 1) [Figure 30-50-2] to loosen the
pulley from the pump drive shaft.
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
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. 
P-90221
1
P-90222
1
P-90223
1
1
30-50-3 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Removal And Installation (Cont’d)
Figure 30-50-4
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 START UP: Fill the hydrostatic pump with
hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-50-3.)
Hydrostatic Pump Startup
Follow the hydraulic pump startup procedure. (See
Hydrostatic Pump Startup on Page 30-50-3.)
P-90224
1
30-50-4 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Replenishing / High Pressure Relief Valve Removal 
And Installation
Figure 30-50-5
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
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.
Check for damage and replace as needed.
Check the O-ring (Item 2) [Figure 30-50-6] for damage
and replace as needed.
If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
The pressure setting for a new high pressure relief valve
is 36,2 MPa (362 bar) (5250 PSI).
P-43857
1
P-66670
1
2
30-50-5 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
1
2
3
1
1
4
1
5
6
7
8
9
4
3
9
10
11
12
9
8
4
9
10
11
13
14
15
16
17
2
12
17
18
2
19
17
2
20
12
21
4
42
9
12
9
8
9
8
22
19
23
24
9
12
9
25
11
9
24
D-2428C
9
26
Ref. Description
1. Snap Ring
2. Washer
3. Seal
4. Bearing
5. Key
6. Shaft
7. Housing
8. Plug
9. O-ring
10. Cover
11. Bolt
12. Pin
13. Swash Plate
14. Wear Plate
15. Piston Assembly
16. Piston Retainer
17. Retainer
18. Block
19. Spring
20. Valve Plate
21. Gasket
22. Poppet
23. Shim
24. Replenishing/High
Pressure Relief Valve
25. Coupler
26. Dust Seal
30-50-6 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
1
2
3
4
3
4
5
1
6
7
3
4
5
8
13
10
11
10
12
13
8
10
13
23
14
15
16
8
17
3
7
18
19
4
1
20
21
7
21
7
4
21
3
4
19
9
1
D-2427B
22
4
4
Ref. Description
1. Bolt
2. End Cap
3. Plug
4. O-ring
5. Replenishing/High
Pressure Relief Valve
6. Gasket
7. Bearing
8. Pin
9. Valve Plate
10. Washer
11. Spring
12. Block
13. Retainer
14. Piston Assembly
15. Wear Plate
16. Swash Plate
17. Housing
18. Seal
19. Cover
20. Shaft
21. Snap Ring
22. Dust Seal
23. Piston Retainer
4
30-50-7 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Disassembly
Figure 30-50-7
Remove the four mounting bolts (Item 1) [Figure 30-50-
7].
Figure 30-50-8
Separate the two hydrostatic pumps [Figure 30-50-8].
Figure 30-50-9
Remove the pump coupler (Item 1) [Figure 30-50-9].
Remove the large O-ring (Item 2) [Figure 30-50-9].
Remove the two small O-rings (Item 3) [Figure 30-50-9].
Figure 30-50-10
Remove the four bolts (Item 1) [Figure 30-50-10] from
the pump housing end cap.
P-43858
1
1
1
N-19570
N-19571
3
1
2
3
N-19550
1
1
30-50-8 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Disassembly (Cont'd)
Figure 30-50-11
Remove the pump housing end cap (Item 1) [Figure 30-
50-11].
Remove the gasket (Item 2) [Figure 30-50-11].
Figure 30-50-12
Remove the valve plate (Item 1) [Figure 30-50-12].
Check the valve plate for wear. (Both Sides.)
Figure 30-50-13
Check the valve plate locating pin (Item 1) [Figure 30-50-
13] for wear and replace if needed.
Check the needle bearing (Item 2) [Figure 30-50-13] for
wear and replace if needed.
Figure 30-50-14
Remove the rotating group (Item 1) [Figure 30-50-14]
from the pump.
N-19551
1
2
N-17193
1
N-17194
1
2
N-17197
1
30-50-9 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Disassembly (Cont'd)
Figure 30-50-15
Remove the slipper guide and pistons (Item 1) [Figure
30-50-15] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-50-15] for wear
and replace the rotating group as needed.
Figure 30-50-16
Remove the ball guide retainer (Item 1) [Figure 30-50-
16] from the cylinder block.
Figure 30-50-17
Check the ball guide retainer (Item 1) and washer (Item
2) [Figure 30-50-17] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-50-17] from the
cylinder block.
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-50-17] to see if they are
all the same length.
Figure 30-50-18
Remove the thrust plate (Item 1) [Figure 30-50-18] from
the pump housing.
N-17198
2
1
N-17199
1
N-17200
3
3
3
3
2
1
N-17201
1
30-50-10 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Disassembly (Cont'd)
Figure 30-50-19
Remove the driveshaft 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 30-50-20
Use a seal puller and remove the seal (Item 1) [Figure
30-50-20] from the pump housing.
Figure 30-50-21
Remove the snap ring (Item 1) [Figure 30-50-21] from
the pump housing and remove the driveshaft and bearing
from the housing.
Figure 30-50-22
Remove the snap ring (Item 1) [Figure 30-50-22] from
the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.
N-17481
1
2
3
N-17239
1
N-17240
1
N-17241
1
30-50-11 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Disassembly (Cont’d)
Figure 30-50-23
Check the pump shaft (Item 1) [Figure 30-50-23] for
wear and replace if needed.
Figure 30-50-24
Remove the four mount bolts (Item 1) [Figure 30-50-24]
from the lower trunnion cover. Remove the cover.
Figure 30-50-25
Remove the O-ring (Item 1) and bearing race (Item 2)
[Figure 30-50-25] from the pump housing.
Figure 30-50-26
Check the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-50-26] for wear and replace as needed.
N-17242
1
N-17243
1
1
N-17244
2
1
N-17245
1
2
30-50-12 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Disassembly (Cont’d)
Figure 30-50-27
Inspect the dust seal on the pintle shaft.
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
Remove the upper trunnion cover (Item 1) [Figure 30-50-
28].
Figure 30-50-29
Inspect the seal (Item 1) [Figure 30-50-29] in the upper
trunnion cover and replace if needed.
Figure 30-50-30
Remove the O-ring (Item 1) and bearing race (Item 2)
[Figure 30-50-30] from the pump housing.
N-17246
1
1
2
N-17247
1
N-17250
1
N-17248
1
2
30-50-13 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Disassembly (Cont’d)
Figure 30-50-31
Inspect the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-50-31] and replace as needed.
Figure 30-50-32
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.
Figure 30-50-33
Tilt the swash plate (Item 1) [Figure 30-50-33] and
remove the swash plate and lower bearing from the
pump housing.
N-17249
1
2
N-17251
1
N-17252
1
30-50-14 S650 Service Manual
HYDROSTATIC PUMP (CONT'D)
Assembly
Figure 30-50-34
Install the lower bearing (Item 1) [Figure 30-50-34] on
the swash plate.
Figure 30-50-35
Install the swash plate and bearing into the pump
housing [Figure 30-50-35].
Figure 30-50-36
Install the tapered bearing (Item 1) [Figure 30-50-36] on
the swash plate shaft.
Figure 30-50-37
Install the bearing race (Item 2) [Figure 30-50-36] and O-
ring (Item 3) [Figure 30-50-36] as shown in [Figure 30-
50-37].
N-17253
1
N-17252
N-17249
1
2
3
N-17248
30-50-15 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-38
Install the upper trunnion seal (Item 1) [Figure 30-50-38]
and cover.
Figure 30-50-39
Install the linkage bracket (Item 1) [Figure 30-50-39] and
the four mounting bolts and tighten to 24 - 30 N•m (18 -
22 ft-lb) torque.
Install the dust seals onto the pintle shafts
Figure 30-50-40
Figure 30-50-41
Install the bearing race (Item 1) [Figure 30-50-40] and O-
ring (Item 2) [Figure 30-50-40] at the lower trunnion as
shown in [Figure 30-50-41].
N-17247
1
N-17246
1
N-17245
1
2
N-17244
30-50-16 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-42
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-50-42].
Install the four mounting bolts and tighten to 24 - 30 N•m
(18 - 22 ft-lb) torque.
Figure 30-50-43
Install the snap ring (Item 1) [Figure 30-50-43] on the
pump shaft.
Figure 30-50-44
Install the bearing and snap ring (Item 1) [Figure 30-50-
44] on the pump shaft.
Figure 30-50-45
Install the pump shaft into the pump housing [Figure 30-
50-45].
Install the snap ring (Item 1) [Figure 30-50-45].
N-17243
N-17242
1
N-17241
1
N-17240
1
30-50-17 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-46
Install the four slipper pins (Item 1) [Figure 30-50-46]
into the cylinder block.
Apply a small amount of grease to the washer (Item 2)
and install into the ball guide retainer (Item 3) [Figure 30-
50-46].
Figure 30-50-47
Install the ball guide retainer and washer (Item 1) [Figure
30-50-47] onto the slipper holddown pins.
Figure 30-50-48
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 30-
50-48].
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
Figure 30-50-49
Place the pump on a work surface with the end cap
opening up [Figure 30-50-49].
N-17200
1
1
1
1 2
3
N-17199
1
N-17198
N-17197
30-50-18 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-50
Replace the needle bearing (Item 1) and valve plate
locating pin (Item 2) [Figure 30-50-50] in the charge
pump.
Figure 30-50-51
The bearing cage (Item 1) [Figure 30-50-51] 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 30-
50-51] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.
Figure 30-50-52
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 30-50-52].
The notch (Item 1) [Figure 30-50-52] on the valve plate
must engage the locating pin.
Figure 30-50-53
Coat a new end cap gasket (Item 1) [Figure 30-50-53]
with petroleum jelly and install onto the end cap.
N-17194
1
2
N-17196
1
2
N-17193
1
N-19551
1
30-50-19 S650 Service Manual
HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-54
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-50-54] to 47 - 61
N•m (35 - 45 ft-lb) torque.
Figure 30-50-55
Install the two small O-rings (Item 1) [Figure 30-50-55].
Install the large new O-ring (Item 2) [Figure 30-50-55].
Install the pump coupler (Item 3) [Figure 30-50-55].
Figure 30-50-56
Install the two pumps together [Figure 30-50-56].
Figure 30-50-57
Tighten the four bolts (Item 1) [Figure 30-50-57] to 47 -
61 N•m (35 - 45 ft-lb) torque.
N-19550
1
1
N-19571
1
3
2
1
N-19570
P-43858
1
1
30-50-20 S650 Service Manual
30-51-1 S650 Service Manual
HYDROSTATIC PUMP (SJC)
Description
The SJC hydrostatic pump is a fully proportional dual
piston pump in one pump casing. The endcaps 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. 
Figure 30-51-1
P-90206
A,B      Service Line Ports (High Pressure Outlet Ports to Drive Motors) 
T
1            Case Drain Port
M
A           Operating Pressure of “A” Port
M
B          Operating Pressure of “B” Port
R          Air Bleed Port 
X
1,X2     Control Pressure Gauge Port
G         Charge Pressure Inlet Port
M
G          Gauge Port For Charge Pressure
30-51-2 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
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.
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.
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 30-51-2
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Figure 30-51-3
Disconnect the electrical harness connectors (Item 1)
[Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
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 30-51-4
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.
P-90207
1
P-90239
1
1
P-90208
1
1
30-51-3 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Removal And Installation 
(Cont'd)
Figure 30-51-5
Remove the controller (Item 1) [Figure 30-51-5] from the
pump.
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump.
Installation:
Figure 30-51-6
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 30-
51-6].
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].
Figure 30-51-7
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.
NOTE: When a hydraulic controller is replaced, the
hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Page 30-51-26.)
Figure 30-51-8
With the engine running and the loader on jack stands:
Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
torque.
Repeat the bleed procedure for all the solenoids.
P-90210
1
2
2
3
P-90209
1
2
2
P-90210
1
1
P-64978
1
30-51-4 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
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 30-
60-1.)
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
Figure 30-51-9
Loosen the nut (Item 1) [Figure 30-51-9] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque
Figure 30-51-10
Use a puller (Item 1) [Figure 30-51-10] to loosen the
pulley from the pump drive shaft.
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.
Figure 30-51-11
Remove the two mounting bolts and nuts (Item 1)
[Figure 30-51-11].
Installation: Tighten the mounting bolts and nuts to 88 -
95 N•m (65 - 70 ft-lb) torque. 
P-90221
1
P-90222
1
P-90223
1
1
30-51-5 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Removal And Installation (Cont’d) 
Figure 30-51-12
Remove the two mounting bolts (Item 1) [Figure 30-51-
12] 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 START UP: Fill the hydrostatic pump with
hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Start Up on Page 30-51-6.)
P-90224
1
30-51-6 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydrostatic Pump Start Up
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 start up.
Figure 30-51-13
Remove the air bleed plugs (Item 1) [Figure 30-51-13].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up. 
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.
P-90226
1
30-51-7 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Parts Identification 
P-90240
2
1
3
4
5
6
7
8
2
9
13
11
10
12
15
16
17
14
18
19
20
19
28
27
29
4
7
18
6
25
24
23
21
22
1. O-ring
2. Bolt
3. End Housing
4. O-ring
5. Right Rotating Assembly
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring
12. O-ring
13. Position Sensor
14. Washer
15. Bolt
16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
22. Plug
23. Plug
24. Dowel Pin
25. Charge Pressure Relief
26. Left Servo
27. Right Servo
28. Left Rotating Assembly
29. End Housing
26
26
30-51-8 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
High Pressure Relief And Bypass Valve
Figure 30-51-14
There are four system check relief valves (Item 1)
[Figure 30-51-14] in the back of the hydrostatic pump. 
Remove the relief valve cap (Item 1) [Figure 30-51-14].
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb)
torque. 
Figure 30-51-15
Check the valve cap O-ring (Item 1) and back-up ring
(Item 2) [Figure 30-51-15], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-15]
from the valve cap.
Check the conical spring (Item 4) [Figure 30-51-15] to
ensure it is not broken or flattened.
Figure 30-51-16
Check the valve seat surface (Item 1) [Figure 30-51-16]
for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-16] for
breakage.
Inspect seats inside case housing.
Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.
Factory setting on the relief valve is 36,2 MPa (362 bar)
(5250 PSI). 
P-64431
1
1
P-64436
2
3
1
4
P-64437
1
2
30-51-9 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Charge Relief Valve 
Figure 30-51-17
The charge relief valve (Item 1) [Figure 30-51-17] is
located on the back of the hydrostatic pump. 
Remove the charge relief valve.
Assembly: Tighten charge relief valve to 70 N•m (52 ft-
lb) torque.
Figure 30-51-18
Check and replace the O-ring (Item 1) [Figure 30-51-18].
Figure 30-51-19
Inspect the poppet (Item 1) and the mating seat (Item 2)
[Figure 30-51-19] for damage or foreign material. Ensure
the poppet moves freely in it’s bore. 
Inspect the sealing ring (Item 3) [Figure 30-51-19] and
the mating seat in the pump housing for damage or
foreign material.
Inspect the spring (Item 4) and the charge relief valve
shims (Item 5) [Figure 30-51-19].
NOTE:  1,0 mm shim (Item 5) [Figure 30-51-19] = 296,5
kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure. 
P-64431
1
P-64435
1
P-64435
1
2
3
4
5
30-51-10 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly
Remove the hydrostatic pump / engine assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the hydrostatic pump. (See Removal And
Installation on Page 30-51-4.)
Figure 30-51-20
Remove the hydraulic controllers (Item 1) [Figure 30-51-
20]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-21
Swash plate angle sensors (Item 1) are mounted on the
bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-21]. 
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-21] from both sides.
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.
Note the connectors facing each other. 
Figure 30-51-22
Remove the mounting bolts (Item 1) for the swash plate
angle sensor (Item 2) [Figure 30-51-22].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.
P-90226
1
1
P-90227
1
1
2
2
3
3
3
3
P-90228
2
1
1
30-51-11 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-23
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 30-51-
23].
Figure 30-51-24
Check and replace the O-ring (Item 1) [Figure 30-51-24].
Right End Housing
Figure 30-51-25
Left End Housing
Figure 30-51-26
Remove the four mount bolts (Item 1) securing the end
housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-25] and [Figure 30-51-26].
Assembly: Alternately, tighten mount bolts to 130 N•m
(96 ft-lb) torque. 
P-90217
2
1
P-90218
1
P-64445
2
1
1
3
P-64447
2
1
1
3
30-51-12 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-27
Pull the end housings from the case housing [Figure 30-
51-27].
Figure 30-51-28
Replace O-ring (Item 1) [Figure 30-51-28].
Figure 30-51-29
Ensure servo follower (Item 2) [Figure 30-51-28] is
swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-29].
Figure 30-51-30
Assembly: Ensure dowel pin (Item 1) is aligned with hole
in case housing (Item 2) [Figure 30-51-30] before
tightening screws.
P-64464
P-64465
2
1
P-64466
1
P-64463
1
2
30-51-13 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-31
Figure 30-51-32
Remove valve plate (Item 1) [Figure 30-51-31] and
[Figure 30-51-32] 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
30-51-31] and [Figure 30-51-32] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.
P-64454
1
2
RIGHT SIDE
P-64501
1
2
LEFT SIDE
30-51-14 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-33
Figure 30-51-34
Figure 30-51-35
Figure 30-51-36
Assembly: Align the timing pin (Item 1) [Figure 30-51-
33] and [Figure 30-51-34] in the case housing with the
notch (Item 1) [Figure 30-51-35] and [Figure 30-51-36]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure
30-51-33] and [Figure 30-51-34] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-35] and [Figure
30-51-36]. 
NOTE: Valve plate should sit FLUSH with the case
housing when properly installed.
P-64455
1
2
RIGHT SIDE
P-64502
1
2
LEFT SIDE
P-64456
2
1
RIGHT SIDE
P-64503
2
1
LEFT SIDE
30-51-15 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-37
Right Side Rotating Group [Figure 30-51-37].
Figure 30-51-38
Left Side Rotating Group [Figure 30-51-38].
Figure 30-51-39
Remove the piston assembly (Item 1) [Figure 30-51-39].
Figure 30-51-40
Remove the pistons (Item 1) [Figure 30-51-40] from the
rotating block. 
B25012
B25011
P-64469
1
P-64475
1
30-51-16 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-41
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-41] in the
slippers, are not plugged. 
Figure 30-51-42
Inspect the mating surface of the spherical washer for
scoring or scratches (Item 1) [Figure 30-51-42].
Figure 30-51-43
Remove the spherical washer (Item 1) [Figure 30-51-
43].
Figure 30-51-44
Inspect the pins (Item 1) [Figure 30-51-44]. They should
be all the same length. Do not remove.
P-64476
1
P-64477
1
P-64471
1
P-64472
1
1
30-51-17 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-45
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-51-45].
Figure 30-51-46
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-46] where the valve plate seals. Ensure
there is no scratches or scoring.
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-46] are not bent or damaged.
Figure 30-51-47
Inspect mating surface for the slippers on the swash
plate (Item 1) [Figure 30-51-47].
Remove the swash plate from the endcap housing (Item
2) [Figure 30-51-47].
Remove the slide ring (Item 3) [Figure 30-51-47], ensure
it pivots freely.
Figure 30-51-48
Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-48].
P-64474
1
P-64478
1
2
3
P-64479
1
2
3
P-64480
1
2
30-51-18 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-49
Assembly: Ensure bearing pins are in the holes of the
swash plate (Item 1) [Figure 30-51-49]. 
Figure 30-51-50
Remove the shell bearing (Item 1) [Figure 30-51-50].
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-51-50] on swash plate. 
Figure 30-51-51
Remove the shell bearing races (Item 1) [Figure 30-51-
51].
Assembly: Note shell bearing races have an edge (Item
2) [Figure 30-51-51] on them. The edges face towards
the outside of the endcap housing 
Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-51-51].
Figure 30-51-52
Replace O-ring (Item 1) [Figure 30-51-52].
Inspect wear surfaces (Item 2) [Figure 30-51-52] for
scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
P-64481
1
P-64482
1
2
P-64483
1
1
2
2
3
P-64485
1
2
30-51-19 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-53
Figure 30-51-54
Remove the snap ring (Item 1) [Figure 30-51-53] and
[Figure 30-51-54] from the end housing.
Figure 30-51-55
The pump seal (Item 1) [Figure 30-51-55] is removed by
inserting a screw into the seal and prying out. 
Figure 30-51-56
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 30-51-56] and remove
bearing.
P-64486
1
LEFT SIDE
P-76743
1
RIGHT SIDE
P-76742
1
P-64488
2
1
30-51-20 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-57
Servo Piston Assembly [Figure 30-51-57].
The Servo Piston Assembly [Figure 30-51-57] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-58
Measure and record servo piston depth at the adjustment
screw [Figure 30-51-58].
Figure 30-51-59
Remove servo piston mounting bolts (Item 1) [Figure 30-
51-59].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-51-60
Use a rubber mallet to rotate servo piston cover (Item 1)
[Figure 30-51-60].
B25013
P-64490
P-90232
1
1
P-90231
1
30-51-21 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-61
Slide the servo piston assembly out of the bore. [Figure
30-51-61]. 
Figure 30-51-62
Figure 30-51-63
Assembly: Align the servo piston so the guide slot
(Item 1) [Figure 30-51-63] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-51-
62].
Figure 30-51-64
Remove the bushings (Item 1), seals and O-rings (Item
2) [Figure 30-51-64] from the pump housing.
P-90237
P-64467
P-64466
1
P-64493
1
1
2
2
30-51-22 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-65
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-51-65].
Figure 30-51-66
Remove the lock nut (Item 1) [Figure 30-51-66] from the
servo piston.
Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque.
Figure 30-51-67
Remove the servo cover (Item 1) [Figure 30-51-67] from
the servo piston.
Figure 30-51-68
Remove snap ring (Item 1) [Figure 30-51-68] from the
servo piston.
P-64494
1
2
3
P-64495
1
P-64496
1
P-64497
1
30-51-23 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-51-69
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-69] from the servo piston.
Inspect mechanism for broken parts. 
Replace O-ring (Item 2) [Figure 30-51-69]
Figure 30-51-70
Bearings (Item 1) [Figure 30-51-70] in case housing are
replaced by using a press and bearing driver.
Inspect center coupler (Item 2) [Figure 30-51-70]. 
Mechanical Neutral Adjustment
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.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
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.)
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.    
Disconnect the speed sensors located on the top of the
motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
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-64498
1
2
P-64502
1
2
30-51-24 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-71
Connect a hydraulic hose (Item 1) [Figure 30-51-71]
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
Remove the plugs (Item 1) [Figure 30-51-72] from the
MB ports on the front side of the pump, and install 51,7
MPa (517 bar) (7500 psi) pressure gauges.
Figure 30-51-73
Remove the plugs (Item 1) [Figure 30-51-73] from the
MA ports on the bottom of the pump, and install 51,7
MPa (517 bar) (7500 psi) pressure gauges.
Figure 30-51-74
Remove drive hoses from the A and B ports (Item 1)
[Figure 30-51-74]. Plug the ports with metal caps. The
caps must be able to handle at least 51,7 MPa (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.
P-64973
1
1
P-90242
1
1
P-64438
1
P-90243
1
1
1
1
30-51-25 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-75
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-75].
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
Figure 30-51-76
Turn the adjustment screw (Item 1) [Figure 30-51-76]
clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-77
Turn the adjustment screw (Item 1) [Figure 30-51-77]
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Figure 30-51-78
Turn the adjustment screw (Item 1) [Figure 30-51-78]
clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90226
1
P-90238
1
P-90238
1
P-90238
1
30-51-26 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-79
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-51-79] to 30 N•m
(22 ft-lb) torque.
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 ft-
lb) 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 30-51-
26.)
Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
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.
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 jackstands. (See Procedure on Page
10-10-1.)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
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 -
7003031 on Page 10-61-1.)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P-90238
1
2
30-51-27 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-80
Disconnect the hydraulic controller connectors (Item 1)
[Figure 30-51-80] from the loader wiring harness for the
hydraulic controller you are adjusting.
Figure 30-51-81
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-81] pertaining to the side of the hydrostatic
pump you are adjusting.
Figure 30-51-82
Install 3,4 MPa (34,5 bar) (500 psi) pressure gauges in
the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.
Figure 30-51-83
Loosen the locking screw (Item 1) [Figure 30-51-83].
Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
P-90239
1
1
P-90226
1
2
P-64975
P-90236
1
30-51-28 S650 Service Manual
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-84
Turn the adjustment screw (Item 1) [Figure 30-51-84]
clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-85
Turn the adjustment screw (Item 1) [Figure 30-51-85]
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Figure 30-51-86
Turn the adjustment screw (Item 1) [Figure 30-51-86]
clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
Figure 30-51-87
While holding the adjustment screw (Item 1) in position,
tighten the locking screw (Item 2) [Figure 30-51-87] to
6,1 N•m (4.5 ft-lb) torque.
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 procedure. (See
CALIBRATION on Page 60-160-1.)
P-90236
1
P-90236
1
P-90236
1
P-90236
1
2
30-60-1 S650 Service Manual
DRIVE BELT
Belt Adjustment
The drive belt does not need adjustment. The belt has a
spring loaded idler which constantly maintains the correct
belt tension.
Belt Replacement
Stop the engine and open the rear door.
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Figure 30-60-1
Remove the drive belt shield bolt (Item 1) [Figure 30-60-
1].
Figure 30-60-2
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 30-60-2].
P-85518
1
P-90467
1
2
30-60-2 S650 Service Manual
DRIVE BELT (CONT’D)
Belt Replacement (Cont’d)
Figure 30-60-3
Loosen the spring loaded idler adjustment bolt (Item 1).
Insert a 12,7 mm (0.50 in). breaker bar (Item 2) [Figure
30-60-3] into the slot provided in the stop arm as shown
and push breaker bar down to release tension on drive
belt.
Tighten the adjustment bolt (Item 1) [Figure 30-60-3] 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.
Install new drive belt.
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-3] and allow the idler to contact the drive
belt.
Figure 30-60-4
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-60-4] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-3] to 105 - 115 N•m (78 - 85 ft-lb) torque.
Figure 30-60-5
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 30-60-5].
Figure 30-60-6
Install the drive belt shield bolt (Item 1) [Figure 30-60-6].
Install the battery. (See Removal And Installation on
Page 60-20-1.)
Close the rear door.
P-90470
1
2
P-90471
1
P-90468A
1
Top Mounting Bolt
P-90469A
2
Bottom Mounting Bolt
P-85518
1
30-60-3 S650 Service Manual
DRIVE BELT (CONT’D)
Stop Adjustment
Stop the engine and open the rear door.
Figure 30-60-7
Loosen the spring loaded idler adjustment bolt (Item 1)
and insert a 12,7 mm (0.50 in) breaker bar (Item 2)
[Figure 30-60-7] into the slot provided in the stop arm as
shown.
Figure 30-60-8
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-60-8] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-7] to 105 - 115 N•m (78 - 85 ft-lb) torque.
P-90470
1
2
P-90471
1
30-60-4 S650 Service Manual
DRIVE BELT (CONT’D)
Tensioner Pulley Removal And Installation
Remove the engine air cleaner. (See Housing Removal
And Installation on Page 70-40-1.)
Remove the belt. (See Belt Replacement on Page 30-60-
1.)
Figure 30-60-9
Loosen the spring loaded idler adjustment bolt (Item 1).
Insert a 12,7 mm (0.50 in) breaker bar (Item 2) [Figure
30-60-9] 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.
Figure 30-60-10
Remove the two mounting bolts (Item 1) [Figure 30-60-
10].
Remove the tensioner pulley (Item 2) [Figure 30-60-10].
Installation: Apply Loctite® 242 to the mounting bolts
(Item 1) [Figure 30-60-10].
Tensioner Pulley Disassembly And Assembly
Figure 30-60-11
Loosen the two bolts (Item 1) [Figure 30-60-11] but do
not remove.
Release the spring tension by allowing the adjustment
plate (Item 2) to slide past the tensioner pulley stop (Item
3) [Figure 30-60-11].
Remove the two bolts (Item 1) and the adjustment plate
(Item 2) [Figure 30-60-11].
Figure 30-60-12
Remove the pivot sleeve (Item 1) [Figure 30-60-12]. 
P-85520
1
2
P-85741
2
1
P-90306
1
3
2
1
P-90304
1
30-60-5 S650 Service Manual
DRIVE BELT (CONT'D)
Tensioner Pulley Disassembly And Assembly 
(Cont’d)
Figure 30-60-13
Disassembly the tensioner pulley as shown [Figure 30-
60-13].
Check the parts for wear and replace as needed.
NOTE: The wheel and arm assembly (Item 1) [Figure
30-60-13] are not serviceable and must be
replaced as a complete assembly.
P-90303
1
30-60-6 S650 Service Manual
30-70-1 S650 Service Manual
TWO-SPEED / BRAKE VALVE
Description
Figure 30-70-1
The two-speed / brake valve (Item 1) [Figure 30-70-1] is
located on top of the chaincase 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 oil to the shift spool in each
motor. The charge pressure hydraulic oil 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.
P-90507
1
30-70-2 S650 Service Manual
TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Removal And Installation
DANGER
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
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 30-70-2
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 30-
70-2] from the brake / two speed valve block.
Figure 30-70-3
Disconnect the three hydraulic hoses (Item 1) [Figure
30-70-3] from the brake / two speed block.
P-90437
1
2
2
P-90425
1
30-70-3 S650 Service Manual
TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Removal And Installation (Cont’d)
Figure 30-70-4
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
Remove the two mounting bolts (Item 1) [Figure 30-70-
5] from the valve block.
P-90444
1
2
P-90446
1
30-70-4 S650 Service Manual
TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Disassembly And Assembly
Figure 30-70-6
Mark all hydraulic hoses and fittings for proper
installation.
Remove the hydraulic fittings (Item 1) [Figure 30-70-6]
from the valve block.
Figure 30-70-7
Remove the check valves (Items 1 and 2) [Figure 30-70-
7] from the two-speed valve.
NOTE: The check valves (Items 1 and 2) [Figure 30-
70-7] are interchangeable.
Figure 30-70-8
Check the back-up washers (Item 1) and O-rings (Item 2)
[Figure 30-70-8] for wear and replace as needed.
Figure 30-70-9
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 - 9,49 N•m (60 - 84 in-
lb) torque.
P-90548
1
1
1
P-90549
1
2
N-22580
2
1
P-90550
1
2
3
4
30-70-5 S650 Service Manual
TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-10
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
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.
Assembly: Always install new O-rings [Figure 30-70-
10]. 
Figure 30-70-12
Remove the make-up solenoid (Item 1) [Figure 30-70-
12] from the valve block.
Figure 30-70-13
Assembly: Always install new O-rings and back-up
washers [Figure 30-70-13]. Tighten the solenoid valve to
27,1 N•m (20 ft-lb) torque.
P-90435
1
P-90551
1
P-90552
1
N-22584
30-70-6 S650 Service Manual
TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-14
Remove the plugs (Item 1) [Figure 30-70-14] from the
brake / two-speed valve block.
Check the O-ring [Figure 30-70-14] on the plugs and
replace as needed.
Figure 30-70-15
Remove the two speed solenoid bolts (Item 1) [Figure
30-70-15].
Figure 30-70-16
Use a test meter and test the solenoid (Item 1) [Figure
30-70-16] for resistance.
The resistance value for the solenoid coil can be found
on the electrical schematic.
Assembly: Always install new O-rings [Figure 30-70-
10]. 
P-90553
1
1
P-90554
1
P-90547
1
30-80-1 S650 Service Manual
DRAIN MANIFOLD
Description
The drain manifold is an external assembly in the drain
circuit that returns the hydraulic oil to the reservoir.
Drain Manifold Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 30-80-1
Remove and plug all hose’s from the drain manifold (Item
1) [Figure 30-80-1].
Disconnect the wiring harness from the oil temperature
switch (Item 2) [Figure 30-80-1].
Figure 30-80-2
Remove the two bolts (Item 1) [Figure 30-80-2].
P-90484
1
2
P-90485
1
30-80-2 S650 Service Manual
40-01 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
DRIVE COMPONENTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-20-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-20-1
Axle Seal Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-20-2
Axle, Sprocket And Bearings Removal And Installation  . . . . . . . . . . . . . . . . . . . . . .  40-20-4
Chain Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-20-9
CHAINCASE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-30-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-30-1
Front Cover Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-30-1
Center Cover Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40-30-3
40-02 S650 Service Manual
40-10-1 S650 Service Manual
BRAKE (SINGLE SPEED)
Description
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.
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.
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 TRACTION
LOCK on Page 60-120-1.)
Figure 40-10-1
Disc Removal And Installation
Raise the loader 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.
W-2059-0598
Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Disconnect and remove the engine speed control. (See
Removal And Installation on Page 70-20-1.)
Remove the control panel from the loader. (See Removal
And Installation on Page 50-100-2.)
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-2.)
Remove the traction lock assembly. 
Figure 40-10-2
The parking brake discs (Item 1) [Figure 40-10-2] are
located beneath the center chaincase cover.
Figure 40-10-3
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.)
P-85491
1
N-19081A
1
1
N-19105
1
40-10-2 S650 Service Manual
BRAKE (SINGLE SPEED) (CONT’D)
Disc Removal And Installation (Cont’d)
Figure 40-10-4
Figure 40-10-5
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.
N-19082A
1
2
N-19083A
1
40-11-1 S650 Service Manual
BRAKE (TWO-SPEED)
Description
Figure 40-11-1
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 oil to
the brakes. The charge pressure oil 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 oil to hold the spring away from the brake discs. 
When the hold signal is interrupted the solenoid will close
the circuit and the charge oil 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.
For more information on the brake. (See TWO-SPEED /
BRAKE VALVE on Page 30-70-1.)
.
P-85413
1
40-11-2 S650 Service Manual
40-20-1 S650 Service Manual
DRIVE COMPONENTS
Description
The drive components consist of the chaincase, drive
chains, sprockets, axleshafts, 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.
NA1285
40-20-2 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool
MEL1407 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)
Lift and block the loader. (See Procedure on Page 10-10-
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.)
Remove the tire/wheel assembly. (See Mounting on
Page 10-160-1.)
Remove the front chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-1.)
Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
Figure 40-20-1
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.
Figure 40-20-2
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.
WARNING
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
Remove the key (Item 1) [Figure 40-20-3] from the axle.
P4850
1
2
2
P4849
1
P4848
1
40-20-3 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation
Figure 40-20-4
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
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].
P4817
1
P4814
40-20-4 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle, Sprocket And Bearings Removal And 
Installation
The tools listed will be needed to do the following
procedure:
MEL1242 - Port-a-Power
MEL1202B - Axle Bearing Service Set
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.
DANGER
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
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 Procedure 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 chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-1.)
Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
Figure 40-20-6
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
Install a Port-a-Power ram between the two sprockets
[Figure 40-20-7].
P-68196
1
2
P-4158A
40-20-5 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle, Sprocket And Bearings Removal And 
Installation (Cont'd)
Figure 40-20-8
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the 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
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].
NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
the mounting surface.
Figure 40-20-10
Press the splined end of the axle free from the bearing
[Figure 40-20-10].
P5406A
1
2
P-4170
1
P-4171
40-20-6 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle, Sprocket And Bearings Removal And 
Installation (Cont'd)
Figure 40-20-11
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it
will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-
20-11] 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].
Figure 40-20-12
Use the tools provided in the MEL1202B Axle Bearing
Service Set. A slide hammer is also needed.
Use the long driver handle (Item 1) [Figure 40-20-12]
and the bearing cup removal tool to remove the inner
bearing cup.
The bearing cup removal tool must fall into the recess
behind the bearing cup, drive the cup out of the axle tube
[Figure 40-20-13].
Figure 40-20-13
P-4175
1
P4812
1
MC-2164
Recess
Tool
Bearing Cup
40-20-7 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle, Sprocket And Bearings Removal And 
Installation (Cont'd)
Figure 40-20-14
To remove the outer bearing, install a bearing cup
removal tool on the slide hammer.
Install the slide hammer/tool assembly behind the
bearing cup [Figure 40-20-14].
Figure 40-20-15
Use the slide hammer to remove the bearing cup from
the axle tube [Figure 40-20-15].
Figure 40-20-16
Use the bearing cup installation tool (Item 1) [Figure 40-
20-16] and (Item 1) [Figure 40-20-17].
Put the inner cup (Item 2) [Figure 40-20-16] in the axle
tube.
Install the long threaded rod (Item 2) [Figure 40-20-17]
into the axle tube and through the installation tool (Item
1) [Figure 40-20-16].
Install the nut (Item 3) [Figure 40-20-16].
Figure 40-20-17
Install the installation tool (Item 1) [Figure 40-20-17] on
the threaded rod. Install the nut.
Hold the inside nut (Item 3) [Figure 40-20-16] with a
wrench and tighten the outside nut [Figure 40-20-17].
Tighten the nut until the bearing cup is seated.
Remove the installation tool and threaded rod.
P5637
P4816
P5468A
1
2
3
P4811
1
2
40-20-8 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Axle, Sprocket And Bearings Removal And 
Installation (Cont'd)
Figure 40-20-18
To install the outer bearing cup, install the bearing cup
installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-18].
P4813
40-20-9 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Chain Removal And Installation
DANGER
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
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 Procedure 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 Oil on Page 10-130-1.)
Remove the brake disc. (See Disc Removal And
Installation on Page 40-10-1.)
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
Figure 40-20-19
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
removed.
Remove the motor carrier. (See Removal And Installation
on Page 30-30-2.)
P-68194
Front Drive
Chain
Rear Drive
Chain
40-20-10 S650 Service Manual
DRIVE COMPONENTS (CONT'D)
Chain Removal And Installation (Cont’d)
Figure 40-20-20
The tool listed is needed for the following procedure:
MEL1246 - Chain Link Tool
Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
Use MEL1246 Chain Link Tool and #120 chain adapter.
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-20].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-20]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307
B-13504A
40-30-1 S650 Service Manual
CHAINCASE
Description
The chaincase contains the drive components. 
Front 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 10-
30-2.)
Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
DANGER
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
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
Figure 40-30-1
Remove the front chaincase cover mounting screws
(Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-
30-1] from the loader.
NOTE:  There are tabs (Item 3) [Figure 40-30-1] on the
side of the cover to help pry the covers off.
Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
P-34255
2
1
3
3
3
3
40-30-2 S650 Service Manual
CHAINCASE (CONT’D)
Center Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Raise the loader operator cab. (See Raising on Page 10-
30-2.)
DANGER
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 control panel. (See Removal And Installation
on Page 50-100-2.)
Figure 40-30-2
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].
Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Disconnect the electrical connector (Item 3) [Figure 40-
30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
30-2].
Remove the crossbar and wire harness from the center
chaincase cover.
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
Figure 40-30-3
Remove the chaincase cover mounting screws (Item 1)
[Figure 40-30-3].
Remove the center chaincase cover (Item 2) [Figure 40-
30-3] from the loader.
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 oil leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
P-90047
3
4
2
1
P-90048
1
1
2
3
40-30-3 S650 Service Manual
CHAINCASE (CONT’D)
Rear Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Raise the loader operator cab. (See Raising on Page 10-
30-2.)
DANGER
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
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 two-
speed 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 Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to
remove the rear chaincase cover.
Figure 40-30-4
Remove the rear chaincase cover mounting screws (Item
1) [Figure 40-30-4].
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 oil leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
P-90056
1
1
3
2
3
40-30-4 S650 Service Manual
50-01 S650 Service Manual
MAINFRAME
SEAT BAR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-10-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-10-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-10-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-10-2
Compression Spring Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . .  50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-20-1
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-20-1
Gas Spring Bracket Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-20-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-30-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-30-1
Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-30-1
Seat Belt And Bracket Removal And Installation (Standard)  . . . . . . . . . . . . . . . . . .  50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-30-2
OPERATOR SEAT (SUSPENSION)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-1
Slide Rail Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-2
Lower Cushion Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-4
3-Point Seat Belt Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-40-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-40-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-40-1
Lever And Wedge Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .  50-40-5
BOB-TACH (POWER)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-41-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-41-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-41-1
Lever And Wedge Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .  50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-50-1
Stabilizer Bar Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-50-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-50-3
REAR GRILLE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-60-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-60-1
50-02 S650 Service Manual
REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-2
Striker Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-2
Striker (Adjusting)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-2
Latch Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-70-3
FUEL TANK  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-80-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-80-1
Fuel Level Sender Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-80-3
Fuel Fill Screen Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-1
Pedal Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-3
Floor Pan Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-90-4
CONTROL PEDALS AND LINKAGES (ACS)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-1
Pedal Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-2
Floor Pan Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-100-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-100-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Lever Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Boot Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-2
50-03 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
Handle Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-5
Lever Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-5
Boot Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1
Joystick Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-120-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-120-1
Removal And Installation (Right)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-120-1
ACCESS PANEL (INSIDE) (SJC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-121-1
Removal And Installation (Right)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-121-1
WINDOW (REAR)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-130-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-130-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-130-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-131-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-131-1
WINDOW (SIDE)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-132-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-132-1
CAB DOOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-2
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-4
Checking Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-140-4
ARMREST  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-150-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-150-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-150-2
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-150-3
LEFT SIDE LOWER PANEL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-160-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-160-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-160-3
50-04 S650 Service Manual
RIGHT SIDE LOWER PANEL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-170-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-170-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-170-2
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-180-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50-180-1
50-10-1 S650 Service Manual
SEAT BAR
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.
Removal And Installation
Figure 50-10-1
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.
Lower the seat bar.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 50-10-2
Remove the seat bar mounting nuts (Item 1) [Figure 50-
10-2] (both sides).
Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Lower the operator cab. (See Lowering on Page 10-30-
3.)
Figure 50-10-3
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.
P-85654
P-85653
2
1
P-85652
1
P-90021
1
50-10-2 S650 Service Manual
SEAT BAR (CONT'D)
Disassembly And Assembly
Figure 50-10-4
Figure 50-10-5
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10-
5].
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)
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.
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
lb) torque. 
Figure 50-10-6
Figure 50-10-7
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
7].
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 ft-
lb) torque. 
P-90022
4
3
2
1
10
9
8
7
6
5
N-19219
1
3
4
5
9
8
6
10
7
2
P-90023
1
2
3
4
5
6
7
N-19220
1
2
3
4
5
6
7
50-10-3 S650 Service Manual
SEAT BAR (CONT'D)
Compression Spring Disassembly And Assembly
Figure 50-10-8
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50-
10-9] 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.
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
Figure 50-10-9
Disassemble and assemble the seat bar compression
spring and parts as shown in [Figure 50-10-9].
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)
N-19222
1
P-90028
1
2
3
4
5
8
7
6
50-10-4 S650 Service Manual
50-20-1 S650 Service Manual
OPERATOR CAB
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Raise the operator cab (See Raising on Page 10-30-2.)
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.
W-2760-0309
Figure 50-20-1
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).
Figure 50-20-2
Remove the two bolts (Item 1) [Figure 50-20-2].
Figure 50-20-3
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
1
P-85657
1
P-85652
1
2
3
50-20-2 S650 Service Manual
OPERATOR CAB (CONT’D)
Gas Spring Bracket Disassembly And Assembly
Figure 50-20-4
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4].
Installation: Apply a small amount of thread-locker on
the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4].
WARNING
AVOID INJURY
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
Removal And Installation
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.
W-2760-0309
Remove the throttle 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.)
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.
Figure 50-20-5
Disconnect the cab harness connector screw (Item 1)
[Figure 50-20-5]. 
Installation: Tighten the connector screw to 3,39 - 3,96
N•m (30 - 35 in-lb) torque.
P-85661
3
2
1
1
P-85663
1
50-20-3 S650 Service Manual
OPERATOR CAB (CONT’D)
Removal And Installation (Cont’d)
Figure 50-20-6
Remove the two cab mount bolts and nuts (Item 1)
[Figure 50-20-6] 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 50-20-7
Using a strap and a hoist remove the cab from the loader.
P-85658
1
P-85662
50-20-4 S650 Service Manual
50-30-1 S650 Service Manual
OPERATOR SEAT
Removal And Installation
Figure 50-30-1
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the four seat mounting nuts (Item 1) [Figure 50-
30-1] and washers from the operator seat mounting
studs.
Lower the operator cab. (See Lowering on Page 10-30-
3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.
Seat Belt Removal And Installation (Retractable)
Figure 50-30-2
Remove the mounting nut (Item 1) [Figure 50-30-2].
Remove the seat belt.
Installation: Tighten the mounting nut to 73 N•m (54 ft-
lb) torque.
P-85776
1
P-90355
1
50-30-2 S650 Service Manual
OPERATOR SEAT (CONT’D)
Seat Belt And Bracket Removal And Installation 
(Standard)
Figure 50-30-3
Remove the lower mounting bolt, washer and nut (Item
1). Remove the upper mounting bolt and nut (Item 2)
[Figure 50-30-3].
Remove the seat belt.
Installation: Tighten the mounting bolts to 73 N•m (54 ft-
lb) torque.
Seat Belt Bracket Removal And Installation
Figure 50-30-4
Raise the operator cab. (See Raising on Page 10-30-2.) 
Remove the bracket mounting bolts (Item 1) [Figure 50-
30-4].
Remove the bracket (Item 3) [Figure 50-30-3].
Installation: Tighten the mounting bolts to torque.
P101249
1
2
3
P101250
1
50-31-1 S650 Service Manual
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Figure 50-31-1
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Lower the operator cab. (See Lowering on Page 10-30-
3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.
Slide Rail Removal And Installation
Figure 50-31-2
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-2].
Figure 50-31-3
Remove the two slide rails mounting bolts (Item 1)
[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the
bottom of the seat frame.
P-85776
1
P-85769
1
1
P-85770
1
2
50-31-2 S650 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Seat Belt Removal And Installation
Figure 50-31-4
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount. 
Figure 50-31-5
Remove the nut (Item 1) [Figure 50-31-5] from the seat
belt mount. 
Remove the seat belt.
Lower Cushion Removal
Figure 50-31-6
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
P-85771
1
P-85772
1
P-85773
1
50-31-3 S650 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Lower Cushion Installation
Figure 50-31-7
Insert the tab (Item 1) into the slot (Item 2) [Figure 50-31-
7].
Figure 50-31-8
Push down on the front of the seat (Item 1) and push
back (Item 2) [Figure 50-31-8] to lock the seat into
position.
Back Cushion Removal And Installation
Figure 50-31-9
Tilt the seat all the way forward.
Remove the two screws (Item 1) [Figure 50-31-9] and tilt
the seat back to the upright position.
Remove the back cushion from the seat
P-85778
2
P-85774
2
1
P-85775
1
1
2
P-85773
1
50-31-4 S650 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Shock Removal And Installation
Figure 50-31-10
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Remove the seat shock clips (Item 1) [Figure 50-31-10].
(Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-10].
3-Point Seat Belt Removal And Installation
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Figure 50-31-11
Remove the mounting nut (Item 1) [Figure 50-31-11]. 
Remove the end release buckle (Item 2) [Figure 50-31-
11].
Figure 50-31-12
Remove the mounting nut (Item 1) [Figure 50-31-12].   
Remove the seat belt retractor (Item 2) [Figure 50-31-
12].
P-85777
1
1
2
P-85785
1
2
P-85784
1
2
50-31-5 S650 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-31-13
Remove the two mounting bolts (Item 1) [Figure 50-31-
13].
Figure 50-31-14
Remove the shoulder harness retractor (Item 1) [Figure
50-31-14].
Figure 50-31-15
Remove the nut (Item 1) [Figure 50-31-15].
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
P-85786
1
P-85787
1
P-85788
2
1
3
50-31-6 S650 Service Manual
50-40-1 S650 Service Manual
BOB-TACH (HAND LEVER)
Description
The Bob-Tach is the section of the loader lift arm that
attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach .
The Bob-Tach is located on the front of the loader
connected to the loader lift arms. 
Removal And Installation
Figure 50-40-1
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].
Lower the Bob-Tach onto the blocks.
Remove the retainer bolt and nut (Item 1) [Figure 50-40-
1] 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
Remove the rod end pivot pin (Item 1) [Figure 50-40-2].
P-85554
1
P-85649
1
50-40-2 S650 Service Manual
BOB-TACH (HAND LEVER) (CONT'D)
Removal And Installation (Cont’d)
Figure 50-40-3
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
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].
Figure 50-40-5
Check and replace O-ring (Item 1) [Figure 50-40-5] on
the grease plug.
Figure 50-40-6
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
Tach pivot pin retaining bolt (both sides).
P-31402
1
P-31404
1
P-31405
1
P-31403
1
50-40-3 S650 Service Manual
BOB-TACH (HAND LEVER) (CONT'D)
Removal And Installation (Cont’d)
Figure 50-40-7
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.
Figure 50-40-8
With a punch (Item 1) [Figure 50-40-8] and a hammer,
drive the pivot pin out of the lift arm and Bob-Tach.
Lever And Wedge Disassembly And Assembly
Figure 50-40-9
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 50-40-10
Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
P-31406
1
P-31407
1
P-85664
1
P-85665
1
2
50-40-4 S650 Service Manual
BOB-TACH (HAND LEVER) (CONT'D)
Lever And Wedge Disassembly And Assembly 
(Cont'd)
Figure 50-40-11
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 50-
40-11].
Figure 50-40-12
Remove the wedge (Item 1) [Figure 50-40-12] out the
bottom of the Bob-Tach.
Always replace bent or broken wedges.
Figure 50-40-13
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as
needed.
P-85666
1
2
P-85667
1
P-85668
1
2
3
4
50-40-5 S650 Service Manual
BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-14
Remove the Bob-Tach. (See Removal And Installation on
Page 50-40-1.)
Use a seal pick to remove seal (Item 1) [Figure 50-40-
14] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-14]
with a driver tool and hammer.
P-85669
1
2
50-40-6 S650 Service Manual
50-41-1 S650 Service Manual
BOB-TACH (POWER)
Description
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. 
The Power Bob-Tach block is located on the rear of the
gear pump.
The Bob-Tach is located on the front of the loader
connected to the loader lift arms. 
Removal And Installation
Figure 50-41-1
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].
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.
P-85570
1
2
2
50-41-2 S650 Service Manual
BOB-TACH (POWER) (CONT'D)
Removal And Installation (Cont’d)
Figure 50-41-2
Remove the retainer bolt and nut (Item 1) [Figure 50-41-
2] from the rod end pivot pin.
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.
Figure 50-41-3
Remove the rod end pivot pin (Item 1) [Figure 50-41-3].
Figure 50-41-4
Remove the snap ring (Item 1) [Figure 50-41-4] at the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5
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-85554
1
P-85649
1
P-31402
1
P-31404
1
50-41-3 S650 Service Manual
BOB-TACH (POWER - OPTION) (CONT’D)
Removal And Installation (Cont’d)
Figure 50-41-6
Check and replace the O-ring (Item 1) [Figure 50-41-6]
on the grease plug.
Figure 50-41-7
Remove the nut (Item 1) [Figure 50-41-7] from the Bob-
Tach pivot pin retaining bolt (both sides).
Figure 50-41-8
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
the Bob-Tach pivot pin (both sides).
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 50-41-9
With a punch (Item 1) [Figure 50-41-9] and a hammer,
drive the pivot pin out of the lift arm and Bob-Tach (both
sides).
Remove the Bob-Tach from the loader.
P-31405
1
P-31403
1
P-31406
1
P-31407
1
50-41-4 S650 Service Manual
BOB-TACH (POWER) (CONT'D)
Lever And Wedge Disassembly And Assembly
Figure 50-41-1
Remove the washers and bolts (Item 1) [Figure 50-41-1]
from the cylinder (both ends).
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.
Remove the cylinder from the lever pivots.
Figure 50-41-2
Remove the lever mounting nut (Item 1) [Figure 50-41-
2].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 50-41-3
Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-41-3].
Figure 50-41-4
Use a punch and hammer to remove the roll pin (Item 1)
[Figure 50-41-4] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-
41-4].
P-85570
1
1
P-85664
1
P-85665
1
2
P-85666
1
2
50-41-5 S650 Service Manual
BOB-TACH (POWER - OPTION) (CONT'D)
Lever And Wedge Disassembly And Assembly 
(Cont'd)
Figure 50-41-5
Remove the wedge (Item 1) [Figure 50-41-5] out the
bottom of the Bob-Tach.
Always replace bent or broken wedges.
Figure 50-41-6
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-6] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as
needed.
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-41-7
Remove the Power Bob-Tach. (See Removal And
Installation on Page 50-41-1.)
Use a seal pick to remove seal (Item 1) [Figure 50-41-7]
from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-7]
with a driver tool and hammer.
P-85667
1
P-85668
1
2
3
4
P-85669
1
2
50-41-6 S650 Service Manual
50-50-1 S650 Service Manual
LIFT ARMS
Stabilizer Bar Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
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 50-
50-1].
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 50-50-2
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.
Figure 50-50-3
With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4
Remove the bushings (Item 1) [Figure 50-50-4] from the
stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90592A
1
2
P-90593
1
P-90591
1
P-31595
1
50-50-2 S650 Service Manual
LIFT ARMS (CONT'D)
Link Removal And Installation
Figure 50-50-5
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].
Figure 50-50-6
Remove the retainer bolt and nut (Item 1) [Figure 50-50-
6] from the lift arm pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 50-50-7
Remove the retainer bolt and nut (Item 1) [Figure 50-50-
7] from the lift arm link pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 50-50-8
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]
(both sides).
P-90595
P-90597
1
P-90594
1
P-90598
1
50-50-3 S650 Service Manual
LIFT ARMS (CONT'D)
Link Removal And Installation (Cont’d)
Figure 50-50-9
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Remove the lift arm link from the loader.
Removal And Installation
Put jackstands under the rear corners of the loader.
Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 50-50-10
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
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.
P-90610
1
P-90600
1
P-90599
1
50-50-4 S650 Service Manual
LIFT ARMS (CONT'D)
Removal And Installation (Cont’d)
Figure 50-50-12
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
Figure 50-50-13
Remove the retaining bolt and nut (Item 1) [Figure 50-
50-13] 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.
Figure 50-50-14
With a slide hammer, remove the pin (Item 1) [Figure 50-
50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Install slings (Item 1) [Figure 50-50-15] on the lift arms
and connect to a chain hoist.
P-85692
1
P-90602
1
P-90611
1
P-90606
1
1
1
50-50-5 S650 Service Manual
LIFT ARMS (CONT'D)
Removal And Installation (Cont’d)
Figure 50-50-16
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].
Disconnect the stabilizer bar from both sides of the lift
arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
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.
Figure 50-50-18
Remove the retaining bolt and nut (Item 1) and the pin
(Item 2) [Figure 50-50-18] (both sides).
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Remove the lift arms from the loader.
P-90604
1
2
P-90605
1
P-90609
2
1
50-50-6 S650 Service Manual
50-60-1 S650 Service Manual
REAR GRILLE
Removal And Installation
Figure 50-60-1
Flip up the lockable handle (Item 1) [Figure 50-60-1] and
turn the handle a quarter turn counter-clockwise. Lift and
pull the rear grille to remove it from the loader.
Figure 50-60-2
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].
Figure 50-60-3
Align the tabs of the two side covers into the slots in the
loader frame and lower [Figure 50-60-3].
Figure 50-60-4
Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
Turn the lockable handle a quarter turn clockwise and
fold the handle down.
P-85496
1
P100052
1
P-85602
P-85604
50-60-2 S650 Service Manual
50-70-1 S650 Service Manual
REAR DOOR (TAILGATE)
Removal And Installation
Figure 50-70-1
Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the main frame harness.
Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Figure 50-70-2
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.
Figure 50-70-3
Remove the top and bottom door hinge mounting bolts
and nuts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
retainer (Item 3) in the top hinge as shown
[Figure 50-70-3].
Installation: Tighten the mounting bolts and nuts to 34 -
38 N•m (25 - 28 ft-lb) torque.
Lift the door away from the loader frame and put the door
flat on the floor.
P-85697
2
1
P-90584
1
1
2
P-85695
2
1
3
50-70-2 S650 Service Manual
REAR DOOR (TAILGATE) (CONT’D)
Striker Removal And Installation 
Figure 50-70-4
Remove the two striker mount bolts (Item 1) [Figure 50-
70-4].
Remove the striker assembly from the loader.
Striker Disassembly And Assembly 
Figure 50-70-5
Remove the lock nut (Item 1) [Figure 50-70-5].
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].
Check 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.
Striker (Adjusting) 
WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
Align the striker assembly in the center of the mounting
holes.
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.
Tighten both striker mount bolts (Item 1) [Figure 50-70-6]
to 125 - 135 N•m (90 - 100 ft-lb) torque.
Close the rear door. 
P-85698A
1
1
P-31320A
1
3
2
4
P-85698A
1
1
50-70-3 S650 Service Manual
REAR DOOR (TAILGATE) (CONT’D)
Latch Removal And Installation 
Figure 50-70-7
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
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.
Figure 50-70-9
Remove the door handle (Item 1) [Figure 50-70-9] from
the rear door.
P-85699
1
2
P-85700
1
2
3
P-85701
1
50-70-4 S650 Service Manual
50-80-1 S650 Service Manual
FUEL TANK
Removal And Installation
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Figure 50-80-1
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
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.
Figure 50-80-3
Disconnect the fuel vent hose (Item 1) and remove the
two bolts (Item 2) [Figure 50-80-3].
Figure 50-80-4
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].
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-85714
1
1
P-85713
1
P-85707
1
2
P-85708
1
3
2
4
50-80-2 S650 Service Manual
FUEL TANK (CONT'D)
Removal And Installation (Cont'd)
Figure 50-80-5
Remove the bolts (Item 1) [Figure 50-80-5] from the
battery hold down plate.
Remove the hold down plate from the loader.
Figure 50-80-6
Remove the two mounting bolts (Item 1) and the bracket
(Item 2) [Figure 50-80-6].
Figure 50-80-7
At the right side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount bolts to 542 -
583 N•m (400 - 430 ft-lb) torque.
Figure 50-80-8
At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].
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.
P-85710
1
1
P-85709
1
2
1
P-85711
1
1
P-85712
1
1
50-80-3 S650 Service Manual
FUEL TANK (CONT'D)
Fuel Level Sender Removal And Installation
Figure 50-80-9
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
Inspect the fuel level sender and replace if worn or
damaged.
Fuel Fill Screen Removal And Installation
Figure 50-80-11
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
Figure 50-80-12
Remove the fuel fill screen (Item 1) [Figure 50-80-12].
Inspect and replace as needed.
P-85708
1
P-85716
P-85707
2
1
P-85715
1
50-80-4 S650 Service Manual
50-90-1 S650 Service Manual
CONTROL PEDALS AND LINKAGES
Description
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 operators feet.
Pedal 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.
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
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
Figure 50-90-1
Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the pedal linkage.
Check the bushing in the pedal for wear and replace as
needed.
Figure 50-90-2
Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
Remove the pedal assembly from the loader.
P-85675
1
P-85676
1
50-90-2 S650 Service Manual
CONTROL PEDALS AND LINKAGES (CONT’D)
Linkage Removal And Installation 
Figure 50-90-3
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.
Figure 50-90-4
Remove the hairpin clips (Item 1) and cross-pins (Item 2)
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve. 
Figure 50-90-5
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-
5].
Remove the crossbar from the pivot (Item 2) [Figure 50-
90-6].
Figure 50-90-6
Installation: Check the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed.
P-85678
1
P-85680
1
2
1
2
P-85679
1
2
P-85681
1
50-90-3 S650 Service Manual
CONTROL PEDALS AND LINKAGES (CONT’D)
Linkage Removal And Installation (Cont’d)
Figure 50-90-7
Remove the bolt (Item 1) [Figure 50-90-7] and nut from
the pedal linkage.
Remove the linkage (Item 2) [Figure 50-90-7].
Figure 50-90-8
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage.
Remove the linkage (Item 2) [Figure 50-90-8].
Pedal (Adjusting)
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. 
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. 
Figure 50-90-9
Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
Figure 50-90-10
Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Check 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.
P-85675
1
2
P-85675A
1
2
P-85676
1
P-85675
1
2
50-90-4 S650 Service Manual
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.)
Figure 50-90-11
Figure 50-90-12
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].
P-85860
P-85859
1
1
P-85858
2
1
1
50-91-1 S650 Service Manual
CONTROL PEDALS AND LINKAGES (ACS)
Description
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 operators feet.
Pedal 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.
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
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
Figure 50-91-1
Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
Check the bushing in the pedal for wear and replace as
needed.
Figure 50-91-2
Remove the two nuts (Item 1) [Figure 50-91-2] from the
pedal mounting bracket.
Remove the pedal assembly from the loader.
P-85675
1
P-85676
1
50-91-2 S650 Service Manual
CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Linkage Removal And Installation 
Figure 50-91-3
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.
Figure 50-91-4
Remove the linkage (Item 1) [Figure 50-91-4] and the
rubber boot.
Repeat for other side.
Pedal (Adjusting)
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. 
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. 
Figure 50-91-5
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]
from the pedal mounting bracket.
Figure 50-91-6
Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Check 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.
P-90979
1
1
P-90981
1
P-85676
1
P-85675
1
2
50-91-3 S650 Service Manual
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.)
Figure 50-91-7
Figure 50-91-8
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].
P-85860
P-85859
1
1
P-85858
2
1
1
50-91-4 S650 Service Manual
50-100-1 S650 Service Manual
CONTROL PANEL
Description
Figure 50-100-1
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”.
Steering linkage bars attach to the pintle arms where a
rubber torsion bushing is pressed into the pintle arms. 
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
NA1034
50-100-2 S650 Service Manual
CONTROL PANEL (CONT'D)
Removal And Installation
DANGER
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
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10-
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.)
Figure 50-100-2
Figure 50-100-3
Disconnect the control harness connectors (Item 1) and
the back-up alarm wires (Item 2) [Figure 50-100-2] &
[Figure 50-100-3] from the control levers.
P-85846
2
1
P-85847
1
2
50-100-3 S650 Service Manual
CONTROL PANEL (CONT'D)
Removal And Installation (Cont'd)
Figure 50-100-4
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-4] which are connected to the
steering shaft on the control panel.
Remove the four steering linkage 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
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].
Disassembly And Assembly
Remove Control Panel. (See Removal And Installation
on Page 50-100-2.)
Figure 50-100-6
Remove the nuts (Item 1) and the steering stabilizers
(Item 2) [Figure 50-100-6].
P-90612
1
2
2
P-85848
1
3
2
3
3
3
4
P-85864
1
1
2
1
2
1
50-100-4 S650 Service Manual
CONTROL PANEL (CONT'D)
Disassembly And Assembly (Cont’d)
Figure 50-100-7
Figure 50-100-8
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50-
100-8].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8].
Figure 50-100-9
Remove the four bolts (Item 1) [Figure 50-100-9] from
the control panel.
Remove the control handle assembly (Item 2) [Figure
50-100-9].
Figure 50-100-10
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].
P-85865
2
3
3
2
3
3
1
1
P-85861
1
P-85867
1
2
P-85868
1
2
3
4
50-100-5 S650 Service Manual
CONTROL PANEL (CONT'D)
Disassembly And Assembly (Cont’d)
Figure 50-100-11
Remove the two bolts (Item 1) from the bellcrank (Item 2)
[Figure 50-100-11].
Remove the bellcrank from the bracket [Figure 50-100-
11].
Figure 50-100-12
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. 
Linkage 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.
W-2059-0598
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10-
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-85872
21
1
P-85873
2
1
3
50-100-6 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Removal And Installation (Cont’d)
Figure 50-100-13
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.
Remove the four steering linkage mounting bolts, nuts
and rubber isolators (Item 2) [Figure 50-100-13].
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.
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.)
Figure 50-100-14
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-14].
Remove the bolt / spring assembly.
Installation: Tighten the centering spring bolt and a
NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-100-15
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.
P-90612
1
2
2
P-48631
1
2
P-48632
1
50-100-7 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Removal And Installation (Cont’d)
Figure 50-100-16
The centering plate / centering spring assembly consists
of the following parts:
Figure 50-100-17
Check the wear on the centering blocks (Item 1) [Figure
50-100-17].
If the centering blocks need replacement, remove the
bolts (Item 2) [Figure 50-100-17]. Remove the centering
blocks.
Installation: Tighten the centering block bolts to 47,5 -
54,2 N•m (35 - 40 ft-lb) torque.
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. 
P-48630
8
7
6
1
2
2
4
5
3
ITEM DESCRIPTION
1Bolt
2 Bushings
3 Washer
4 Bushing Spacer
5Spring
6Lock Nut
7 Centering Plate
8 Guide Bushings
P-48629
2
2
1
1
50-100-8 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Removal And Installation (Cont’d)
Figure 50-100-18
Remove the bolts and washers (Item 1) [Figure 50-100-
18] 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
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: The washers (Item 2) [Figure 50-100-19] are
hardened, and should only be replaced
through Bobcat Parts. 
Figure 50-100-20
Loosen the bolt (Item 1) [Figure 50-100-20]. 
Remove the pintle base (Item 2) [Figure 50-100-20].
Figure 50-100-21
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].
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.
NOTE: After installing the linkage onto the
hydrostatic pumps the linkage neutral
adjusting procedure must be performed. (See
Linkage Neutral (Adjusting) on Page 50-100-
10.)
P-54617
1
2
3
P-48624
1
3
2
1
2
4
P-54615
2
1
P-48659
1
2
3
50-100-9 S650 Service Manual
CONTROL PANEL (CONT'D)
Pintle Arm Disassembly And Assembly 
Figure 50-100-22
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-22].
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
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) from the base pintle
[Figure 50-100-23]. 
Inspect parts for wear and damage, replace as needed
[Figure 50-100-23].
NOTE: Anti-seize should be used on the adjusting
screw to prevent corrosion and allow free
movement while adjusting.
Figure 50-100-24
Using a bushing driver (Item 1) remove the torsion
bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-24]. 
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.
P-54624
1
2
3
2
4
P-54626
1
2
4
3
P-48619
1
2
3
50-100-10 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) 
The following tool listed will be needed to do the following
procedure:
Kit - 6689778 Remote Start Tool (Service Tool) or
MEL1563 Remote Start Tool.
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT-MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 50-100-25
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.
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
Figure 50-100-26
Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing. 
Figure 50-100-27
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.
P-48450A
1
2
3
P-85845
1
P-54613
2
1
50-100-11 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-28
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
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.
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
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 - 7003031 on Page 10-61-1.)
Start the engine and run at low idle.
Move the traction lock override switch so the traction
function is unlocked. On a standard loader the wedge
brake will unlock.
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).
NOTE:  Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-28] & [Figure 50-
100-29].
P-54614
2
1
P-48451
3
1
2
50-100-12 S650 Service Manual
CONTROL PANEL (CONT'D)
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
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
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary
between the hydrostatic pumps.
NOTE: This procedure is shown for neutral
adjustment on the left side of the loader. The
procedure is the same for the right side
neutral adjustment.
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. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.
P-48632
1
2
P-54610
1
50-100-13 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-32
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 50-
100-32] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and re-install 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 pre-applied
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.)
P-48632
1
1
2
2
50-100-14 S650 Service Manual
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, check 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. 
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10-
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.)
Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
Figure 50-100-33
Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
until the tension is released from the torsion bushing.
Figure 50-100-34
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.
P-85845
1
P-54613
2
1
50-100-15 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-35
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
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].
Figure 50-100-37
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 50-
100-37].
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
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.
P-85878
1
P-51131
3
1
2
4
P-51132
2
1 3
P-51133
1
2
3
50-100-16 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-39
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
39] on each steering linkage bar.
Figure 50-100-40
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 50-100-40]. 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.
Check 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.
Figure 50-100-41
Remove the spacer (Item 1) [Figure 50-100-41].
Figure 50-100-42
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-85844
1
1
P-90615
P-51132
1
P-54613
1
2
50-100-17 S650 Service Manual
CONTROL PANEL (CONT'D)
Linkage Travel (Adjusting) (Cont'd)
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
Figure 50-100-43
Tighten the two bolts and nuts (Items 1) [Figure 50-100-
43] 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 60-210-1.)
Figure 50-100-44
Figure 50-100-45
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.
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3 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.
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.
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.
P-85845
1
P-85877
1
P-85878
1
50-100-18 S650 Service Manual
CONTROL PANEL (CONT'D)
Shock Removal And Installation
Figure 50-100-46
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.
P-85845
1
2
2
1
50-101-1 S650 Service Manual
CONTROL PANEL (SJC)
Description
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.
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.
W-2017-0286
DANGER
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
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.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 50-101-1
Remove the three mount bolts (Item 1) [Figure 50-101-1]
that secure the controller.
Figure 50-101-2
Remove the 10 panel mount bolts (Item 1) [Figure 50-
101-2].
Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-101-2].
Remove the control panel (Item 3) [Figure 50-101-2].
P-85879
1
1
P-85881
1
1
1
1
1
1
3
2
50-101-2 S650 Service Manual
50-110-1 S650 Service Manual
CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the
forward and reverse travel.
The control handles / levers are mounted to the control
panel assembly.
Lever Removal And Installation
Figure 50-110-1
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)
[Figure 50-110-1] 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.
P-85882
1
2
3
4
50-110-2 S650 Service Manual
CONTROL HANDLE/LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal
And Installation on Page 50-110-1.)
Figure 50-110-2
Remove the rubber boot (Item 1) [Figure 50-110-2].
Install the new boot and reinstall the steering lever.
P-85883A
1
50-111-1 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) 
Description
Figure 50-111-1
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.
Handle Sensor Removal And Installation
Figure 50-111-2
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. 
P-21879
1
P-85882
1
50-111-2 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) (CONT'D)
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-3
Disconnect the harness connector (Item 1) from the
handle sensor connector.[Figure 50-111-3].
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector.
Figure 50-111-4
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.
Figure 50-111-5
Remove the handle lock solenoid connector (Item 1)
[Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the
connector down.
Figure 50-111-6
Remove one of the two mounting screws (Item 1) [Figure
50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-
lb) 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].
P-21836
2
1
P-21861
1
P-21860
1
P-21862
1
4
5
1
2
3
50-111-3 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) (CONT’D)
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-7
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.
Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-8
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.
Check 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.
Figure 50-111-9
Figure 50-111-10
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
111-10] to assure proper return of the control handle to
neutral and minimize harness movement.
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 50-
111-10] to avoid wire damage.
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.)
P-21880
1
P-21882
8
1
5
4
3
2
6
7
7
P-21878
1
2
3
P-21799
1
3
2
50-111-4 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) (CONT'D)
Handle Removal And Installation
Figure 50-111-11
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
Figure 50-111-12
Remove the switch handle (Item 1) [Figure 50-111-12].
(See Switch Handle Removal on Page 60-130-4.)
Figure 50-111-13
Remove the rubber handle cover (Item 1) [Figure 50-
111-13] from the handle.
Figure 50-111-14
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.
Installation: Tighten the allen head screws to 4 N•m (35
in-lb) torque.
P-21879
1
P16534
1
N-17384
1
N-17385
2
1
2
50-111-5 S650 Service Manual
CONTROL HANDLE / LEVER (ACS) (CONT'D)
Handle Disassembly And Assembly
Figure 50-111-15
Remove the handle sleeve (Item 1) and bushings (Item
2) [Figure 50-111-15] from the handle.
Check all parts for wear and replace as needed.
Figure 50-111-16
Check the mounting bolt (Item 1) [Figure 50-111-16] that
connects the handle to the handle sensor unit for wear,
replace as needed.
Lever Removal And Installation
Figure 50-111-17
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)
[Figure 50-111-17] used to mount the control lever.
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.
N-17394
1
2
2
N-22796
1
P-85882
1
2
3
4
50-111-6 S650 Service Manual
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
Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.
P-85883A
1
50-112-1 S650 Service Manual
CONTROL HANDLE / LEVER (SJC)
Description
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.
Joystick Testing
See Bobcat Advanced Troubleshooting System (B.A.T.S.)
or connect to service analyzer to check function.
50-112-2 S650 Service Manual
CONTROL HANDLE / LEVER (SJC) (CONT'D)
Joystick Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Figure 50-112-1
Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
Remove the four screws (Item 1) [Figure 50-112-2] and
lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35
- 40 in-lb) torque.
Figure 50-112-3
Disconnect the joystick connector (Item 1) [Figure 50-
112-3] from the harness connector.
P-85890
1
P-85889
1
1
1
1
P-85891
1
50-120-1 S650 Service Manual
ACCESS PANEL (INSIDE)
Removal And Installation (Left)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Figure 50-120-1
Remove the four mounting screws, (Item 1), washer (Item
2), and remove the left access panel (Item 3) [Figure 50-
120-1].
Remove the front access panel from the loader.
Removal And Installation (Right)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Figure 50-120-2
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.
P-85677
1
1
3
2
P-85677A
3
1
1
2
50-120-2 S650 Service Manual
50-121-1 S650 Service Manual
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Figure 50-121-1
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1].
Figure 50-121-2
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2].
Removal And Installation (Right)
Figure 50-121-3
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Figure 50-121-4
Remove the bolt and throttle 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].
P-85887
2
1
P-85884
1
1
2
P-90587
12
P-90588
1
2
2
2
3
50-121-2 S650 Service Manual
50-130-1 S650 Service Manual
WINDOW (REAR)
Removal And Installation
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
Figure 50-130-1
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] 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.
Disassembly And Assembly
Figure 50-130-2
Remove the screw (Item 1) from the latch [Figure 50-
130-2]. 
Installation: Tighten the screw (Item 1) [Figure 50-130-
2] to 21 - 23 N•m (180 - 200 in-lb) torque. 
Figure 50-130-3
Inspect and replace any damaged parts.
The items listed below refer to [Figure 50-130-3].
1. Latch
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal
P-85706
1
1
P-85705
1
P-85704
1
2
3
4
5
6
7
50-130-2 S650 Service Manual
50-131-1 S650 Service Manual
WINDOW (TOP)
Removal And Installation
Figure 50-131-1
Install the bolts (Item 1) [Figure 50-131-1] through the
window grommets and through the cab holes.
Figure 50-131-2
From inside the operator cab, install and tighten the four
nuts (Item 1) [Figure 50-131-2] on the window bolts. 
Tighten the nuts (Item 1) [Figure 50-131-2] to 9 - 10 N•m
(80 - 90 in-lb) torque.
P-85807
1
1
P-85808
1
1
1
1
50-131-2 S650 Service Manual
50-132-1 S650 Service Manual
WINDOW (SIDE) 
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Figure 50-132-1
Figure 50-132-2
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.
Figure 50-132-3
Support the window assembly and remove the six bolts
(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
Installation: Tighten the six bolts (Item 1) [Figure 50-
132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.
Remove the window assembly.
NOTE: The window assembly can only be replaced
as a complete unit.
P-85821
2
P-85819
1
2
3
4
5
P-90586
1
1
1
1
1
1
50-132-2 S650 Service Manual
50-140-1 S650 Service Manual
CAB DOOR
Description
The standard cab door is available as an option or dealer
installed kit. 
Removal And Installation
Figure 50-140-1
Open the cab door.
Disconnect electrical connector (Item 2) and washer fluid
hose (Item 1) [Figure 50-140-1].
Figure 50-140-2
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].
Figure 50-140-3
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
Remove the four bolts and nuts (Item 2) [Figure 50-140-
4] from the cab.
Remove the hinges (Item 1) [Figure 50-140-4] from the
cab.
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 in-
lb) torque.
P-85781A
1
2
P-85588A
1
P-85589A
2
3
P-85828
1
2
2
1
1
P-85837
50-140-2 S650 Service Manual
CAB DOOR (CONT’D)
Disassembly And Assembly
Figure 50-140-5
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5]. 
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.
Remove the wiper motor shaft nut (Item 4) [Figure 50-
140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88
- 124 in-lb) torque.
Remove the door from the loader. (See Removal And
Installation on Page 50-140-1.)
Figure 50-140-6
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6]. 
Figure 50-140-7
Remove the three bolts (Item 1) and the wiper motor
assembly (Item 2) [Figure 50-140-7]. 
Figure 50-140-8
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8]. 
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m
(270 - 300 in-lb) torque.
P-85829
3
1
2
4
P-85841
2
1
1
1
P-85834
2
1
1
1
P-85835
1
2
4
3
4
50-140-3 S650 Service Manual
CAB DOOR (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 50-140-9
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-9]. 
Remove the two nuts and bolts (Item 4) [Figure 50-140-
9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m
(270 - 300 in-lb) torque.
Figure 50-140-10
Disconnect the harness (Item 1) [Figure 50-140-10].
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10]. 
Remove the glass from the frame.
Aligning
Figure 50-140-11
Figure 50-140-12
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 50-140-
4.)
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.
After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
P-85836
1
2
4
4
3
P-85830A
1
2
3
2
P-85832A
1
WRONG
P-85839A
1
WRONG
P-85833A
1
CORRECT
P-85838A
1
CORRECT
50-140-4 S650 Service Manual
CAB DOOR (CONT’D)
Adjusting
Figure 50-140-13
Loosen the two bolts (Item 1) [Figure 50-140-13] and
adjust the latch as needed.
Figure 50-140-14
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-
140-3.)
Checking Operation
Figure 50-140-15
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].
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.
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.
P-85830
1
1
P-85831
1
P-85413
2
1
50-150-1 S650 Service Manual
ARMREST
Description
The armrests are located on each side of the seat. They
are adjustable for comfort. 
Figure 50-150-1
Adjustable armrests (Item 1) [Figure 50-150-1].
P-90837
1
50-150-2 S650 Service Manual
ARMREST (CONT’D)
Removal And Installation
Slide the seat and the backrest all the way forward.
Remove the seat belt (See Seat Belt Removal And
Installation on Page 50-31-2.) 
Figure 50-150-2
Remove the two nuts and bolts (Item 1) [Figure 50-150-
2].
Figure 50-150-3
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.
Figure 50-150-4
Remove the top spacer (Item 1) and the bottom spacer
(Item 2) [Figure 50-150-4] from the seat.
Repeat for the other side.
P-90835
1
P-90836
1
2
3
4
P-90845
1
2
50-150-3 S650 Service Manual
ARMREST (CONT’D)
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
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
Remove the two bolts and washers (Item 1) and the
armrest shell (Item 2) [Figure 50-150-6].
Figure 50-150-7
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
P-90838
1
P-90839
2
1
1
P-90840
1
1
P-90841
2
1
50-150-4 S650 Service Manual
ARMREST (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 50-150-9
Figure 50-150-10
Remove the nut (Item 1), washer (Item 2), and the plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10].
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 in-
lb) torque.
Figure 50-150-11
Remove the two nuts (Item 1) and the slide rail (Item 2)
[Figure 50-150-11] from the armrest mount.
Repeat for the other side.
P-90842
1
2
3
P-90843
1
2
3
4
5
6
P-90844
2
1
1
50-160-1 S650 Service Manual
LEFT SIDE LOWER PANEL
Removal And Installation
Raise the operator’s cab.
Figure 50-160-1
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Remove the seat. (See Removal And Installation on
Page 50-30-1.) 
Remove the 3-Point seat belt retractor (If equipped).
(See 3-Point Seat Belt Removal And Installation on Page
50-31-4.)
Lower the operator’s cab.
NOTE: With the seat removed, the cab may raise.
Figure 50-160-2
Remove the storage compartment (Item 1) (if equipped)
[Figure 50-160-3] from the left side lower panel.
Figure 50-160-3
Disconnect the wiper washer pump (Item 1) (if equipped)
[Figure 50-160-3] from the left side lower panel.
Figure 50-160-4
Remove three plastic screws and the anchors (Item 1)
[Figure 50-160-4] from the left side lower panel.
P-90897
1
1
1
1
1
P-90867
1
P-90856
1
P-90863
1
P-90856
1
1
1
50-160-2 S650 Service Manual
LEFT SIDE LOWER PANEL (CONT’D)
Removal And Installation (Cont’d)
Figure 50-160-5
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].
Figure 50-160-6
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-160-6].
Figure 50-160-7
Disconnect the hose (if equipped) (Item 1) and remove
the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Pull the left side lower panel (Item 1) [Figure 50-160-8]
rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
side of the cab far enough to access the wire
harness.
P-90855
1
1
1
2
P-90857
2
1
1
P-90858
1
2
P-90852
1
50-160-3 S650 Service Manual
LEFT SIDE LOWER PANEL (CONT’D)
Removal And Installation (Cont’d)
Figure 50-160-9
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped).
Disassembly And Assembly
Figure 50-160-10
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
NOTE: If the three clips (Item 1) [Figure 50-160-11] are
removed the cup holder will need to be
replaced.
P-90859
1
1
1
1
P-90860
1
1
1
1
1
P-90865
1
50-160-4 S650 Service Manual
LEFT SIDE LOWER PANEL (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 50-160-12
Remove the four screws (Item 1) [Figure 50-160-12] and
remove the speaker from the left side lower panel.
Figure 50-160-13
Remove the three screws (Item 1) [Figure 50-160-13]
and remove the washer tank from the left side lower
panel.
P-90866
1
1
1
1
P-90864
1
50-170-1 S650 Service Manual
RIGHT SIDE LOWER PANEL
Removal And Installation
Raise the operator’s cab.
Figure 50-170-1
Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on
Page 50-30-1.) 
Lower the operator’s cab.
NOTE: With the seat removed, the cab may raise.
Figure 50-170-2
Remove the three plastic screws and the anchors (Item
1) [Figure 50-170-2] from the right side lower panel.
Figure 50-170-3
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-170-3].
Figure 50-170-4
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90897
1
1
1
1
1
P-90869
1
1
1
P-90870
1
1
1
2
P-90871
2
1
1
50-170-2 S650 Service Manual
RIGHT SIDE LOWER PANEL (CONT’D)
Removal And Installation (Cont’d)
Figure 50-170-5
Pull the right side lower panel (Item 1) [Figure 50-170-5]
rear out and away from the side of the cab.
NOTE: Pull the right side lower panel away from the
side of the cab far enough to access the wire
harness.
Figure 50-170-6
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.
Disassembly And Assembly
Figure 50-170-7
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
power port from the right side lower panel.
NOTE: The power port lock washer must be replaced
with a new when it has been removed.
Figure 50-170-8
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.
P-90872
1
P-90873
1
2
1
1
P-90879
1
P-90881
P-90877
2
1
50-170-3 S650 Service Manual
RIGHT SIDE LOWER PANEL (CONT’D)
Disassembly And Assembly (Cont’d)
Figure 50-170-9
Remove the nut, washer, and cover, (Item 1) [Figure 50-
170-9] from the input.
Remove the input from the right side lower panel.
Figure 50-170-10
Remove the four screws (Item 1) [Figure 50-170-10] and
remove the speaker from the right side lower panel.
P-90875
1
P-90876
1
1
1
1
50-170-4 S650 Service Manual
50-180-1 S650 Service Manual
HEADLINER
Removal And Installation
Figure 50-180-1
Remove the two screws (Item 1) and the rear shelf (Item
2) [Figure 50-180-1] (if equipped).
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.
Installation:  Tighten the screws to 2,3 N•m (20 in-lb)
torque.
Figure 50-180-2
Remove the air duct (Item 1) [Figure 50-180-2] (if
equipped).
Figure 50-180-3
Remove the air duct (Item 1) [Figure 50-180-3] (if
equipped).
Remove the cab light (if equipped). (See Cab Light
Removal And Installation on Page 60-60-2.) 
Figure 50-180-4
Remove the four retainers (Item 1) and remove the
headliner (Item 2) [Figure 50-180-4].
Installation:  Route the cab light wire harness in the
grove on the topside of the headliner (if equipped with
HVAC).
NOTE: Replace the retainers if needed.
P-90893
1
1
2
P-90894
1
P-90895
1
P-90896
1
1
1
1
2
50-180-2 S650 Service Manual
60-01 S650 Service Manual
ELECTRICAL SYSTEM & ANALYSIS
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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-10-12
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-20-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-20-2
Using A Booster Battery (Jump Starting)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-20-3
ALTERNATOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-1
Belt Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-3
Low Voltage Testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-4
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-5
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-30-6
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-40-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-40-1
Parts Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-40-2
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-1
Left Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-1
Display Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-3
Right Panel (Standard Key Panel)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-6
Left Switch Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-8
Right Switch Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-8
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-9
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . .  60-50-9
Right Panel (Keyless Start Panel) Removal And Installation  . . . . . . . . . . . . . . . . .  60-50-10
Right Panel (Deluxe Instrumentation Panel) Removal And Installation  . . . . . . . . .  60-50-10
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-12
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-50-12
60-02 S650 Service Manual
LIGHTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-60-2
Cab Light Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)  . . . . . . . . . . . . . . . . . . . . . .  60-70-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-70-1
Connector Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-70-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-70-8
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-71-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-71-1
Connector And Wire Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-71-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-71-3
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-72-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-72-1
Connector Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-72-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-72-4
SPEED SENSORS (SJC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-80-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-80-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-80-3
DIAGNOSTIC SERVICE CODES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-90-1
Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-90-1
Service Codes List  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-90-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . . . . . . . . . . . . . .  60-100-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-100-1
Inspecting The BICS (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . .  60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . .  60-100-2
Inspecting The Traction Lock (Engine RUNNING)  . . . . . . . . . . . . . . . . . . . . . . . . .  60-100-2
Inspecting The Lift Arm Bypass Control  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . .  60-100-2
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-100-3
SEAT BAR SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-3
Bobcat Interlock Control System (BICS) Circuit Test  . . . . . . . . . . . . . . . . . . . . . . . .60-110-4
60-03 S650 Service Manual
TRACTION LOCK  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-120-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-120-1
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-120-2
Inspecting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-1
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-2
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . .  60-130-3
Switch Handle Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-6
Actuator Connector Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-9
Handle Lock Solenoid Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . .  60-130-10
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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-1
Identification Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-140-6
ELECTRICAL / HYDRAULIC CONTROLS (ACS)  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-1
Identification Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-141-6
ELECTRICAL / HYDRAULIC CONTROLS (SJC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-1
Identification Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-142-6
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-150-1
Connecting Remote Start Tool  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-150-1
60-04 S650 Service Manual
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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-161-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-161-1
Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-161-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-170-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-170-1
Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-170-2
CONTROL PANEL SETUP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-180-1
Right Panel Setup (Deluxe Instrumentation Panel)  . . . . . . . . . . . . . . . . . . . . . . . .  60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)  . . . . . . . . . . . . . . . . .  60-190-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-190-1
Changing The User Passwords  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-191-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-191-1
MAINTENANCE CLOCK  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-200-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-200-5
BACK-UP ALARM SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-1
Inspecting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-1
Adjusting Switch Position  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-3
Troubleshooting (Joystick)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-4
Alarm Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-220-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-220-1
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
GROUNDING 2000 THROUGH 2999
BLACK BLK
MONITORING 3000 THROUGH 3999
LIGHT BLUE LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
CONNECTOR ASSIGNMENTS
CONN DESCRIPTION
NUM OF 
PINS
SHEET CONN DESCRIPTION
NUM OF 
PINS
SHEET CONN DESCRIPTION
NUM OF 
PINS
SHEET
C101 FUEL SHUTOFF SOLENOID 3 6
C421 TILT SPOOL LOCK
3 10
FC1 FUSE CENTER 1
3
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 FC2 FUSE CENTER 2 3
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11
T1 BATT GROUND 4
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T2 BUZZER GROUND
8
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 T3 FLASHER
13
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7
T6
BATT GROUND 4
C126 HORN 2 13 C441 TWO SPEED 2 7
T8
BATT GROUND 4
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7
T13
BUZZER POWER
8
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5
T14 PRE HEATER
6
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C250 DOOR SENSOR 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C251 WIPER 5 9 C480 LEFT PANEL(GRAY) 12 8
T17
LEFT REAR WORK LIGHT (+)
11
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9
T18
LEFT REAR WORK LIGHT (-)
11
C277 AIR RIDE SEAT
6 9
C483 TEMP CONTROL SWITCH 3 12
T19
BACKUP ALARM
10
C278 RIGHT SPEAKER 2 9 C486 AC COMPRESSOR 2 12 T20
BACKUP ALARM (GND)
10
C279 LEFT SPEAKER 2 9 C489 ACCESSORY 2 3,4
C308 BRAKE SOLENOID 2 7
C499 PTOL 4
8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8
C362 REAR AUX SOLENOID  8 7 C602 LEFT REAR TAIL LIGHT 2 11
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB CONNECTOR 48 3-5, 8-13 C611 BLOWER MOTOR 4 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12
SW1 BRAKE SWITCH
9
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW2 BEACON SWITCH 13
C411 LEFT HANDLE 5 WAY 5 10,13 C667 DOOR KIT 6 9 SW3 HAZARD SWITCH 13
C412 HANDLE(HORN) 2 10,13 C670 EXTERIOR BEACON 6 13 SW4 HAND/FOOT, H/ISO SWITCH 9
C413 REAR ROD 2
7
C676 RADIO 6 9 SW5 POWER BOBTACH SWITCH 13
C414 REAR BASE 2
7
SW6 BUCKET POSITION SWITCH 13
C415 HIGH FLOW SOLENOID 2
7
SW8 FRONT WIPER SWITCH 9
C416 DIVERTER SOLENOID 2
7
SW9 TRAVEL CONTROL SWITCH 8
C417
REAR AUX RELIEF
2
7
J1A GATEWAY COTROLLER 34 SW10 BLOWER SWITCH 12
C418 FRONT ROD 2
7
J1B GATEWAY CONTOLLER 26 SW11 AC SWITCH 12
C419 FRONT BASE 2
7
J2A AUX CONTROLLER 34
C420 HYD LOCK 2 7
J2B AUX CONTROLLER 26
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 1 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
A-1
HYDRAULIC LOCK RETURN
B-1
HYD CHARGE PRESS
A-2
LIFT SPOOL LOCK RETURN
B-2
UNSW BATT
A-3
FUEL PULL RELAY
B-3 UNSW BATT
A-4
SWITCHED POWER OUT RELAY
B-4
FUEL HOLD
A-5
LIGHT 1 RELAY
B-5
LIFT SPOOL LOCK
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD
A-7
STARTER RELAY
B-7
TILT SPOOL LOCK
A-8
TRACTION PULL RELAY
B-8
CAN LO 1
A-9 FAN 1 RELAY B-9 CAN HI 1
A-10
TILT SPOOL LOCK RETURN
B-10
SPOOL LOCK SENSOR 2
A-11
SPARE DIGITAL, ECU SINKS
B-11
SEAT BAR
A-12
SPARE DIGITAL, ECU SOURCES
B-12 FUEL LEVEL
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD
A-14
GLOW PLUG RELAY FDBK
B-14
CAN HI 2
A-15
ENGINE SPEED
B-15
GROUND P1
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17
LIGHT 2 RELAY
B-17
GROUND P3, SENSOR
A-18 FAN 2 RELAY B-18
ENGINE COOLANT TEMP
A-19 PTOL LED B-19 FAN 2 OUTPUT
A-20
PTOL SWITCH
B-20
CAN LO 2
A-21
SWITCHED POWER OUT RELAY FDBK
B-21
REMOTE KEY
A-22 STATER RELAY FDBK B-22 RUN/ENTER
A-23
HYD OIL FILTER SW2
B-23
SENSOR SUPPLY 8V
A-24
START ENGINE
B-24
SENSOR SUPPLY 5V
A-25
ENGINE OIL PRESS
B-25
TWO SPEED MAKEUP
A-26 SPARE B-26 TWO SPEED COIL
A-27
SPARE
A-28
LIGHT 2 RELAY FDBK
A-29 FAN 1 RELAY FDBK
A-30 FUEL PULL RELAY FDBK
A-31
LIGHT 1 RELAY FDBK
A-32 HYD OIL TEMP
A-33
SPARE ANALOG
A-34
HYD OIL FILTER SW1
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION
A-1
FRONT AUX (F) RETURN
B-1
A-2
REAR AUX (F) RETURN
B-2
UNSW BATT
A-3
LEFT BLINKER RELAY
B-3 UNSW BATT
A-4
RIGHT BLINKER RELAY
B-4
DIVERTED SOLENOID
A-5
HORN RELAY
B-5
REAR AUX (F)
A-6 B-6 RELIEF SOLENOID
A-7
OUTPUT SPARE
B-7
REAR AUX (M)
A-8 B-8
CAN LO 1
A-9 B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-11
LH PADDLE RIGHT
B-11
A-12 LH PADDLE LEFT B-12
A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14
DIGITAL INPUT SPARE
B-14
CAN HI 2
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
LH FLOAT BUTTON
B-20
CAN LO 2
A-21
HYDRAULIC DETENT
B-21
RH TRIGGER
A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23
RH CENTER BUTTON
B-23
HANDLE POT POWER
A-24
DIGITAL INPUT SPARE
B-24
A-25 B-25
BUCKET POSITION (SPARE)
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27
BUCKET POSITION(SPARE) RETURN
A-28
LH RIGHT BUTTON
A-29 RH RIGHT BUTTON DOWN
A-30 RH LEFT UP
A-31
RH LEFT DOWN
A-32
A-33
A-34
DIGITAL INPUT SPARE
HARNESS PART NUMBER
MAIN FRAME 7174782
STD CAB 7165991
DLX CAB
7176098
DLX FUEL 7175293
STD FUEL 7149219
DOOR
7155024
S/R
6733370
TAILGATE DOM
7175271
TAILGATE EUR 7175287
2 SPD ADP
7159366
BACKUP ALARM
7175017
BRAKE ADAPTER
7165061
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 2 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
25 A
FC2 FUSE 2
25 A
FRC1 FUSE 11
20 A
FRC1 FUSE 10
15 A
FRC1 FUSE 9
POWER
SWITCHED
85 86
30
87
1760/RNG/WHT
C489 A
1040/RED
1070/RED
30 A
FRC1 FUSE 5
30 A
FRC 1  FUSE 6
MEGAFUSE
100.0 Amps
1010/RED
BATTERY
BATT_CABLE
1110/RED/WHT
1130/RED/WHT
1790/RNG/WHT
1310/RED
1050/RED
1050/RED
SHEET 6
2055/BLK
1300/RED
1060/RED
1030/RED
8000/TAN
C408 17
C408 43
1660/RNG/WHT
1340/RED
1120/RED/WHT 1450/RED/WHT
1150/RED/WHT
1180/RED/WHT
J2B 2
J2B 3
J1B 3
J1B 2
J1A 4
SHEET 12
1450/RED/WHT
1660/RNG/WHT
1785/RNG/WHT
SHEET 5
SHEET 5
SHEET 9
25 A
FC1 FUSE 2
1160/RED/WHT1025/RED
25 A
FC1  FUSE 1
SHEET 6
SHEET 6
1830/RNG/WHT
1840/RNG/WHT
SHEET 13
SHEET 8
1440/RED/WHT
SHEET 8
1420/RED/WHT
15 A
FRC1  FUSE 3
1795/RNG/WHT
SHEET 9
1400/RED/WHT
15 A
FC2 FUSE 4
25 A
FRC1  FUSE1
25 A
FRC1  FUSE 2
25 A
FRC1  FUSE 8
5 A
FRC1  FUSE 4
25 A
FRC1  FUSE 7
SHEET 8
1940/RNG/WHT
SHEET 8
1620/RNG/WHT
SHEET 8
1930/RNG/WHT
SHEET 8
1950/RNG/WHT
SHEET 9
1775/RNG/WHT
SHEET 8
1960/RNG/WHT
POWER
C408 6
1920/RNG/WHT
1920/RNG/WHT
SHEET 13
1460/RED/WHT
25 A
FC2  FUSE 1
SHEET 12
2030/BLK
C404 B
1410/RED/WHT
1490/RED/WHT
1190/RED
SHEET 10
1570/RNG/WHT
1765/RNG/WHT
SHEET 8
SHEET 8
1590/RNG/WHT
1240/RED/WHT
1290/RED
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
GROUNDING 2000 THROUGH 2999 BLACK BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999
TAN TAN
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SHEET 9
1580/RNG/WHT
SHEET 9
1370/RED/WHT
SHEET 9
1850/RNG/WHT
SHEET 13
1550/RNG/WHT
SHEET 5
1165/RED/WHT
SHEET 5
1730/RNG/WHT
SHEET 7
1360/RED/WHT
SHEET 6
1350/RED/WHT
SHEET 12
1140/RED/WHT
SHEET 11
1320/RED/WHT
SHEET 11
1330/RED/WHT
SHEET 6
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
1780/RNG/WHT1750/RNG/WHT
1720/RNG/WHT
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 3 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
C489 B
SHEET 6
3800/LBL
SHEET 5
SHEET 9
2790/BLK
2390/BLK
SHEET 7
SHEET 9
3910/LBL
3410/LBL
2900/BLK
C103 B
2600/BLK
SHEET 7
2720/BLK
2000/BLK
2200/BLK
T1
BATT GND
SHEET 12
2745/BLK
SHEET 7
3310/LBL
SHEET 6
3510/LBL
SHEET 6
3110/LBL
T8
BATT GND
2110/BLK
SHEET 11
SHEET 13
SHEET 9
2765/BLK
2780/BLK
2730/BLK
T6
BATT GND
2500/BLK
3010/LBL
2510/BLK
SHEET 6
3710/LBL
2300/BLK2710/BLK
SHEET 13
2741/BLK
2540/BLK
2550/BLK
SHEET 7
2480/BLK
J2B 15
J2B 16
SHEET 7
2450/BLK
J1B 15
J1B 16
J1B 17
2900/BLK
C408 42
SHEET 8
SHEET 5
2920/BLK
SHEET 11
2070/BLK
SHEET 5
2080/BLK
SHEET 13
2830/BLK
SHEET 8
2940/BLK
SHEET 8
2960/BLK
SHEET 9
2930/BLK
SHEET 8
2700/BLK
GROUND
SHEET 13
2751/BLK
C408 32
2950/BLK 2950/BLK
SHEET 13
2785/BLK
SHEET 7
3530/LBL
2090/BLK
SHEET 8
2250/BLK
2600/BLK
SHEET 10
2650/BLK
SHEET 11
2640/BLK
SHEET 11
2610/BLK
SHEET 11
2620/BLK
SHEET 11
2630/BLK
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499
RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
GROUNDING 2000 THROUGH 2999 BLACK BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
SHEET6
2810/BLK
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 4 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
FF
EE
GG
DD
BB
AA
SHEET 4
2710/BLK
9400/PUR
9500/PUR/WHT
9600/PUR
C426
C408 7
C408 8
9120/PUR/WHT
9220/PUR
J2B 9
J2B 8
J1B 8
J1B 9
J1B 14
J1B 20
J1B 21
C479 3
C479 4
C503 2
C503 4
9530/PUR/WHT9130/PUR/WHT
9630/PUR9230/PUR
4
1
2
3
3
1
2
4
2070/BLK
2080/BLK
1830/RNG/WHT
1840/RNG/WHT
9640/PUR
9540/PUR/WHT
C450
C449
SHEET 3
SHEET 4
SHEET 4
SHEET 3
9650/PUR
9550/PUR/WHT
9260/PUR
9160/PUR/WHT
9230/PUR
9130/PUR/WHT
9240/PUR 9250/PUR
9140/PUR/WHT 9150/PUR/WHT
CAN BUS
9200/PUR
9100/PUR/WHT
RESISTOR
120 OHM
RESISTOR
120 OHM
9660/PUR
9560/PUR/WHT
9270/PUR
9170/PUR/WHT
SHEET 3
1165/RED/WHT
SHEET 3
1730/RNG/WHT
CC
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
#
CONNECTOR DOES NOT EXIST IN 7165991
#
#
CAN (Remote Start Tool, ACD)
RIGHT
JOYSTICK
LEFT
JOYSTICK
LEFT PANEL
RH DLX PANEL
AUX CTRLR
GWY CTRLR
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 5 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
SHEET 4
SHEET 4
C
A
B
3520/LBL
3510/LBL
3600/LBL
3800/LBL
STARTER
85 86
30
87
8200/TAN
8250/TAN
PULL
FUEL
85 86
30
87
A
B
C
8800/TAN
PLUG
GLOW
85 86
30
87
8500/TAN
A3700/LBL
B3710/LBL
C110
T14 PRE HEATER
2016/BLK 8510/TAN
8550/TAN
8110/TAN
8150/TAN
8210/TAN
3200/LBL
SHEET 4
SHEET 4
L
S 1020/RED
1015/RED
A
B
3210/LBL
2015/BLK
B
A
ENGINE SPEED SENSOR
3610/LBL
SWITCH
AIR FILTER
SENSOR (500-3000 OHM)
ENGINE COOLANT
SENDER (0.5 ~ 4.5V)
ENGINE OIL PRESSURE
SOLENOID
FUEL SHUTOFF
2800 BLK
8800 TAN
8100 TAN
C101
24.5 OHM
0.33 OHM
C405
M
S
R
STARTER
G
ALTERNATOR
C104
B
EXCITATION
PULL
HOLD
8100/TAN8120/TAN
2800/BLK
J1B 4
J1B 12
J1B 18
J1A 22
J1A 15
J1A 16
J1A 25
J1A 14
J1A 6
J1A 30
J1A 3
J1A 7
D5
A
B
C109
8250/TAN
8200/TAN
SHEET 3
1060/RED
SHEET 3
1030/RED
SHEET 12
2005/BLK
SHEET 7
2025/BLK
15 A
FRC1 FUSE 12
ENGINE
SHEET 12
1815/RNG/WHT
A
B
SHEET 3
2055/BLK
3110/LBL 3110/LBL
3100/LBL 3100/LBL
C355 D
C355 C
SHEET 9
3500/LBL
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 7000 THROUGH 7999
WHITE WHT
ENGINE 8000 THROUGH 8999 TAN TAN
COMMUNICATION 9000 THROUGH 9999
PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SHEET 3
1350/RED/WHT
1800/RNG/WHT
C106
SIG
GND
SIG
GND
+5V PWR
SIG
GND
C107
C406
GND
SIG
SHEET 3
B
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
SIG
GND
FUEL
SENDER
SHEET4
2810/BLK
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 6 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
LOCK
TRACTION
85 86
30
87
B
C
A
SHEET 4
2200/BLK
4200/LGN
4150/LGN
4110/LGN
A
C
B
3400/LBL
3420/LBL
3410/LBL
A
B
4410/LGN
2410/BLK
SHEET 4
A
C112
B
A3300/LBL
3310/LBL
3430/LBL
B
1
2
4010/LGN
2910/BLK
B
A4200/RED
2200/BLK
0.5-7.5V
PRESSURE
CHARGE
HYDRAULIC
HARN BRAKE ADAPTER 7165061
9.8 OHM 12V
HYD LOCK SOLENOID
12 V
9.8 OHM
SOLENOID
BRAKE
C425
12 V
7.2 OHM
FAN SOLENOID
HYDRAULIC
C105
C446
C420
C108
C308
TRACK MACHINES
B
C
A
C425
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
2
1
C441
2350/BLK
TWO SPEED SOLENOID
4350/LGN
1
2
4340/LGN
2340/BLK
4430/LGN
4440/LGN
4450/LGN
4480/LGN
1
2
4330/LGN
2330/BLK
B
A4460/LGN
3.3 OHM PWM
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
FRONT BASE SOLENOID (FEMALE)
12 V
7.5 OHM
SOLENOID
OPTIONAL HIGH FLOW
C415
C419
C418
2
2
1
2440/BLK
1
2430/BLK
7.5 OHM 12V
MALE COUPLER
DIRECTIONAL SOLENOID
OPTIONAL REAR AUX
7.5 OHM 12V
FEMALE COUPLER
DIRECTIONAL SOLENOID
OPTIONAL REAR AUX
C413
C414
1
2
2
1
2450/BLK
7.5 OHM 12 V
SOLENOID MALE COUPLER
BLEED / LOCK VALVE
OPTIONAL REAR AUX
SOLENOID FEMALE COUPLER
BLEED / LOCK VALVE
OPTIONAL REAR AUX
C417
C416
2480/BLK
SHEET 4
2460/BLK
J2B 13
J2B 19
J2B 26
J2B 5
J2B 7
J2B 4
J2B 6
J2A 2
J2A 10
J2A 1
J2A 18
J2A 26
B
A
D
C
F
E
H
G 4480/LGN
2480/BLK
2450/BLK
4450/LGN
4430/LGN
2430/BLK
2440/BLK
4440/LGN
C362
SHEET 4
J1B 6
J1B 13
J1B 19
J1B 26
J1B 1
J1B 23
J1A 18
J1A 1
J1A 32
J1A 34
J1A 13
J1A 8
2
1
C437
MAKEUP SOLENOID
TWO SPEED
J1B 25
4360/LGN
2360/BLK
J1A 27
J1A 26
HYDRAULICS
SHEET 11
2035/BLK
+8V
SHEET 6
2025/BLK
4100/LGN
SHEET 4
3530/LBL
SHEET 3
1360/RED/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 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
SIG
GND
SIG
GND
SIG
GND
SIG
GND
GND
SIG
GND
SIG
GND
SIG
GND
SIG
GND
SIG
GND
SIG
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
HYDRAULIC
FILTER SWITCH
WHEEL MACHINES
0.3 OHM
10.9 OHM
HOLD
PULL
TRACTION
LOCK
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 7 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
9350/PUR
C408 4
C408 40
C408 1
C408 37
9370/PUR
9380/PUR
9360/PUR
J1B 22
J1A 24
J1A 20
J1A 19
22
1212
C480
C479 8
C479 7
C479 10
C479 9
C479 11
C479 1
C479 2
C479 5
2920/BLK
T2
BUZZER (-)
1940/RNG/WHT
9320/PUR
T13
BUZZER (+)
4730/LGN
2700/BLK
GROUND
Left Blinker Input
Battery (+)
Right Blinker Input
Travel Control Input
Switched Power
BUZZER
Park Break Output
Reserved Output 5
Park Break Input
1960/RNG/WHT
SWITCH (OPTIONAL)
TRAVEL CONTROL
SW9
1
2
3
4
5
6
1440/RED/WHT
1620/RNG/WHT
11
22
33
44
C499
SWITCH POWER
PTOL OUTPUT
PTOL LED
GROUND
9380/PUR
9370/PUR
1930/RNG/WHT
2940/BLK
2960/BLK
1950/RNG/WHT
44
11
55
33
22
C500
RUN/ENTER SW
START
Switched Power
Battery (+)
GROUND
1420/RED/WHT
SHEET 4
SHEET 3 SHEET 3
SHEET 9
4750/LGN
SHEET 3
SHEET 3
SHEET 3
SHEET 4
SHEET 4
SHEET 3
SHEET 4
SHEET 3
9360/PUR
9350/PUR
SHEET 13
SHEET 13
6550/PNK
6450/PNK
CAB DISPLAY
2250/BLK
1590/RNG/WHT
C503 1
C503 5
C503 3
Switched Power
Battery (+)
GROUND
1240/RED/WHT
SHEET 3
SHEET 4
SHEET 3
SHEET 9
9310/PUR
SHEET 9
4500/LGN
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
GROUNDING 2000 THROUGH 2999 BLACK BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
66
LEFT PANEL (BLACK) RH KEY SWITCH
RH DLX PANEL
LEFT PANEL (GRAY)
PTOL
(Press To Operate Loader)
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 8 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
SHEET 4
3920/LBL
3910/LBL
3900/LBL
2790/BLK
C408 24
C408 44
C408 45
C408 46
C408 33
C408 23
SHEET 4
2730/BLK
3930/LBL
SHEET 4
J1B 11
BRAKE SWITCH
SW1
2
1
3
5
6
4
2930/BLK
C408 5
C408 3
C408 2
1775/RNG/WHT
2
5
6
4
3
1
2840/BLK
C667
SWITCH
FRONT WIPER
SW8
2
1
3
5
4
6
C408 27
7330/WHT
7300/WHT
7310/WHT
BB
AA
22
11
1390/RED/WHT1370/RED/WHT
2010/BLK2790/BLK
2840/BLK
C
B
A
C251
X
L
C252
MOTOR
WIPER
PARK
LOW
GND
MOTOR
WASHER
DOOR SENSOR
2730/BLK
2795/BLK
1400/RED/WHT
-
+
C212
SENSOR SHOWN 
WITH DOOR OPEN
SWITCH
(SJC, AWS)
H/ISO
(ACS)
HAND/FOOT
SW4
5
6
4
2
1
3
4550/LGN
2060/BLK
C
B
C129
2820/BLK
1375/RED/WHT
A
1210/RED/WHT
SHEET 3
1785/RNG/WHT
4235/LGN
4275/LGN
C
3900/LBL
A
B
3910/LBL
3920/LBL
SENSOR
SEATBAR
GND
SIG
PWR
SHEET 3
SHEET 8
1850/RNG/WHT
C408 16
SHEET 4
SHEET 3
2
5
6
3
4
1
C676
1
2
1
2
C279
7830/WHT
7820/WHT
7810/WHT
7800/WHT
C278
RIGHT SPEAKER
LEFT SPEAKER
1865/RNG/WHT1580/RNG/WHT
1885/RNG/WHT
2885/BLK
J1B 24
+5V
D
SW PWR
E
4740/LGN
1400/RED/WHT
7310/WHT
2845/BLK
1850/RNG/WHT
1860/RNG/WHT
1570/RNG/WHT
2
1
C250
CC
4750/LGN
4740/LGN
4760/LGN
5
4
C277
1510/RNG/WHT
2210/BLK
SHEET 6
3500/LBL
7165991Standard Cab Harness
7176098 Deluxe Cab Harness
SHEET 8
9310/PUR
SHEET 8
4500/LGN
7176098 ONLY
SHEET 3
1580/RNG/WHT
SHEET 3
1370/RED/WHT
SHEET 3
1850/RNG/WHT
C209
-
+
-
+
SEAT SOLENOID
AIR RIDE
C482
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
*    SPLICE DOES NOT EXIST IN 7165991
*
*
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
ACCESSORY
CONN
POWER SOCKET
RADIO CONN
DOME LIGHT
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 9 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
2370/BLK
2380/BLK
3
14370/LGN
1
3
4380/LGN
TILT SPOOL LOCK SOLENOID
LIFT SPOOL LOCK SOLENOID
J2B 22
J1B 7
J1B 5
J1A 2
J1A 10
1560/RNG/WHT
G
F
B
C
D
A
E
H
J
K
4810/LGN
4820/LGN
4830/LGN
4840/LGN
1710/RNG/WHT
C410
B
C
E
D
J
H
4300/LGN
4310/LGN
4920/LGN
4930/LGN
4320/LGN
4940/LGN
A
F
G
K
1590/RNG/WHT
4910/LGN
C409
SKI CTRL
SIDE SHIFT
PWM
TWO SPD
DETENT FLOW
SKI CTRL
F
G
B
C
D
A
+B
D
-C
A
H
J
E
F
E
H
G
K
J
K
E
C
A
D
B
B
A HORN
TURN SIGNAL
J2B 23
J2B 17
J2A 22
J2A 30
J2A 31
J2B 21
J2A 13
J2B 18
J2A 28
J2A 12
J2A 11
SHEET 3
1570/RNG/WHT
2
2
C103 C
C404 A
7100/WHT
7001923
BACKUP ALARM
+
-
7100/WHT
SHEET 4
2650/BLK
MANUAL 
CONTROLS
C411
C412
C421
C422
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
T19 1
T20 1
LEFT HANDLE
RIGHT HANDLE
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 10 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
LIGHTS
WORK
FRONT
85 86
30
87
LIGHT
REAR
85 86
30
87
C103 A
C103 H
6310/PNK
6000/PNK
6210/PNK
6320/PNK
C408 25
C408 28
SHEET 4
2765/BLK
6230/PNK
6330/PNK
6340/PNK
J1A 28
J1A 17
J1A 5
J1A 31
A
B
6110/PNK
A
B
6120/PNK
2760/BLK
2750/BLK
WORK LIGHT
LEFT FRONT
50.00 Watts
WORK LIGHT
RIGHT FRONT
37.00 Watts
6000/PNK
2765/BLK
2045/BLK
2045/BLK
SHEET 4
2000/BLK
LIGHTS
A
B
WORK LIGHT
LEFT FRONT
37.00 Watts
A
B
WORK LIGHT
RIGHT FRONT
50.00 Watts
6100/PNK
6130/PNK
2735/BLK
2705/BLK
SHEET 7
2035/BLK
6200/PNK
1
C603
2
WORK LIGHT
RIGHT REAR
TAIL LIGHT
RIGHT REAR
1
C602
2
WORK LIGHT
LEFT REAR
TAIL LIGHT
LEFT REAR
6330/PNK
6320/PNK
6200/PNK
T16 1
T15 1
T18 1
T17 1
6210/PNK
6310/PNK
SHEET 4
2640/BLK
SHEET 4
2610/BLK
SHEET 4
2620/BLK
SHEET 4
2630/BLK
SHEET 3
1320/RED/WHT
SHEET 3
1330/RED/WHT
C435-2
C435-1
C434-1
C434-2
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 11 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
HVAC
85 86
30
87
1500/RNG/WHT
2745/BLK
SHEET 4
8020/TAN
A
B
7024/WHT
C350
(AC PRESS SWITCH)
EVAPORATOR
J1A 21
A
B
C
D
C611
2745/BLK
C408 22
1500/RNG/WHT 5
SWITCH
BLOWER
SW10
6
3
OFF
2
1
4
C408 21
1970/RNG/WHT
1520/RNG/WHT
7320/WHT
1900/RNG/WHT
C408 34
A
B
C
1980/RNG/WHT
C483
A
D
C
B
E
F
C635
1910/RNG/WHT
7220/WHT
2560/BLK
2130/BLK
High14.00 Amps
Med7.50 Amps
Low5.00 Amps
SWITCH)
(TEMP CONTROL
POTENTIOMETER
DBL
WHT
BLK
VALVE
HEATER
12V
SIG
GND
2580/BLK
MOTOR
BLOWER
A
B
C
3320/LBL
C630
2570/BLK
7020/WHT
THERMOSTAT
AC SWITCH
SW11
C
1
2100/BLK
3
7040/WHT
SHEET 3
1790/RNG/WHT
SHEET 3
2030/BLK
HVAC
SHEET 6
1815/RNG/WHT
2
2280/BLK
1
2290/BLK
7025/WHT
D4
SHEET 13
7020/WHT
7023/WHT
J1A 11
7021/WHT
SHEET 6
2005/BLK
C486
(COMPRESSOR)
MAGNET CLUTCH
SHEET 3
1140/RED/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
C355 A
7024/WHT
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 12 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
C103 D
C103 E
6410/PNK
6510/PNK
C408 29
C408 36
C408 15
C408 26
SHEET 4
SHEET 12
2290/BLK
C408 30
C408 13
SHEET 4
2780/BLK
C408 35
6500/PNK
6400/PNK
BB2740/BLK
AA
7030/WHT
9.8 OHM
SOLENOID
POSITION
BUCKET
OPTIONAL
A
B
D
C411
6515/PNK
6010/PNK
6415/PNK
A
B
C126
A
B 7210/WHT
C412
SHEET 4
2785/BLK
1460/RED/WHT 7022/WHT
SHEET 4
2741/BLK
D3
6500/PNK
HAZARD SWITCH
SW3
5
4
6
2
1
3
6530/PNK
6400/PNK
E
D
A
C
F
B
C670
6440/PNK
6430/PNK
6540/PNK
6540/PNK
6700/PNK
2780/BLK
L
X
1430/RED/WHT
1410/RED/WHT
T3
FLASHER CONN
6570/PNK
6010/PNK
2725/BLK
SWITCH
BOBTACH
POWER
SW5
5
4
6
2
1
3
C408 9
C408 10
1380/RED/WHT
BLINKER
RIGHT
BEACON
STROBE
BLINKER
LEFT
1200/RED/WHT
2420/BLK2850/BLK
D2
D1
SWITCH
POSITION
BUCKET
SW6
2
1
3
5
6
4
1550/RNG/WHT
7022/WHT
2830/BLK
(PINS 3 & 6 
INTERNALLY 
INSULATED)
6550/PNK
6450/PNK
SHEET 3
SHEET 3
1410/RED/WHT
SHEET 4
OPTIONS
SHEET 8
SHEET 8
A
C606
B 2775/BLK
B
A
C607
2770/BLK
7000/WHT
7010/WHT
C408 38
7210/WHT
2751/BLK 2751/BLK
C355 B
C355 E
C355 F
7010/WHT
7010/WHT
7000/WHT
7000/WHT
SHEET 3
1550/RNG/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
C
E
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
C423
LEFT HANDLE
2 PIN
LEFT
HANDLE
5 PIN
PWR BOB CLOSE
PWR BOB OPEN
SWITCH
BEACON
SW2
1
2
3
4
5
6
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 13 of 13
(PRINTED JUNE 2009)
7175752
Printed In U.S.A.
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
CONN DESCRIPTION
NUM OF 
PINS
SHEET CONN DESCRIPTION
NUM OF 
PINS
SHEET CONN DESCRIPTION
NUM OF 
PINS
SHEET
C101 FUEL SHUTOFF SOLENOID
3 6
C421 TILT SPOOL LOCK
3 10 J1A
GATEWAY COTROLLER
34
C103 TAILGATE
8 4,10,11,13
C422 LIFT SPOOL LOCK
3 10 J1B
GATEWAY CONTOLLER
26
C104 ENGINE COOLANT SENSOR
2 6
C423 BUCKET POSITION
2 13 J2A
AUX CONTROLLER
34
C105 HYD CHARGE PRESSURE
3 7
C425 BRAKE SOLENOID
3 7 J2B
AUX CONTROLLER
26
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD)
7 5
J1-ACS ACS CONTROLLER 8
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11 J2-ACS ACS CONTROLLER 10
C108 HYD TEMPERATURE SENDER 2
7
C434-2 LEFT WORKLIGHT 2 2 11 J3-ACS ACS CONTROLLER 10
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11
J5
DRIVE CONTROLLER 50
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C112 HYD OIL FILTER SWITCH 2
7
C437 TWO SPEED MAKEUP 2
7
C126 HORN 2 13 C441 TWO SPEED 2
7
FC1 FUSE CENTER 1 3
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2
7
FC2 FUSE CENTER 2 3
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK
4
5,15 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK
4
5,15
C250 DOOR SENSOR 2 9
C459
LEFT JOYSTICK
4
15
C251
WIPER 5
9 C460 RIGHT JOYSTICK
4
15 T1 BATT GROUND
4
C252 WASHER 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T2 BUZZER GROUND
8
C277 AIR RIDE SEAT 6 9 C480 LEFT PANEL(GRAY) 12 8 T3 FLASHER
13
C278 RIGHT SPEAKER 2 9 C482 SEATBAR SENSOR 3 9
T6
BATT GROUND 4
C279 LEFT SPEAKER 2 9 C483 TEMP CONTROL SWITCH 3 12
T8
BATT GROUND
4
C308 BRAKE SOLENOID 2
7
C486 AC COMPRESSOR 2 12
T13
BUZZER POWER
8
C350 AC EVAPORATOR SWITCH 2 12 C489 ACCESSORY 2 3,4
T14 PRE HEATER
6
C355 DLX or STD FUEL HARNESS 6 6,12,13 C492 ACS/SJC/AWS 1 8 3,5,9,14,15
T15
RIGHT REAR WORK LIGHT(+)
11
C362 REAR AUX SOLENOID  8
7
C493 ACS/SJC/AWS 2
4
3,4,14,15 T16 RIGHT REAR WORK LIGHT(-) 11
C404 BACKUP ALARM 2 3,10 C497 SJC HORN/BLINKER 3 13
T17
LEFT REAR WORK LIGHT (+)
11
C405 AIR FILTER SWITCH 2 6 C499 PTOL
4
8
T18
LEFT REAR WORK LIGHT (-)
11
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8
T19
BACKUP ALARM
10
C408 CAB CONNECTOR 48 3-5, 8-13 C503
RH DLX PANEL
6 5,8 T20
BACKUP ALARM (GND)
10
C409 RIGHT HANDLE 10 10 C602 LEFT REAR TAIL LIGHT 2 11
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11
C411 LEFT HANDLE 5 WAY 5 10,13 C606 POWER BOBTACH OPEN 2 13 SW1 BRAKE SWITCH 9
C412 HANDLE(HORN) 2 10,13 C607 POWER BOBTACH CLOSE 2 13 SW2 BEACON SWITCH 13
C413 REAR ROD 2 7 C611 BLOWER MOTOR 4 12 SW3 HAZARD SWITCH 13
C414 REAR BASE 2 7 C630 THERMOSTAT 3 12 SW4 HAND/FOOT, H/ISO SWITCH 9
C415 HIGH FLOW SOLENOID 2 7 C635 HEATER VALVE 6 12 SW5 POWER BOBTACH SWITCH 13
C416 DIVERTER SOLENOID 2 7 C667 DOOR KIT 6 9 SW6 BUCKET POSITION SWITCH 13
C417 REAR AUX RELIEF 2 7 C670 EXTERIOR BEACON 6 13 SW8 FRONT WIPER SWITCH 9
C418 FRONT ROD 2 7 C676 RADIO 6 9 SW9 TRAVEL CONTROL SWITCH 8
C419 FRONT BASE 2 7 SW10 BLOWER SWITCH 12
C420 HYD LOCK 2 7
SW11 AC SWITCH 12
CONNECTOR ASSIGNMENTS (ACS)
CONN DESCRIPTION
NUM OF 
PINS
SHEET
C428 TILT ACTUATOR
8 14
C429 LIFT ACTUATOR
8 14
C467 LIFT PEDAL LOCK
3 14
C468 TILT PEDAL LOCK
3 14
C469
TILT HANDLE
3 14
C470
TILT PEDAL
3 14
C471
LIFT PEDAL
3 14
C472
LIFT HANDLE
3 14
CONNECTOR ASSIGNMENTS (SJC)
CONN DESCRIPTION
NUM OF 
PINS
SHEET
C536 RIGHT SWASHPLATE
4 15
C537 LEFT SWASHPLATE
4 15
C428 TILT ACTUATOR
8 15
C429 LIFT ACTUATOR
8 15
C453 RIGHT QUAD A DRIVE
4 15
C454 LEFT QUAD DIRVE
4 15
C474 BRAKE LIGHT
1 15
C501 A22 PUMP HARNESS
8 15
C544 LEFT FORWARD DRIVE
2 15
C545 LEFT REVERSE DRIVE
2 15
C546 RIGHT FORWARD DRIVE
2 15
C547 RIGHT REVERSE DRIVE
2 15
C542 LEFT SWASHPLATE
3 15
C543 RIGHT SWASHPLATE
3 15
C707 OBW STOP BRAKE LIGHT
3 15
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 1 of 15
Printed In U.S.A.
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2
LIFT SPOOL LOCK RETURN
B-2
UNSW BATT
A-3 FUEL PULL RELAY B-3
UNSW BATT
A-4
SWITCHED POWER OUT RELAY
B-4
FUEL HOLD
A-5
LIGHT 1 RELAY
B-5
LIFT SPOOL LOCK
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD
A-7
STARTER RELAY
B-7
TILT SPOOL LOCK
A-8
TRACTION PULL RELAY
B-8
CAN LO 1
A-9 FAN 1 RELAY B-9
CAN HI 1
A-10
TILT SPOOL LOCK RETURN
B-10
SPOOL LOCK SENSOR 2
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR
A-12
SPARE DIGITAL, ECU SOURCES
B-12 FUEL LEVEL
A-13
TRACTION PULL RELAY FDBK
B-13
BICS HYD LOCK HOLD
A-14
GLOW PLUG RELAY FDBK
B-14
CAN HI 2
A-15
ENGINE SPEED
B-15
GROUND P1
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17
LIGHT 2 RELAY
B-17
GROUND P3, SENSOR
A-18 FAN 2 RELAY B-18
ENGINE COOLANT TEMP
A-19
PTOL LED
B-19
FAN 2 OUTPUT
A-20
PTOL SWITCH
B-20
CAN LO 2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY
A-22
STATER RELAY FDBK
B-22
RUN/ENTER
A-23
HYD OIL FILTER SW2
B-23
SENSOR SUPPLY 8V
A-24
START ENGINE
B-24
SENSOR SUPPLY 5V
A-25
ENGINE OIL PRESS
B-25
TWO SPEED MAKEUP
A-26 SPARE B-26 TWO SPEED COIL
A-27
SPARE
A-28 LIGHT 2 RELAY FDBK
A-29 FAN 1 RELAY FDBK
A-30 FUEL PULL RELAY FDBK
A-31 LIGHT 1 RELAY FDBK
A-32
HYD OIL TEMP
A-33 SPARE ANALOG
A-34
HYD OIL FILTER SW1
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION
A-1 FRONT AUX (F) RETURN B-1
A-2
REAR AUX (F) RETURN
B-2
UNSW BATT
A-3 LEFT BLINKER RELAY B-3
UNSW BATT
A-4
RIGHT BLINKER RELAY
B-4
DIVERTED SOLENOID
A-5
HORN RELAY
B-5
REAR AUX (F)
A-6 B-6 RELIEF SOLENOID
A-7
OUTPUT SPARE
B-7
REAR AUX (M)
A-8 B-8
CAN LO 1
A-9 B-9
CAN HI 1
A-10
REAR AUX (M) RETURN
B-10
A-11 LH PADDLE RIGHT B-11
A-12 LH PADDLE LEFT B-12
A-13
RH RIGHT BUTTON UP
B-13
FRONT AUX (F)
A-14
DIGITAL INPUT SPARE
B-14
CAN HI 2
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
LH FLOAT BUTTON
B-20
CAN LO 2
A-21 HYDRAULIC DETENT B-21 RH TRIGGER
A-22
LH RIGHT BUTTON DOWN
B-22
SWITCHED POWER
A-23
RH CENTER BUTTON
B-23
HANDLE POT POWER
A-24
DIGITAL INPUT SPARE
B-24
A-25 B-25
BUCKET POSITION (SPARE)
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27
BUCKET POSITION(SPARE) RETURN
A-28 LH RIGHT BUTTON
A-29
RH RIGHT BUTTON DOWN
A-30 RH LEFT UP
A-31 RH LEFT DOWN
A-32
A-33
A-34
DIGITAL INPUT SPARE
J5 DRIVE CONTROLLER
PIN FUNCTION
1 SAFETY IN
2
TWO SPEED SWITCH
3
SPARE DIGITAL INPUT 2
4
H PAT SWITCH
5
ISO PAT SWITCH
6 ISO LITE
7
L SWASH PLATE ANGLE
8
R SWASH PLATE ANGLE
9
SPARE ANALOG 4
10
SPARE ANALOG 5
11
L FWD RETURN
12
CAN HIGH
13
LF ANGLE
14
RF ANGLE
15
LR ANGLE
16
H PAT LITE
17
RR ANGLE
18
L JOYSTICK X
19
L JOYSTICK Y
20
R JOYSTICK X
21
L FWD DRIVE
22
CAN LOW
23
R QUAD A DRIVE
24
R QUAD B DRIVE
25
TWO SPEED 1
26 BRAKE LIGHT OUTPUT
27
GROUND
28 GROUND
29
SENSOR GROUND
30
SENSOR SUPPLY 2 +5V
31
L REV DRIVE
32
CAN SHIELD
33 L QUAD A DRIVE
34
L QUAD B DRIVE
35
SAFETY OUT
36 BACKUP ALARM
37
R JOYSTICK Y
38 SPARE ANALOG 1
39
SPARE PWM COIL 7
40
SENSOR SUPPLY 1 +5V
41
L REV RETURN
42 R FWD RETURN
43 R FWD DRIVE
44 R REV DRIVE
45 R REV RETURN
46 TWO SPEED 2
47
UNSWITCHED BATTERY
48 UNSWITCHED BATTERY
49
SPARE PWN COIL 6
50
SWITCHED BATTERY
ACS CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A
+5V TO SENSORS
A
LIFT CYLINDER SENSOR-SPARE
A
TILT MOTOR 1
B
SWITCHED POWER
B
FLOAT-SPARE
B
UNSWITCHED POWER
C HAND/FOOT INPUT C
RESPONSE SELECTOR-SPARE
C UNSWITCHED POWER
D
CAN HIGH
D
TILT CYLINDER SENSOR-SPARE
D
LIFT MOTOR 2
E
CAN LOW
E
TILT ACTUATOR FEEDBACK
E HANDLE ENABLE
F F LIFT HANDLE F
LIFT MOTOR 1
G GROUND G
TILT HANDLE
G
PEDAL ENABLE
H
GROUND
H
LIFT ACTUATOR FEEDBACK
H
GROUND
J LIFT PEDAL J
GROUND
K TILT PEDAL K
TILT MOTOR 2
HARNESS PART NUMBER
MAINFRAME 7175625
STD CAB 7165991
DLX CAB
7176098
DLX FUEL 7175293
STD FUEL
7149219
DOOR
7155024
S/R 6733370
TAILGATE DOM
7175271
TAILGATE EUR
7175287
2 SPD ADP
7159366
ACS
7164144
SJC WHEEL 7159325
HARNESS PART NUMBER
SJC TRACK 7159458
A22 PUMP 7169309
SUSP JSTK
7163706
BACKUP ALARM
7175017
BRAKE ADAPTER 7165061
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 2 of 15
Printed In U.S.A.
25 A
FC2 FUSE 2
25 A
FRC1 FUSE 11
20 A
FRC1 FUSE 10
15 A
FRC1 FUSE 9
POWER
SWITCHED
85 86
30
87
1760/RNG/WHT
C489 A
1040/RED
1070/RED
30 A
FRC1 FUSE 5
30 A
FRC 1  FUSE 6
25 A
FC1 FUSE 3
MEGAFUSE
100.0 Amps
1010/RED
BATTERY
BATT_CABLE
1110/RED/WHT
1130/RED/WHT
1790/RNG/WHT
1310/RED
1050/RED
1050/RED
SHEET 6
2055/BLK
1300/RED
1060/RED
1030/RED
8000/TAN
1740/RNG/WHT
C408 17
C408 43
1660/RNG/WHT
1340/RED
1120/RED/WHT
1270/RED
1450/RED/WHT
1150/RED/WHT
1180/RED/WHT
J2B 2
J2B 3
J1B 3
J1B 2
J1A 4
SHEET 12
25 A
FC1  FUSE 4
1235/RED/WHT
1170/RED/WHT
1280/RED
1450/RED/WHT
1660/RNG/WHT
1785/RNG/WHT
SHEET 5
SHEET 5
SHEET 9
25 A
FC1 FUSE 2
1160/RED/WHT1025/RED
25 A
FC1  FUSE 1
SHEET 6
SHEET 6
1830/RNG/WHT
1840/RNG/WHT
SHEET 13
SHEET 8
1440/RED/WHT
SHEET 8
1420/RED/WHT
15 A
FRC1  FUSE 3
1795/RNG/WHT
SHEET 9
1400/RED/WHT
15 A
FC2 FUSE 4
25 A
FRC1  FUSE1
25 A
FRC1  FUSE 2
25 A
FRC1  FUSE 8
5 A
FRC1  FUSE 4
25 A
FRC1  FUSE 7
SHEET 8
1940/RNG/WHT
SHEET 8
1620/RNG/WHT
SHEET 8
1930/RNG/WHT
SHEET 8
1950/RNG/WHT
SHEET 9
1775/RNG/WHT
SHEET 8
1960/RNG/WHT
POWER
C493 1
C493 2
C492 6
C408 6
1920/RNG/WHT 1920/RNG/WHT
SHEET 13
1460/RED/WHT
25 A
FC2  FUSE 1
SHEET 12
2030/BLK
C404 B
1410/RED/WHT
1490/RED/WHT
1190/RED
SHEET 10
1570/RNG/WHT
1765/RNG/WHT
SHEET 8
SHEET 8
1590/RNG/WHT
1240/RED/WHT
1290/RED
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999
TAN TAN
COMMUNICATION 9000 THROUGH 9999
PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SHEET 9
1580/RNG/WHT
SHEET 9
1370/RED/WHT
SHEET 9
1850/RNG/WHT
SHEET 13
1550/RNG/WHT
SHEET 5
1165/RED/WHT
SHEET 5
1730/RNG/WHT
SHEET 7
1360/RED/WHT
SHEET 6
1350/RED/WHT
SHEET 12
1140/RED/WHT
SHEET 11
1320/RED/WHT
SHEET 11
1330/RED/WHT
SHEET 6
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
1780/RNG/WHT
1750/RNG/WHT
1720/RNG/WHT
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 3 of 15
Printed In U.S.A.
C489 B
SHEET 6
3800/LBL
SHEET 5
SHEET 9
2790/BLK
2390/BLK
SHEET 7
SHEET 9
3910/LBL
3410/LBL
2900/BLK
C103 B
2600/BLK
SHEET 7
2720/BLK
2000/BLK
2200/BLK
T1
BATT GND
SHEET 12
2745/BLK
SHEET 7
3310/LBL
SHEET 6
3510/LBL
SHEET 6
3110/LBL
T8
BATT GND
2110/BLK
SHEET 11
SHEET 13
SHEET 9
2765/BLK
2780/BLK
2730/BLK
T6
BATT GND
2500/BLK
3010/LBL
2510/BLK
SHEET 6
3710/LBL
2300/BLK2710/BLK
SHEET 13
2741/BLK
2540/BLK
2550/BLK
SHEET 7
2480/BLK
J2B 15
J2B 16
SHEET 7
2450/BLK
J1B 15
J1B 16
J1B 17
2235/BLK
2240/BLK
2900/BLK
C408 42
SHEET 8
SHEET 5
2920/BLK
SHEET 11
2105/BLK
2070/BLK
SHEET 5
2080/BLK
SHEET 13
2830/BLK
SHEET 8
2940/BLK
SHEET 8
2960/BLK
SHEET 9
2930/BLK
SHEET 8
2700/BLK
GROUND
SHEET 13
2751/BLK
C493 3
C493 4
SHEET 10
2530/BLK
SHEET 10
2520/BLK
C408 32
2950/BLK 2950/BLK
SHEET 13
2785/BLK
SHEET 7
3530/LBL
2090/BLK
SHEET 8
2250/BLK
2600/BLK
SHEET 10
2650/BLK
SHEET 11
2640/BLK
SHEET 11
2610/BLK
SHEET 11
2620/BLK
SHEET 11
2630/BLK
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
SHEET 6
2810/BLK
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 4 of 15
Printed In U.S.A.
FF
EE
GG
DD
BB
AA
SHEET 4
2710/BLK
9400/PUR
9500/PUR/WHT
9600/PUR
C426
C408 7
C408 8
9120/PUR/WHT
9220/PUR
J2B 9
J2B 8
J1B 8
J1B 9
J1B 14
J1B 20
J1B 21
C479 3
C479 4
C503 2
C503 4
9530/PUR/WHT9130/PUR/WHT
9630/PUR9230/PUR
4
1
2
3
3
1
2
4
2070/BLK
2080/BLK
1830/RNG/WHT
1840/RNG/WHT
9640/PUR
9540/PUR/WHT
C450
C449
SHEET 3
SHEET 4
SHEET 4
SHEET 3
9650/PUR
9550/PUR/WHT
9260/PUR
9160/PUR/WHT
9230/PUR
9130/PUR/WHT
9240/PUR 9250/PUR
9140/PUR/WHT 9150/PUR/WHT
CAN BUS
C492 4
C492 1
9210/PUR
9110/PUR/WHT
9200/PUR
9100/PUR/WHT
9240/PUR
9140/PUR/WHT
RESISTOR
120 OHM
RESISTOR
120 OHM
9660/PUR
9560/PUR/WHT
9270/PUR
9170/PUR/WHT
C492 7
C492 8
9280/PUR
9180/PUR/WHT
9190/PUR/WHT
9290/PUR
DRIVE CTRLR
ACS CTRLR
SHEET 3
1165/RED/WHT
SHEET 3
1730/RNG/WHT
CC
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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 DOES NOT EXIST IN 7165991
#
#
CAN (Remote Start Tool, ACD)
RIGHT
JOYSTICK
LEFT
JOYSTICK
AUX CTRLR
GWY CTRLR
RH DLX PANEL
LEFT PANEL
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 5 of 15
Printed In U.S.A.
SHEET 4
SHEET 4
C
A
B
3520/LBL
3510/LBL
3600/LBL
3800/LBL
STARTER
85 86
30
87
8200/TAN
8250/TAN
PULL
FUEL
85 86
30
87
A
B
C
8800/TAN
PLUG
GLOW
85 86
30
87
8500/TAN
A3700/LBL
B3710/LBL
C110
T14 PRE HEATER
2016/BLK 8510/TAN
8550/TAN
8110/TAN
8150/TAN
8210/TAN
3200/LBL
SHEET 4
SHEET 4
L
S
1020/RED
1015/RED
A
B
3210/LBL
2015/BLK
B
A
ENGINE SPEED SENSOR
3610/LBL
SWITCH
AIR FILTER
SENSOR (500-3000 OHM)
ENGINE COOLANT
SENDER (0.5-4.5V)
ENGINE OIL PRESSURE
SOLENOID
FUEL SHUTOFF
2800 BLK
8800 TAN
8100 TAN
C101
24.5 OHM
0.33 OHM
C405
M
S
R
STARTER
G
ALTERNATOR
C104
B
EXCITATION
PULL
HOLD
8100/TAN8120/TAN
2800/BLK
J1B 4
J1B 12
J1B 18
J1A 22
J1A 15
J1A 16
J1A 25
J1A 14
J1A 6
J1A 30
J1A 3
J1A 7
D5
A
B
C109
8250/TAN
8200/TAN
SHEET 3
1060/RED
SHEET 3
1030/RED
SHEET 12
2005/BLK
SHEET 7
2025/BLK
15 A
FRC1 FUSE 12
ENGINE
SHEET 12
1815/RNG/WHT
A
B
SHEET 3
2055/BLK
3110/LBL 3110/LBL
3100/LBL 3100/LBL
C355 D
C355 C
SHEET 9
3500/LBL
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC
4000 THROUGH 4999
LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
ACCESSORIES 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999 TAN TAN
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SHEET 3
1350/RED/WHT
1800/RNG/WHT
C106
SIG
GND
SIG
GND
+5V PWR
SIG
GND
C107
C406
GND
SIG
SHEET 3
B
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
SIG
GND
FUEL
SENDER
SHEET 4
2810/BLK
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 6 of 15
Printed In U.S.A.
LOCK
TRACTION
85 86
30
87
B
C
A
SHEET 4
2200/BLK
4200/LGN
4150/LGN
4110/LGN
A
C
B
3400/LBL
3420/LBL
3410/LBL
A
B
4410/LGN
2410/BLK
SHEET 4
A
C112
B
A3300/LBL
3310/LBL
3430/LBL
B
1
2
4010/LGN
2910/BLK
B
A4200/RED
2200/BLK
0.5-7.5V
PRESSURE
CHARGE
HYDRAULIC
HARN BRAKE ADAPTER 7165061
9.8 OHM 12V
SOLENOID
HYD LOCK
12 V
9.8 OHM
SOLENOID
BRAKE
C425
12 V
7.2 OHM
FAN SOLENOID
HYDRAULIC
C105
C446
C420
C108
C308
TRACK MACHINES
B
C
A
C425 WHEEL MACHINES
0.3 OHM
10.9 OHM
HOLD
PULL
TRACTION
LOCK
SOLENOID
HYDRAULIC
TEMPERATURE
SENDER
500 - 3000 OHM
2
1
C441
2350/BLK
SOLENOID
TWO SPEED
4350/LGN
1
2
4340/LGN
2340/BLK
4430/LGN
4440/LGN
4450/LGN
4480/LGN
1
2
4330/LGN
2330/BLK
B
A4460/LGN
3.3 OHM PWM
FRONT ROD SOLENOID (MALE)
3.3 OHM PWM
FRONT BASE SOLENOID (FEMALE)
7.5 OHM 12 V
SOLENOID
OPTIONAL HIGH FLOW
C415
C419
C418
2
2
1
2440/BLK
1
2430/BLK
7.5 OHM 12V
MALE COUPLER
DIRECIONAL SOLENOID
OPTIONAL REAR AUX
7.5 OHM 12V
FEMALE COUPLER
DIRECTIONAL SOLENOID
OPTIONAL REAR AUX
C413
C414
1
2
2
1
2450/BLK
7.5 OHM 12 V
SOLENOID MALE COUPLER
BLEED / LOCK VALVE
OPTIONAL REAR AUX
9.8 OHM 12 V
SOLENOID FEMALE COUPLER
BLEED / LOCK VALVE
OPTIONAL REAR AUX
C417
C416
2480/BLK
SHEET 4
2460/BLK
J2B 13
J2B 19
J2B 26
J2B 5
J2B 7
J2B 4
J2B 6
J2A 2
J2A 10
J2A 1
J2A 18
J2A 26
B
A
D
C
F
E
H
G 4480/LGN
2480/BLK
2450/BLK
4450/LGN
4430/LGN
2430/BLK
2440/BLK
4440/LGN
C362
SHEET 4
J1B 6
J1B 13
J1B 19
J1B 26
J1B 1
J1B 23
J1A 18
J1A 1
J1A 32
J1A 34
J1A 13
J1A 8
2
1
C437
MAKEUP SOLENOID
OPTIONAL TWO SPEED
J1B 25
4360/LGN
2360/BLK
J1A 27
J1A 26
SHEET 11
2035/BLK
+8V
SHEET 6
2025/BLK
4100/LGN
SHEET 4
3530/LBL
SHEET 3
1360/RED/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SIG
GND
SIG
GND
SIG
GND
SIG
GND
GND
SIG
GND
SIG
GND
SIG
GND
SIG
GND
SIG
GND
SIG
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
HYDRAULIC OIL
FILTER SWITCH
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 7 of 15
Printed In U.S.A.
9350/PUR
C408 4
C408 40
C408 1
C408 37
9370/PUR
9380/PUR
9360/PUR
J1B 22
J1A 24
J1A 20
J1A 19
22
1212
C479 8
C479 7
C479 10
C479 9
C479 11
C479 1
C479 2
C479 5
2920/BLK
T2
BUZZER (-)
1940/RNG/WHT
9320/PUR
T13
BUZZER (+)
4730/LGN
2700/BLK
1960/RNG/WHT
SWITCH OPTIONAL
TRAVEL CONTROL
SW9
1
2
3
4
5
6
1440/RED/WHT
1620/RNG/WHT
11
22
33
44
C499
9380/PUR
9370/PUR
1930/RNG/WHT
2940/BLK
2960/BLK
1950/RNG/WHT
44
11
55
33
22
C500
1420/RED/WHT
SHEET 4
SHEET 3
SHEET 3
SHEET 9
4750/LGN
SHEET 3
SHEET 3
SHEET 3
SHEET 4
SHEET 4
SHEET 3
SHEET 4
SHEET 3
9360/PUR
9350/PUR
SHEET 13
SHEET 13
6550/PNK
6450/PNK
CAB DISPLAY
2250/BLK
1590/RNG/WHT
C503 1
C503 5
C503 3
1240/RED/WHT
SHEET 3
SHEET 4
SHEET 3
SHEET 9
9310/PUR
SHEET 9
4500/LGN
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
LIGHTS
6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
66
LEFT PANEL (BLACK)
RH KEY SWITCH
RH DLX PANEL
LEFT PANEL (GRAY)
PTOL
(Press To Operate Loader)
C480
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 8 of 15
Printed In U.S.A.
SHEET 4
3920/LBL
3910/LBL
3900/LBL
2790/BLK
C408 24
C408 44
C408 45
C408 46
C408 33
C408 23
SHEET 4
2730/BLK
3930/LBL
SHEET 4
J1B 11
BRAKE SWITCH
SW1
2
1
3
5
6
4
2930/BLK
C408 5
C408 3
C408 2
1775/RNG/WHT
2
5
6
4
3
1
2840/BLK
C667
SWITCH
FRONT WIPER
SW8
2
1
3
5
4
6
C408 27
7330/WHT
7300/WHT
7310/WHT
BB
AA
22
11
1390/RED/WHT1370/RED/WHT
2010/BLK2790/BLK
2840/BLK
C
B
A
C251
X
L
C252
MOTOR
WIPER
PARK
LOW
GND
MOTOR
WASHER
DOOR SENSOR
2730/BLK
2795/BLK
1400/RED/WHT
-
+
C212
SENSOR SHOWN 
WITH DOOR OPEN
SWITCH
(SJC, AWS)
H/ISO
(ACS)
HAND/FOOT
SW4
5
6
4
2
1
3
4550/LGN
2060/BLK
C
B
C129
2820/BLK
1375/RED/WHT
A
1210/RED/WHT
SHEET 3
1785/RNG/WHT
4235/LGN
4275/LGN
C
3900/LBL
A
B
3910/LBL
3920/LBL
SENSOR
SEATBAR
GND
SIG
PWR
SHEET 3
SHEET 8
1850/RNG/WHT
C408 16
SHEET 4
SHEET 3
2
5
6
3
4
1
C676
1
2
1
2
C279
7830/WHT
7820/WHT
7810/WHT
7800/WHT
C278
RIGHT SPEAKER
LEFT SPEAKER
1865/RNG/WHT1580/RNG/WHT
1885/RNG/WHT
2885/BLK
J1B 24
+5V
D
SW PWR
E
4740/LGN
1400/RED/WHT
7310/WHT
2845/BLK
1850/RNG/WHT
1860/RNG/WHT
1570/RNG/WHT
C492 5
4235/LGN
4220/LGN
C492 3
C492 2
4275/LGN
4550/LGN
2
1
C250
CC
4750/LGN
4740/LGN
4760/LGN
5
4
C277
1510/RNG/WHT
2210/BLK
SHEET 6
3500/LBL
7165991 Standard Cab
7176098 Deluxe Cab
SHEET 8
9310/PUR
SHEET 8
4500/LGN
7176098 ONLY
SHEET 3
1580/RNG/WHT
SHEET 3
1370/RED/WHT
SHEET 3
1850/RNG/WHT
C209
-
+
-
+
SEAT SOLENOID
AIR RIDE
C482
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
*    SPLICE DOES NOT EXIST IN 7165991
*
*
SHEET 10
4230/LGN
SHEET 10
4240/LGN
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
ACCESSORY
CONN
POWER SOCKET
RADIO CONN
DOME LIGHT
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 9 of 15
Printed In U.S.A.
2370/BLK
2380/BLK
3
14370/LGN
1
3
4380/LGN
(NOT USED WITH ACS)
TILT SPOOL LOCK SOLENOID
(NOT USED WITH ACS)
LIFT SPOOL LOCK SOLENOID
J2B 22
J1B 7
J1B 5
J1A 2
J1A 10
1560/RNG/WHT
G
F
B
C
D
A
E
H
J
K
4810/LGN
4820/LGN
4830/LGN
4840/LGN
4640/LGN
1710/RNG/WHT
C410
2520/BLK
B
C
E
D
J
H
4300/LGN
4310/LGN
4920/LGN
4930/LGN
4320/LGN
4940/LGN
A
F
G
K
SHEET 4
1590/RNG/WHT
4910/LGN
2530/BLK
C409
SHEET 4
SKI CTRL
SIDE SHIFT
PWM
TWO SPD
DETENT FLOW
SKI CTRL
F
G
B
C
D
A
+B
D
-C
A
H
J
E
F
E
H
G
K
J
K
E
C
A
D
B
B
A HORN
TURN SIGNAL
J2B 23
J2B 17
J2A 22
J2A 30
J2A 31
J2B 21
J2A 13
J2B 18
J2A 28
J2A 12
J2A 11
J2A 20
SHEET 3
1570/RNG/WHT
2
2
C103 C
C404 A
7100/WHT
7001923
BACKUP ALARM
+
-
7100/WHT
SHEET 4
2650/BLK
MANUAL 
CONTROLS
C411
C412
C421
C422
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS
6000 THROUGH 6999
PINK PNK
ACCESSORIES 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999
TAN TAN
COMMUNICATION 9000 THROUGH 9999
PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SHEET 9
4230/LGN
SHEET 9
4240/LGN
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
T19 1
T20 1
LEFT HANDLE
RIGHT HANDLE
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 10 of 15
Printed In U.S.A.
LIGHTS
WORK
FRONT
85 86
30
87
LIGHT
REAR
85 86
30
87
C103 A
C103 H
6310/PNK
6000/PNK
6210/PNK
6320/PNK
C408 25
C408 28
SHEET 4
2765/BLK
6230/PNK
6330/PNK
6340/PNK
J1A 28
J1A 17
J1A 5
J1A 31
A
B
6110/PNK
A
B
6120/PNK
2760/BLK
2750/BLK
WORK LIGHT
LEFT FRONT
50.00 Watts
WORK LIGHT
RIGHT FRONT
37.00 Watts
6000/PNK
2765/BLK
2045/BLK
2045/BLK
SHEET 4
2105/BLK
LIGHTS
A
B
WORK LIGHT
LEFT FRONT
37.00 Watts
A
B
WORK LIGHT
RIGHT FRONT
50.00 Watts
6100/PNK
6130/PNK
2735/BLK
2705/BLK
SHEET 7
2035/BLK
6200/PNK
1
C603
2
WORK LIGHT
RIGHT REAR
TAIL LIGHT
RIGHT REAR
1
C602
2
WORK LIGHT
LEFT REAR
TAIL LIGHT
LEFT REAR
6330/PNK
6320/PNK
6200/PNK
T16 1
T15 1
T18 1
T17 1
6210/PNK
6310/PNK
SHEET 4
2640/BLK
SHEET 4
2610/BLK
SHEET 4
2620/BLK
SHEET 4
2630/BLK
SHEET 3
1320/RED/WHT
SHEET 3
1330/RED/WHT
C435-2
C435-1
C434-1
C434-2
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 11 of 15
Printed In U.S.A.
HVAC
85 86
30
87
1500/RNG/WHT
2745/BLK
SHEET 4
8020/TAN
A
B
7024/WHT
C350
(AC PRESS SWITCH)
EVAPORATOR
J1A 21
A
B
C
D
C611
2745/BLK
C408 22
1500/RNG/WHT 5
SWITCH
BLOWER
SW10
6
3
OFF
2
1
4
C408 21
1970/RNG/WHT
1520/RNG/WHT
7320/WHT
1900/RNG/WHT
C408 34
A
B
C
1980/RNG/WHT
C483
A
D
C
B
E
F
C635
1910/RNG/WHT
7220/WHT
2560/BLK
2130/BLK
High14.00 Amps
Med7.50 Amps
Low5.00 Amps
SWITCH)
(TEMP CONTROL
POTENTIOMETER
DBL
WHT
BLK
VALVE
HEATER
12V
SIG
GND
2580/BLK
MOTOR
BLOWER
A
B
C
3320/LBL
C630
2570/BLK
7020/WHT
THERMOSTAT
AC SWITCH
SW11
C
1
2100/BLK
3
7040/WHT
SHEET 3
1790/RNG/WHT
SHEET 3
2030/BLK
HVAC
SHEET 6
1815/RNG/WHT
2
2280/BLK
1
2290/BLK
7025/WHT
D4
SHEET 13
7020/WHT
7023/WHT
J1A 11
7021/WHT
SHEET 6
2005/BLK
C486
(COMPRESSOR)
MAGNET CLUTCH
SHEET 3
1140/RED/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
C355 A
7024/WHT
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 12 of 15
Printed In U.S.A.
C103 D
C103 E
6410/PNK
6510/PNK
C408 29
C408 36
C408 15
C408 26
SHEET 4
SHEET 12
2290/BLK
C408 30
C408 13
SHEET 4
2780/BLK
C408 35
6500/PNK
6400/PNK
BB
2740/BLK
AA
7030/WHT
A
B
D
C411
6515/PNK
6010/PNK
6415/PNK
A
B
C126
A
B 7210/WHT
C412
SHEET 4
2785/BLK
1460/RED/WHT 7022/WHT
SHEET 4
2741/BLK
C
A
B
J2A 5
J2A 4
J2A 3
6520/PNK
6420/PNK
7200/WHT
D3
6500/PNK
HAZARD SWITCH
SW3
5
4
6
2
1
3
6530/PNK
6400/PNK
E
D
A
C
F
B
C670
6440/PNK
6430/PNK
6540/PNK
6540/PNK
6700/PNK
2780/BLK
L
X
1430/RED/WHT
1410/RED/WHT
T3
FLASHER CONN
6570/PNK
6010/PNK
2725/BLK
SWITCH
BOBTACH
POWER
SW5
5
4
6
2
1
3
C408 9
C408 10
1380/RED/WHT
BLINKER
RIGHT
BEACON
STROBE
BLINKER
LEFT
1200/RED/WHT
2420/BLK2850/BLK
D2
D1
SWITCH
POSITION
BUCKET
SW6
2
1
3
5
6
4
1550/RNG/WHT
7022/WHT
2830/BLK
(PINS 3 & 6 
INTERNALLY 
INSULATED)
6550/PNK
6450/PNK
SHEET 3
SHEET 3
1410/RED/WHT
SHEET 4
OPTIONS
SHEET 8
SHEET 8
A
C606
B 2775/BLK
B
A
C607
2770/BLK
7000/WHT
7010/WHT
C408 38
7210/WHT
2751/BLK 2751/BLK
C355 B
C355 E
C355 F
7010/WHT
7010/WHT
7000/WHT
7000/WHT
SHEET 3
1550/RNG/WHT
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
C
E
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
SJC
HORN/BLINKER
C497
LEFT HANDLE
2 PIN
LEFT
HANDLE
5 PIN
C423
PWR BOB CLOSE
PWR BOB OPEN
SWITCH
BEACON
SW2
1
2
3
4
5
6
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 13 of 15
Printed In U.S.A.
1
6
4
1
3
2
5
4
1
3
1
3
2
2
5
8
5
8
TILT ACTUATOR
1630/RNG/WHT
1630/RNG/WHT
3
LIFT ACTUATOR
3
1
1530/RNG/WHT
1530/RNG/WHT
7
6
4
2670/BLK
6
7
4
1
2770/BLK
2770/BLK
1
3
2
1
3
2
HALL SENSOR
TILT PEDAL
HALL SENSOR
LIFT PEDAL
PWR
SIG
GND
PWR
SIG
GND
B
C
A
B
C
A
A A
C C
B B
HALL SENSOR
HANDLE LIFT
HALL SENSOR
HANDLE TILT
C470
2510/BLK
2500/BLK
2650/BLK
2760/BLK
2660/BLK
4650/LGN
4750/LGN
4670/LGN
4670/LGN
4770/LGN
4770/LGN
4680/LGN
4690/LGN
4780/LGN
4790/LGN
4280/LGN
4270/LGN4260/LGN
4760/LGN
4660/LGN
1500/RNG/WHT
1620/RNG/WHT
1520/RNG/WHT
1510/RNG/WHT
1510/RNG/WHT
1610/RNG/WHT
1610/RNG/WHT
1190/RED/WHT
1180/RED/WHT
1170/RED/WHT
4450/LGN
9240/PUR
9140/PUR/WHT
2240/BLK
2250/BLK
2280/BLK
2260/BLK
2270/BLK
4220/LGN
4220/LGN
4220/LGN
4275/LGN
4275/LGN
1740/RNG/WHT
SKI CTRL
FLOAT
SHIFT
SIDE
PWM
TWO SPD
FLOW
DETENT
SKI CTRL
F
G
B
C
D
A
B
D
C
A
H
J
E
F
B
A
B
A
E
H
G
K
LOCK
HANDLE
LOCK
HANDLE
2750/BLK
J
K
C465
C466
C472
C469
C467
C468
C410
C409
C492
2
C493
2
2
3
7
8
C429
C428
C471
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
ACS 
CONTROLS
H
G
C
A
E
D
B
F
H
E
A
B
C
D
G
J
K
B
C
D
F
J
H
K
A
G
E
J1-ACS
J2-ACS
J3-ACS
E
C
A
D
B
B
A HORN
TURN SIGNAL
C411
C412
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
See manual controls for harness 
connection
MAINFRAME HARNESS
LIFT
SOLENOID
TILT
SOLENOID
GND
PWR
SIG
GND
PWR
SIG
HALL SENSOR
HANDLE TILT
GND
PWR
SIG
GND
PWR
SIG
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 14 of 15
Printed In U.S.A.
1740/RNG/WHT
4220/LGN
4275/LGN
4550/LGN
1170/RED/WHT
2240/BLK
1
2
3
4
2
C454
4
3
1
C453
3
4
5
1
2
6
7
8
4670/LGN
3
4
5
1
2
6
7
8
4770/LGN
4790/LGN
4780/LGN
4690/LGN
4680/LGN
1180/RED/WHT
1190/RED/WHT
2270/BLK
2260/BLK
2770/BLK
2630/BLK
1630/RNG/WHT
2250/BLK
1500/RNG/WHT
2280/BLK
1610/RNG/WHT
2235/BLK2470/BLK
2490/BLK
7100/WHT
9140/PUR/WHT
9240/PUR
1750/RNG/WHT
1250/RED/WHT
1260/RED/WHT
3070/LBL
3000/LBL
2570/BLK
1530/RNG/WHT
3080/LBL
3020/LBL
2580/BLK
1540/RNG/WHT
1640/RNG/WHT
2510/BLK
1
2
4270/LGN 7
2670/BLK
8
1
22680/BLK 6
4280/LGN 5
1
2
4250/LGN 3
2650/BLK 4
1
2
2660/BLK
2
4260/LGN 1
4210/LGN A
1810/RNG/WHT 2
2810/BLK 4
4950/LGN 3
4720/LGN 3
1710/RNG/WHT 1
4260/LGN
2660/BLK
4250/LGN
2650/BLK
4280/LGN
2680/BLK
4270/LGN
2670/BLK
ACS CONTROLLER
1
2
34950/LGN
1770/RNG/WHT1
2860/BLK4
1
2
34720/LGN
HARNESS, A22 PUMP 7169309
ACTUATOR
LIFT
TILT ACTUATOR
BRAKE LIGHT RELAY
85
86
30
87
4210/LGN
B
C
A1730/RNG/WHT
6600/PNK
2730/BLK
C707
LIGHT
BRAKE
2
1760/RNG/WHT
1770/RNG/WHT
2860/BLK
1820/RNG/WHT
1710/RNG/WHT
2810/BLK
GND
SWASHPLATE
RIGHT
SWASHPLATE
LEFT
SIG
PWR
GND
SIG
PWR
PWR
GND
SIG
1
6
1
4
3
2
5
4
(CONNECTS TO BACKUP 
ALARM C404 ON MFR
HARNESS)
SENSOR
LEFT SPEED
SENSOR
RIGHT SPEED
GND
GND
PWR
PWR
SIG
SIG
SIG
SIG
3
21235/RED/WHT
RIGHT FORWARD DRIVE
RIGHT REVERSE DRIVE
LEFT REVERSE DRIVE
LEFT FORWARD DRIVE
C543
C542
C547
C546
C545
C544
C501
C537
C474
C429
C428
C493
C492
C536
HARNESS, OBW STOP LTS 7151696
J3-ACS
J1-ACS
J2-ACS
29
40
33
34
23
24
8
7
43
42
44
45
31
41
21
11
26
36
50
12
22
16
4
6
48
47
28
27
G
E
B
C
J
H
F
D
A
K
H
C
B
D
E
F
A
G
A
B
D
C
G
F
H
E
J
K
9290/PUR
9190/PUR/WHT
7
8
4
1
2
3
3
1
2
4
JOYSTICK
LEFT
1840/RNG/WHT
9640/PUR
9540/PUR/WHT
+12V PWR
CAN LOW
CAN HIGH
GND2080/BLK
1
4
2
3
JOYSTICK
RIGHT
1830/RNG/WHT
9660/PUR
9560/PUR/WHT
+12V PWR
CAN 
LOW
CAN 
HIGH
GND
2070/BLK
1
4
2
3
C460C450
C449 C459
HARNESS, JOYSTICK  7163706
C103 C
B
A 7100/WHT
C404
ALARM
BACKUP
+
-SHEET4
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
GROUNDING 2000 THROUGH 2999 BLACK
BLK
MONITORING 3000 THROUGH 3999 LIGHT BLUE
LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW
YEL
LIGHTS 6000 THROUGH 6999
PINK PNK
ACCESSORIES 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
SJC
CONTROLS
SCHEMATIC INDEX
OVERVIEW
PAGE 1,2
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
MAINFRAME 
HARNESS
J5 - DRIVE CONTROLLER
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Sheet 15 of 15
Printed In U.S.A.
GND
PWR
SIG
60-10-1 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
CONNECTOR - Harness - Used for
connecting 2 harnesses together or a
harness to a component. The
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
pins can be numbered alphabetical
(shown) or numerical (1, 2, 3 etc.).
The harness wires numbers are
called out next to the connector
(Example: 3500).
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector.
BATTERY - Used for supplying and
storing electrical power for the
machine.
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
NEGATIVE ELECTRICAL CIRCUIT -
Indicates battery ground circuit.
ALTERNATOR - Used to create the
electrical current to supply voltage to
the battery and components.
COMPONENTS
G
-
+
+
-
3
510
3
500
3
520
AA
B
C
B
C
351
0
350
0
352
0
C107
C1
07
35
10
35
00
35
20
B
C
A
3
510
3
500
3
520
B
C
A
SYMBOL DESCRIPTION
CONNECTIONS
SYMBOL DESCRIPTION
COMPONENTS
GROUND - Frame - Used t
o
represent an component that 
is
internally grounded.
LIGHT - 
SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
SWITCH - Single Pole - Double
Throw (ON-OFF-ON) - This switch
can be in any of three positions
.
(Some switches are spring activated
to return them to a certain position
when released.)
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
on switch application.)
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
positions will be specified depending
on switch application.
POTENTIOMETER - Variable
resistance - Provides variable
resistance.
+
-
STARTER - Uses battery current to
start the machine engine.
M
GROUND - Used to represent an
external ground connection.
60-10-2 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)
SWITCH - Ignition - Multi position
switch to activate various start
functions at different positions.
SWITCH - Light - Multi position switch
to activate various lights at different
positions.
RELAY - Uses a low amp switch to
control a high amp component.
FUSE - Used to protect the wire
harness from an overloaded circuit.
(The fuse rating is listed next to the
fuse.)
ROTARY CONTROL - Provides
variable voltage proportional to
position.
25A
8530
868787A
1
3
2
4
6
5
B
ST
I
RUN
S
TART
OFF
SYMBOL DESCRIPTION
COMPONENTS
SYMBOL DESCRIPTION
SOLENOID - Fuel and Traction Lock
-
Dual solenoids. (The ohm rating o
f
the solenoid coils are listed next t
o
the component [if available]). The pu
ll
solenoid is energized for a short time
.
P
U
L
L
HOLD
B
A
1
5 ohm
0
.5 ohm
HORN - Audible alarm. Sound is
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a
predetermined setting to warn the
operator of a component condition.
RESISTOR - Limits current flow.
DIODE - Allows electrical current to
flow in 1 direction only.
MOTOR - HVAC - Multi speed motor.
MOTOR - Wiper - Single or mult
i
speed motor.
MOTOR - Washer - Single speed.
L
M
M
H
G
RD
M
V
P
ARK
H
IGH
GRD
M
SPLICE (•) - Used to show when
multiple wires are connected together
on the schematic.
3110
37103700
7.7 ohm
1
2
SOLENOID - ON / OFF - Electrically
activated coil that controls movement
magnetically. (The ohm rating of the
solenoid coil is listed next to the
component [if available]).
SOLENOID - VARIABLE - Electrically
activated coil that controls movement
magnetically. (The ohm rating and
voltage of the solenoid coil is listed
next to the component [if available]).
7.5 ohm
12V
A
B
PUMP - FUEL
H
+
-
HOURMETER - Records the time the
engine is running.
POWER PLUG - Supplies 12 volt
power for customer supplied
accessories.
-+
GAUGE - Instrument - Indicates
certain engine or other component
conditions. (The different types of
gauge are marked with a icon that
represents what function the gauge is
monitoring. Example: the gauge
shown is for fuel.)
S
G
I
60-10-3 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)
PRESSURE SENDER - Provides a
variable voltage proportional to
pressure. (Sender voltage rating is
listed to show volts at high and low
setting.)
PRESSURE SWITCH - Switch opens
or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
TEMPERATURE SWITCH - The
switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
TEMPERATURE SENDER - Provides
a variable resistance (ohm) signal
proportional to temperature. (Sender
ohm rating is listed to show ohms at
high and low setting.)
t
500-3000ohm
B
A
o
B
A
0.5 - 7.5 V
+
-
C
B
A
B
C
A
SYMBOL DESCRIPTION
SENDERS AND SENSORS
A
B
FUEL SENDER - Provides a variable
resistance, based on the fuel level in
the tank. (Sender ohm rating is listed
to show ohms at full and empty
setting.)
3
0
-
2
7
0
o
h
m
B
A
HALL EFFECT SENSOR - Detects
linear or rotary position and provides
a proportional variable voltage.
A
C
B
SPEED SENSOR - magnetic pickup -
detects RPM.
B
A
60-10-4 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Standard Cab Harness Connectors 
MS2824
C408
C500
C435-1
C435-2
SW1
C126
C434-1
C434-2
C479
C480
T13
T2
C499
C482
C503
C129
60-10-5 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Deluxe Cab Harness Connectors 
MS2827
C278
C676
C212
C126
C253
C279
C483
S3
T3
C129
C277
C449
C450
C611
C630
C635
C426
SW4
SW5
SW9
C252
C667
SW6
SW2
SW3
SW1
C499
C479
C670
C503
C482
C209
C434-1
T13
C500
C435-1
C435-2
C480
C434-2
T2
60-10-6 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Mainframe Harness Connectors 
MS2825
C 408C 350
FRC1
FC1
FC2
C362
J2A
J1A
C489
C497
J2B
J1B
C410
C411
C412
C404
C437
C425
C492
C493
C418
C421
C422
C409
C441
C419
C420
C108
C105
C355
C405
C446
C362
C423
C415
C486
C107
T12
C101
T11
C110
C426
C103
C104
T6
T1
T8
T10 T4
60-10-7 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Description
Figure 60-10-1
The loader has a 12 volt, negative ground, alternator
charging system.
The electrical system is protected by fuses located in the
operator cab (located under the operator cab in earlier
models) and a 100 ampere master fuse [Figure 60-10-1]
located under the air cleaner in the engine compartment.
The fuses will protect the electrical system when there is
an electrical overload. The reason for the overload must
be found before starting the engine again.
P-85472
P-13849
60-10-8 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
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.
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
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5 
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.
60-10-9 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Fuse And Relay Location / Identification
Earlier Models
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 60-10-2
The electrical system is protected from overload by fuses
and relays located under three fuse panel covers (Item 1)
[Figure 60-10-2].
Figure 60-10-3
Remove the covers to check or replace the fuses [Figure
60-10-3].
A decal is located inside the large cover to show location
and amp ratings.
A table is provided with details on amperage ratings and
circuits affected by each fuse and relay. (See Fuse And
Relay Location / Identification (Cont’d) on Page 60-10-
11.)
Later Models
Figure 60-10-4
The fuse / relay panels are located behind an access
panel near the left foot pedal / footrest. Pull the panel at
each end (Item 1) [Figure 60-10-4] to remove.
Figure 60-10-5
The electrical system is protected from overload by fuses
and relays located under three fuse panel covers (Item 1)
[Figure 60-10-5].
P-85411
1
P-85412
P100414
1
P100415
1
60-10-10 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
Later Models (Cont’d)
Figure 60-10-6
Remove the covers to check or replace the fuses [Figure
60-10-6].
A decal is located inside the access panel to show
location and amperage ratings.
Line up the clips on the back of the access panel with the
slots provided and push the panel into place when
finished  [Figure 60-10-4]. A locating pin prevents the
panel from being installed upside down.
A table is provided with details on amperage ratings and
circuits affected by each fuse and relay. (See Fuse And
Relay Location / Identification (Cont’d) on Page 60-10-
11.)
P100416
60-10-11 S650 Service Manual
ELECTRICAL SYSTEM (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
The location and amperage ratings are shown in the table below and on the decal above. Relays are identified by the letter
“R” in the AMP column.
REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 Alternator 15
11 Glow Plugs R 21 Bobcat Controller 25
2 Heater / HVAC 25
12 Fuel Shutoff R 22 ACS Controller 25
3 Front Lights 20
13 Cab Switched
Power
5 23 Attachments 25
4 Rear Lights 15
14 Bucket Position 15 24 Not Used - -
5 Starter R
15 Wiper / Washer 25 25 Auxiliary
Controller
25
6 Front Lights R
16 Switched Power &
Back-up Alarm
(Standard/ACS)
25 26 Drive Controller &
Back-up Alarm
(SJC)
25
7 Heater / HVAC R
17 Switched Power 25 27 Accessories &
Front Horn
25
8 Rear Lights R
18 Switched Power 25 28 Power Port 15
9 Switched Power R
19 Traction 30
10 Traction R 20 Fuel Shutoff 30
6
7
19
18
5
17
11
13
15
8
10
20
12
14
16
9
1
2
3
4
21
22
23
24
25
26
27
28
60-10-12 S650 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Solenoid Testing
Figure 60-10-7
Use a test meter to measure coil resistance [Figure 60-
10-7]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
P9175
60-20-1 S650 Service Manual
BATTERY
Removal And Installation
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
Open the rear door.
Figure 60-20-1
Disconnect the negative (-) cable (Item 1) [Figure 60-20-
1].
Remove the battery hold down clamp (Item 2) [Figure
60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-
1] from the battery.
Remove the battery from the loader.
Figure 60-20-2
Always clean the battery terminals and cable ends when
installing a new or used battery [Figure 60-20-2].
When installing the battery in the loader, do not touch any
metal parts with the battery terminals.
Connect the negative (-) cable last to prevent sparks.
Connect and tighten the battery cables.
Install and tighten the battery hold down.
WARNING
AVOID INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-0705
P-85473
1
2
3
P-09589
P-09590
60-20-2 S650 Service Manual
BATTERY (CONT’D)
Servicing
Figure 60-20-3
The battery cables must be clean and tight [Figure 60-
20-3]. Check electrolyte level in the battery. Add distilled
water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Bobcat Battery Saver or grease on the battery
terminals and cable ends to prevent corrosion.
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
P-09589
P-09590
60-20-3 S650 Service Manual
BATTERY (CONT’D)
Using A Booster Battery (Jump Starting)
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF or the STOP button must be
pressed. The booster battery must be 12 volt.
WARNING
AVOID INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-0705
Figure 60-20-4
Connect the end of the first cable (Item 1) [Figure 60-20-
4] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Connect the end of the second cable (Item 3) [Figure 60-
20-4] to the negative terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
Keep cables away from moving parts. Start the engine.   
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P-85474
1
3
2
4
60-20-4 S650 Service Manual
60-30-1 S650 Service Manual
ALTERNATOR 
Belt Adjustment
The alternator belt is a special maintenance free type
that is pretensioned over the pulleys. This belt eliminates
the need for a tensioning device and does not require
periodic adjustment. Contact your Bobcat dealer for
replacement parts. 
Belt Replacement
Stop the engine and open the rear door.
Remove the air conditioning belt. (See REGULAR
MAINTENANCE on Page 80-20-1.)
Figure 60-30-1
Remove the belt shield mounting nuts and bolts (Item 1)
and remove the belt shield (Item 2) [Figure 60-30-1].
Figure 60-30-2
Remove the cable bracket mounting nut and bolts (Item
1) and move the cable bracket (Item 2) [Figure 60-30-2]
up slightly.
Figure 60-30-3
Remove the top alternator mounting bolt (Item 1) and
loosen the bottom alternator mounting bolt (Item 2)
[Figure 60-30-3].
Move the alternator toward the engine as far as it will go
and remove the belt from the pulleys. Inspect the pulleys
for wear.
Install new belt.
Figure 60-30-4
Use a prybar (Item 1) [Figure 60-30-4] to move the
alternator until the top alternator mounting bolt (Item 1)
[Figure 60-30-3] can be installed.
Tighten the top and bottom alternator mounting bolts
(Items 1 and 2) [Figure 60-30-3].
Install the air conditioning belt. (See REGULAR
MAINTENANCE on Page 80-20-1.)
Install the cable bracket and belt shield.
Close the rear door.
P-90472
1
2
P-90521A
1
2
P-90474
2
1
P-90475
1
60-30-2 S650 Service Manual
ALTERNATOR (CONT’D)
Charging System Inspection
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
WARNING
AVOID INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-0705
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
If the charging system malfunctions check the following:
Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) Replace belt if
worn or deteriorated.
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and
tight.
Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair / replace. If fuse is in
doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)
Verify the charge of the battery. Make sure battery is fully
charged.
Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
60-30-3 S650 Service Manual
ALTERNATOR (CONT’D)
Alternator Voltage Testing
Figure 60-30-5
Open rear door. 
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the
following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at
high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test.
Low Voltage Testing
Figure 60-30-6
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Turn the remote start tool key to the ON position.
Figure 60-30-7
Check the voltage across the “L” terminal (Item 1) and
ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.
P-85916
P-85914
1
P-85915
2
1
60-30-4 S650 Service Manual
ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-8
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Check the continuity between the “S” terminal (Item 1)
[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21°C (70°F)
(Alternator Temperature), then remove alternator for
replacement or repair.
P-85917
1
2
60-30-5 S650 Service Manual
ALTERNATOR (CONT’D)
Removal And Installation
Remove the air conditioning belt. (See Compressor Drive
Belt Replacement on Page 80-20-2.)
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-30-9
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-30-9] from
the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator.
Figure 60-30-10
Remove the alternator rain shield mounting nut and bolts
(Item 1) and remove the alternator rain shield (Item 2)
[Figure 60-30-10].
Figure 60-30-11
Remove the belt shield mounting nuts and bolts (Item 1)
and remove the belt shield (Item 2) [Figure 60-30-11].
P-85914
1
2
P-85718
1
2
P-85609
1
2
60-30-6 S650 Service Manual
ALTERNATOR (CONT'D)
Removal And Installation (Cont’d)
Figure 60-30-12
Remove the top alternator mounting bolt (Item 1) and the
bottom alternator mounting bolt (Item 2) [Figure 60-30-
12].
Remove the belt and alternator from the loader.
Parts Identification
Figure 60-30-13
P-85611
2
1
C-3529B
1. Alternator
2. Nut
3. Pulley
4. Spacer
5. Bolt
6. Bracket
7. Bolt
8. Bearing
9. Retainer
10. Rotor
11. Bearing
12. Stator
13. Bracket
14. Sleeve
15. Regulator
16. Rectifier
17. Cover
18. Spacer
19. Nut
2
3
4
6
7
1
7
8
9
10
11
12
13
14
5
19
17
18
16
15
60-40-1 S650 Service Manual
STARTER
Testing
Figure 60-40-1
The key switch must be in the OFF position.
The battery must be at full charge.
The cable connections on the battery must be clean and
tight.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Connect a jumper wire (of at least 4 gauge in size)
between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
Removal And Installation
Figure 60-40-3
Open the rear door.
Disconnect the negative (-) cable from the battery.
Disconnect the wires and positive (+) cable (Item 1)
[Figure 60-40-3] from the starter solenoid.
Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -
12.3 ft-lb) torque.
Disconnect the wire connector (Item 2) [Figure 60-40-3]
from the two solenoid wires.
Remove the three mounting bolts (Item 3) [Figure 60-40-
3].
Remove the starter from the engine.
A-1992
Bat
S
M
Cranking
Motor
A-1991
Bat
S
M
Cranking
Motor
P-85857
1
2
3
3
60-40-2 S650 Service Manual
STARTER (CONT'D)
Parts Identification
B-19824
1. Starter
2. Shaft
3. Gear
4. Washer
5. Shaft
6. Stop Ring
7. Lever
8. Holder
9. Spring
10. Spring
11. Plate
12. Seal
36
2
8
4
6
23
16
9
17
31
11
7
14
29
22
18
19
10
13
5
3
32
30
33
34
20
15
21
37
14
28
27
26
25
24
24.  Yoke
25.  Holder
26.  Bracket
27.  Ring
28. Bolt
29. Bolt
30. Switch
31. Seal
32. Bolt
33. Washer
34. Nut
35. Boot
36. Bracket
37. Bearing
35
1
23
13. Lever
14. Gear
15. Bracket
16. Spring
17. Gear
18. Stop
19. Stop Ring
20. Ball
21. Armature
22. Washer
23. Seal
12
60-50-1 S650 Service Manual
INSTRUMENT PANELS
Left Panel
Figure 60-50-1
The left instrument panel [Figure 60-50-1] is the same
for Standard Key Panel, Keyless Start Panel and Deluxe
Instrumentation Panel equipped machines.
The table on the facing page shows the DESCRIPTION
and FUNCTION / OPERATION for each of the
components of the left panel.
P-90726B
1
4
5
6
7
8
3
2
13
9
10
11
12
14
15
16
17
18
19
20
21
22
23
60-50-2 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)
REF. 
NO.
DESCRIPTION FUNCTION / OPERATION
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left flasher signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right flasher signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range. 
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED will 
light.) Press a second time to add REAR work lights. (Left and right green LEDs 
will light.) Press a third time to turn all lights off. (Left and right green LEDs will 
be off.)
Press and hold five seconds to display software version in display screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green LED 
will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED will 
light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine RPM
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running. Press 
once to unlock the brakes. Allows you to use the steering levers or joystick(s) to 
move the loader forward or backward when using the backhoe attachment or 
for service. (See TRACTION LOCK OVERRIDE in this manual.) Press a 
second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ System when the seat bar is down and operator is 
seated in operating position. Button will light.
Press and hold three seconds to engage Drive Response and Steering Drift 
Compensation. (See DRIVE RESPONSE and STEERING DRIFT 
COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all loaders) Press the top to engage the Parking Brake. Press the bottom to disengage. 
(See PARKING BRAKE in this manual.)
60-50-3 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Display Screen
The display screen can display the following information: 
• Operating hours.
• Engine revolutions per minute (RPM).
• Speed management setting.
• Maintenance clock countdown.
• Battery voltage.
• Service codes.
• Engine preheat countdown.
• Steering drift compensation setting.
• Drive response setting.
Figure 60-50-2
The display screen is shown in [Figure 60-50-2]. The
data display will show operating hours upon startup.
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine Revolutions Per Minute
6. Battery / Charging Voltage
7. Service
P-76461A
7
1
6
54
3
2
60-50-4 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Right Panel (Standard Key Panel)
Figure 60-50-3
This machine may be equipped with a Standard Key
Panel [Figure 60-50-3].
The Standard Key Panel has a key switch (Item 1)
[Figure 60-50-9] used to turn the loader’s electrical
system on and off, and to start and stop the engine.
The switch location (Item 2) [Figure 60-50-3] can have
different functions depending on machine configuration.
See the following table for more information.
REF. DESCRIPTION
FUNCTION / 
OPERATION
ADVANCED 
CONTROL SYSTEM 
(ACS) (Option)
Press the top to select 
Hand Controls; bottom 
to select Foot 
Controls.
P-85285
1
2
SELECTABLE 
JOYSTICK 
CONTROLS (SJC) 
(Option)
Press the top to select 
‘ISO’ Control Pattern; 
bottom to select ‘H’ 
Control Pattern.
FOUR-WAY 
FLASHER LIGHTS 
(Option)
Press the top to turn 
lights ON; bottom to 
turn OFF.
ROTATING BEACON 
(Option)
or 
STROBE LIGHT 
(Option)
Press the top to turn 
light ON; bottom to 
turn OFF.
REF. DESCRIPTION
FUNCTION / 
OPERATION
60-50-5 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Right Panel (Keyless Start Panel)
Figure 60-50-4
1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press. 
2. LOCK Key: Used to lock keypad. The lock key will
display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock
key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. START Button: Used to start the engine.
5. STOP Button: Used to stop the engine and shut
down the loaders electrical system.
6. RUN Button: Used to turn on the loaders electrical
system.
The switch location (Item 7) [Figure 60-50-4] can have
different functions depending on machine configuration.
See the following table for more information.
P-90819B
7
4
5
6
1
2
3
REF.
DESCRIPTION
FUNCTION / 
OPERATION
ADVANCED 
CONTROL SYSTEM 
(ACS) (Option)
Press the top to select 
Hand Controls; bottom 
to select Foot 
Controls.
SELECTABLE 
JOYSTICK 
CONTROLS (SJC) 
(Option)
Press the top to select 
‘ISO’ Control Pattern; 
bottom to select ‘H’ 
Control Pattern.
FOUR-WAY 
FLASHER LIGHTS 
(Option)
Press the top to turn 
lights ON; bottom to 
turn OFF.
ROTATING BEACON 
(Option)
or 
STROBE LIGHT 
(Option)
Press the top to turn 
light ON; bottom to 
turn OFF.
60-50-6 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Right Panel (Deluxe Instrumentation Panel)
Figure 60-50-5
This machine may be equipped with a Deluxe
Instrumentation Panel [Figure 60-50-5].
1. Keypad (1 through 0): The keypad has two
functions:
- To enter a number code (password) to allow starting
the engine.
- To enter a number as directed for further use of the
display screen.
2. Display Screen: The Display Screen is where all
system setup, monitoring and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen
choices.
4. ENTER Button: Used to make selections on the
display screen.
5. START Button: Used to start the engine.
6. STOP Button: Used to stop the engine and shut
down the loader’s electrical system.
7. RUN Button: Used to turn on the loader’s electrical
system.
The switch location (Item 8) [Figure 60-50-5] can have
different functions depending on machine configuration.
See the following table for more information.
P-90212A
8
2
4
1
3
5
6
7
REF. DESCRIPTION
FUNCTION / 
OPERATION
ADVANCED 
CONTROL SYSTEM 
(ACS) (Option)
Press the top to select 
Hand Controls; bottom 
to select Foot 
Controls.
SELECTABLE 
JOYSTICK 
CONTROLS (SJC) 
(Option)
Press the top to select 
‘ISO’ Control Pattern; 
bottom to select ‘H’ 
Control Pattern.
FOUR-WAY 
FLASHER LIGHTS 
(Option)
Press the top to turn 
lights ON; bottom to 
turn OFF.
ROTATING BEACON 
(Option)
or 
STROBE LIGHT 
(Option)
Press the top to turn 
light ON; bottom to 
turn OFF.
60-50-7 S650 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Right Panel (Deluxe Instrumentation Panel) (Cont’d)
Figure 60-50-6
The first screen you will see on your new loader will be as
shown in [Figure 60-50-6].
When this screen is on the display you can enter the
password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation
Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. Keep your password in a safe
place for future needs.
Change Language:
Press the left or right scroll button to cycle through the
languages. The language that is stopped on will be the
default language used for the deluxe instrumentation
panel [Figure 60-50-6].
The language can be changed at any time. (See
CONTROL PANEL SETUP on Page 60-180-1.)
Enter The Password:
Use the numbers on the keypad to enter the password.
Then press the [Enter] button a symbol will appear on
the display screen for each number entered [Figure 60-
50-6]. The left scroll button can be used to backspace if
an incorrect number is entered.
If the correct password is not entered, [INVALID
PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
See CONTROL PANEL SETUP for further description of
screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
NA3017
60-50-8 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Left Switch Panel
Figure 60-50-7
This machine may be equipped with a Left Switch Panel
[Figure 60-50-7].
Right Switch Panel
Figure 60-50-8
This machine may be equipped with a Right Switch Panel
[Figure 60-50-8].
REF
. 
NO.
DESCRIPTION FUNCTION / OPERATION
1 FOUR-WAY 
FLASHER 
LIGHTS (Option)
Press the top to turn lights ON; 
bottom to turn OFF.
2 ROTATING 
BEACON (Option)
or 
STROBE LIGHT 
(Option)
Press the top to turn light ON; 
bottom to turn OFF.
3 HYDRAULIC 
BUCKET 
POSITIONING 
(Option)
Press the top to engage 
Hydraulic Bucket Positioning; 
bottom to disengage.
P-85319
1
2
3
REF
. 
NO.
DESCRIPTION FUNCTION / OPERATION
1POWER 
BOB-TACH 
(Option)
Press and hold the up arrow to 
disengage the Bob-Tach 
wedges. Press and hold the 
down arrow to engage the 
Bob-Tach wedges into the 
attachment mounting frame 
holes.
2 NOT USED  - - -
P-85320
1
2
60-50-9 S650 Service Manual
INSTRUMENT PANELS (CONT’D)
Left Panel Removal And Installation
Figure 60-50-9
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-9].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels. Tighten the panel screws to 3 - 4 N•m
(25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-9].
Figure 60-50-10
Pull the right instrument panel down and disconnect the
wire harness connectors (Item 1) [Figure 60-50-10] from
the panel.
Remove the panel from the loader cab.
Right Panel (Standard Key Panel) Removal And 
Installation
Figure 60-50-11
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-11].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels. Tighten the panel screws to 3 - 4 N•m
(25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-11].
Figure 60-50-12
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-12].
Remove the panel from the loader cab.
P-85928
1
1
2
3
P-85930
1
1
1
P-85929
2
1
1
3
P-85931
1
60-50-10 S650 Service Manual
INSTRUMENT PANELS (CONT'D)
Right Panel (Keyless Start Panel) Removal And 
Installation
Figure 60-50-13
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-13].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels. Tighten the panel screws to 3 - 4 N•m
(25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-13].
Figure 60-50-14
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-14].
Remove the panel from the loader cab.
Right Panel (Deluxe Instrumentation Panel) Removal 
And Installation
Figure 60-50-15
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-15].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels. Tighten the panel screws to 3 - 4 N•m
(25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-15].
Figure 60-50-16
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-16].
Remove the panel from the loader cab.
P-90819A
2
1
1
3
P-90818A
1
P-90527
2
1
1
3
P-90530
1
60-50-11 S650 Service Manual
INSTRUMENT PANELS (CONT'D)
Key Switch Disassembly And Assembly 
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.)
Disconnect the key switch wiring harness.
Figure 60-50-17
Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure
60-50-17] from the switch. 
Remove the ignition switch from the control panel.
Alarm Disassembly And Assembly 
Remove the left instrument panel. (See Left Panel
Removal And Installation on Page 60-50-9.)
Figure 60-50-18
Remove the left side instrument panel.
Remove the retaining nut (Item 1) [Figure 60-50-18]
from the loader alarm.
Remove the alarm from the loader instrument panel.
P-85948
2
1
P-85947
1
60-50-12 S650 Service Manual
INSTRUMENT PANELS (CONT'D)
Left Switch Panel Removal And Installation
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-9.)
Figure 60-50-19
Remove the two fasteners (Item 1) [Figure 60-50-19].
Figure 60-50-20
Remove the fastener (Item 1) and the left side panel
(Item 2) [Figure 60-50-20].
Right Switch Panel Removal And Installation
Remove the right panel. (See Right Panel (Standard Key
Panel) on Page 60-50-4.)
Figure 60-50-21
Remove the two fasteners (Item 1) and the knob (item 2)
[Figure 60-50-21].
Figure 60-50-22
Remove the fastener (Item 1) and the left side panel
(Item 2) [Figure 60-50-22].
P-85945
1
1
P-85946
2
1
P-85943
2
1
1
P-85944
2
1
60-60-1 S650 Service Manual
LIGHTS
Front Removal And Installation
Disconnect the negative(-) cable from the battery. (See
Removal And Installation on Page 60-20-1.)
Figure 60-60-1
Remove the two bolts (Item 1) [Figure 60-60-1].
Installation: Tighten the two bolts to 22 - 27 N•m (40 - 45
in-lb) torque.
Figure 60-60-2
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the
wire harness connectors.
Figure 60-60-3
Figure 60-60-4
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
turn.
NOTE: Two different light bulbs are used, take note
when removing to assure correct installation.
Reverse the above procedure to install the bulb.
P-85433
1
1
P-85434
1
1
P-85436
1
1
P-85435
1
60-60-2 S650 Service Manual
LIGHTS (CONT’D)
Rear Removal And Installation
Figure 60-60-5
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb
assembly a 1/4 turn.
Figure 60-60-6
Using care press the rear light and housing from the door
[Figure 60-60-6].
Reverse this procedure for installation.
Cab Light Removal And Installation
Figure 60-60-7
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
NOTE: Do not pull the cab light to far away from the
headliner to prevent damage to the wires.
Figure 60-60-8
Disconnect the cab light (Item 1) [Figure 60-60-8].
P-85438
1
2
3
P-85437
P-85274
1
1
P-85783
1
60-70-1 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY)
Description
The Gateway controller is the main controller, it provides
information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
The Gateway and Auxiliary controller are located behind
the access panel near the operators left foot. 
60-70-2 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification
P-76622
P-76623
P-76624
J1A
J1B
1
1
Harness Connector View
Harness Connector View
Gateway Controller
1
1
10
3
579
18
26
28
34
25
17
32
26
25
13
19
7
53
8
14
20
21
J1B
J1A
34
26
60-70-3 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification (Cont’d)
J1A
PIN 
WIRE 
NUMBER
COLOR DESCRIPTION
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL 
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN  FUEL RELAY FEEDBACK
31 6330 PINK  MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS 
60-70-4 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification (Cont’d)
J1B
PIN 
WIRE 
NUMBER
COLOR DESCRIPTION
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL
12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL
60-70-5 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification
P-76647
P-76646
P-76645
J2A
J2B
1
1
Harness Connector View
Harness Connector View
Auxiliary Controller
1
1
10
3
579
18
26
28
34
25
17
32
26
25
13
19
7
53
8
14
20
21
J2B
J2A
34
26
60-70-6 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification (Cont’d)
J2A
PIN 
WIRE 
NUMBER
COLOR DESCRIPTION
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL 
5 7200 WHITE HORN SIGNAL
6OPEN NA NA
7OPEN NA NA
8OPEN NA NA
9OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN  RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN  RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA
60-70-7 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Connector Identification (Cont’d)
J2B
PIN 
WIRE 
NUMBER
COLOR DESCRIPTION
1OPENNA NA
2 1180 RED/WHT COMPUTER FUSE POWER OUT
3 1150 RED/WHT COMPUTER FUSE POWER OUT
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL
60-70-8 S650 Service Manual
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) (CONT’D)
Removal And Installation
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 Procedure on Page 10-10-
1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the left inside access panel. (See Removal And
Installation (Left) on Page 50-120-1.)
Figure 60-70-1
Unplug the two harness connectors (Item 1) [Figure 60-
70-1] from the Gateway controller.
Unplug the two harness connectors (Item 2) [Figure 60-
70-1] from the Auxiliary controller.
NOTE: The connectors are keyed and will only plug
in one way.
Figure 60-70-2
Remove the controller mounting bolts (Item 1) [Figure
60-70-2] from the left fender.
Installation: Tighten the controller mounting bolts to 16 -
19 N•m (12 - 14 ft-lb) torque.
Remove the Gateway and Auxiliary controllers from the
loader.
P-85900
1
2
P-85901
1
1
1
1
60-71-1 S650 Service Manual
BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS
or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic
shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software. 
60-71-2 S650 Service Manual
BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
P/N PIN DESCRIPTION P/N PIN DESCRIPTION
J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND/FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
BOPEN
COPEN
DOPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL
J1
J3
J2
J3
J2
J1
J1
J3
J2
B
A
H
G
C
D
E
F
B
B
A
A
H
H
G
G
C
C
D
D
E
E
F
F
J
K
J
K
P-21843
60-71-3 S650 Service Manual
BOBCAT CONTROLLER (ACS) (CONT’D)
Removal And Installation
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 Procedure on Page 10-10-
1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 60-71-1
Unplug the harness connectors (Item 1) [Figure 60-71-1]
from the controller.
NOTE: The connectors are keyed and will only plug
in one way.
Figure 60-71-2
Remove the two mounting bolts (Item 1) [Figure 60-71-
2] from the controller.
Remove the controller from the loader.
NOTE: The calibration procedure must be followed
when replacing a controller. (See Lift And Tilt
Calibration (ACS) on Page 60-160-11.)
P-85903
1
1
P-85902
1
60-71-4 S650 Service Manual
60-72-1 S650 Service Manual
BOBCAT CONTROLLER (SJC) (DRIVE)
Description
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the
drive functions.
The drive controller is located behind the right side
access panel near the operator’s right foot. 
The drive controller monitors the position of the left
joystick, pump swash plate angles and the output of the
wheel speed sensors.
The drive controller works along with the ACS controller
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades. 
The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
the loader. The control can be switched from ISO and H-
Pattern drive control layouts. 
The workgroup actuators are the same as those used on
the ACS system. 
The hydrostatic drive pump is a Rexroth A22 unit. It has
two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
forward and reverse outputs of the pump to the drive
motors. The Rexroth pump is equipped with position
sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
uncommanded swash plate movement. 
NA1208
ENGINE
GEAR 
PUMP
DRIVE 
PUMP
SPEED 
SENSOR
HYDRAULIC 
MOTOR
ACS 
CONTROL
LIFT / TILT 
ACTUATORS
SPEED 
SENSOR
HYDRAULIC 
MOTOR
ACD 
CONTROL
GATEWAY 
CONTROL
RIGHT 
JOYSTICK
LEFT 
JOYSTICK
AUXILIARY 
CONTROL
DRIVE 
CONTROL
RIGHT
HAND
PANEL 
LEFT
HAND
PANEL 
ISO 
SWITCH
FWD / REV
SWASH PLAT
E
SENSORS
INTERNAL CAN BUS
EXTERNAL
CAN BUS
SERIAL TT BUS
60-72-2 S650 Service Manual
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification
P-64295
60-72-3 S650 Service Manual
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296
60-72-4 S650 Service Manual
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 60-72-1
Remove the three bolts (Item 1) [Figure 60-72-1] that
secure the controller.
Installation: Tighten the mounting bolts to 16 - 19 N•m
(12 - 14 ft-lb) torque.
Figure 60-72-2
Remove the screw and wire harness (Item 1) [Figure 60-
72-2]. 
Installation: Tighten the connector screw to 3,39 - 3,96
N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!
Figure 60-72-3
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
Figure 60-72-4
Remove the drive controller [Figure 60-72-4].
P-85879
1
1
P-64324
1
J
S
P-64325
1
P-64325
60-80-1 S650 Service Manual
SPEED SENSORS (SJC)
Description
Figure 60-80-1
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loader’s controllers to sense if the
drive motor is rotating. The end of the sensor is magnetic
and counts the magnetic pulses as a rotating disc,
attached to the motor carrier shaft, rotates by the sensor
end.
The speed sensor is sealed with an O-ring (Item 1)
[Figure 60-80-1] to keep hydraulic oil inside the motor
carrier and dirt out.
Testing
Figure 60-80-2
The tools listed will be needed to do the following
procedure:
MEL1609-Wheel Speed Sensor Test Harness
[Figure 60-80-2]
MEL1563 or 7003031-Remote Start Tool Kit
Multimeter
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 to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.) or (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)
P-64765
1
P-28302
60-80-2 S650 Service Manual
SPEED SENSORS (SJC) (CONT'D)
Testing (Cont’d)
Figure 60-80-3
Locate the speed sensor (Item 1) [Figure 60-80-3] on the
top of the right or left hydrostatic motor carrier. 
Remove the transmission cover screw (Item 2) [Figure
60-80-3], to loosen the connector clamp.
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)
torque. 
Disconnect the speed sensor wire connector (Item 3)
[Figure 60-80-3] from the loader harness wire connector.
Figure 60-80-4
Connect the speed sensor test harness (Item 1) [Figure
60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
Turn the remote start key to ON position without starting
the loader.
Take a voltage reading, with the multimeter, at the speed
sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-80-4].
The voltage should be approximately 5 volts.
Repeat the procedure for the opposite side speed
sensor. (If needed.)
P-64762
1
3
2
P-64976
1
2
60-80-3 S650 Service Manual
SPEED SENSORS (SJC) (CONT'D)
Removal And Installation
Figure 60-80-5
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.)
Remove the two, speed sensor mount bolts (Item 1)
[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
Remove the transmission cover screw (Item 1) [Figure
60-80-6], to loosen the connector clamp.
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)
torque. 
Disconnect the speed sensor electrical harness
connector (Item 2) [Figure 60-80-6].
Figure 60-80-7
Lift the speed sensor (Item 1) [Figure 60-80-7] out from
the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Figure 60-80-8
Remove the speed sensor [Figure 60-80-8].
P-64762
2
1
P-64762
2
1
P-64764
1
P-64765
60-80-4 S650 Service Manual
SPEED SENSORS (SJC) (CONT'D)
Removal And Installation (Cont'd)
Figure 60-80-9
The electrical connector can be replaced.
Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
Figure 60-80-11
Installation: Be sure to install the speed sensor (Item 1)
[Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
Installation: The alignment pin (Item 1) at the bottom of
the speed sensor must be installed in the hole (Item 2)
[Figure 60-80-12] in the motor carrier.
P-26293
1
P-26294
1
2
4
3
P-26292
1
P-26295
2
1
60-90-1 S650 Service Manual
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
The Service Codes will aid your dealer in diagnosing
conditions which can damage your machine. 
Figure 60-90-1
Press the INFORMATION button (Item 1) to cycle the
DATA DISPLAY (Item 2) [Figure 60-90-1] until the
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the
DATA DISPLAY.
NOTE: Corroded or loose grounds can cause
multiple service codes and / or abnormal
symptoms. All instrument panel lights
flashing, alarm sounding, headlights and
taillights flashing, could indicate a bad
ground. The same symptoms could apply if
the voltage is low, such as loose or corroded
battery cables. If you observe these
symptoms, check grounds and positive leads
first.
Deluxe Instrumentation Panel
The optional Deluxe Instrumentation Panel offers an
additional view of service codes that includes a brief
description.
The last 40 codes stored in history can also be viewed
using the Deluxe Instrumentation Panel. 
Figure 60-90-2
P-76455G
2
1
P-90378 / NA3025 / NA3000 / NA3038 / NA3035
Press a scroll butto
n
(Item 1) repeatedly unt
il
the Active Warning
s
screen icon (Inset) i
s
highlighted.
1 1
The ACTIVE WARNING
S
screen displays activ
e
service codes. Press [9
]
to view the next servic
e
code if more than one i
s
present. Press [4] t
o
display a history o
f
service codes.
The WARNING
S
HISTORY screen will lis
t
the Service Cod
e
Number  (CODE
),
Hourmeter reading whe
n
the error occurre
d
(HOUR), and the Use
r
(USER) who was logge
d
in to operate the machin
e
when the error occurred.
Press [9] to view the next eight Service Codes.
A total of 40 Codes can be stored. When more than 4
0
codes occur, the oldest code will disappear and th
e
newest code will be in the number 1 position.
Press the list numbe
r
next to the service cod
e
for more detail.
Press left scroll button t
o
back up one screen.
60-90-2 S650 Service Manual
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-3
Service Codes may be either a word (Item 1) or a number
(Item 2) [Figure 60-90-3].
The following word errors may be displayed:
[REPLY] One or both instrument panel(s) not
communicating with the controller.
[CODE] The controller is asking for a password.
(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.
(Keyless Start and Deluxe Instrumentation Panels
only.)
[SHTDN] A shutdown condition exists.
[DOOR] Operator cab door is open. (Lift and Tilt
functions will not operate.)
P-76461H
P-76461P
P-76455G
1
2
CODE DESCRIPTION CODE DESCRIPTION
A3623 ACD not programmed A8503 ACD output ‘F’ error OFF
A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003 ACD output ‘A’ error OFF A8506 ACD output ‘F’ short to ground
A8005 ACD output ‘A’ short to battery A8507 ACD output ‘F’ open circuit
A8006 ACD output ‘A’ short to ground A8532 ACD output ‘F’ overcurrent
A8007 ACD output ‘A’ open circuit A8602 ACD output ‘G’ error ON
A8032 ACD output ‘A’ overcurrent A8603 ACD output ‘G’ error OFF
A8102 ACD output ‘B’ error ON A8605 ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high
60-90-3 S650 Service Manual
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)
CODE DESCRIPTION CODE DESCRIPTION
D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF
D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541 Right swash plate sensor out of range high D7592 Right swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7593 Right speed sensor unresponsive 
D7543 Left forward drive solenoid error ON D7594 Left speed sensor unresponsive 
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545 Right forward drive solenoid error ON D7596 Right speed sensor reversed
D7546 Right reverse drive solenoid error ON D7597 Controller programmed
D7547 Right front steer extend short to battery D7598  In drive calibration mode
D7548 Left front steer extend short to battery D7599  In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent
60-90-4 S650 Service Manual
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)
CODE DESCRIPTION CODE DESCRIPTION
H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic/Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely  low
H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure
60-90-5 S650 Service Manual
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)
CODE DESCRIPTION CODE DESCRIPTION
M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807 Lift spool lock open circuit  M4803 Front light relay error OFF
M1832 Lift spool lock overcurrent  M4807 Front light relay open circuit
M2005 Two-speed primary short to battery M4902 Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit  M4907 Rear light relay open circuit
M2032 Two-speed primary overcurrent  M5002 Front light output error ON
M2102 Glow plug output error ON M5003 Front light output error OFF
M2103 Glow plug output error OFF M5007 Front light output open circuit
M2107 Glow plug output open circuit M5028 Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202 Starter output error ON M5103 Rear light output error OFF
M2203 Starter output error OFF M5107 Rear light output open circuit
M2207 Starter output open circuit M5128 Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF
60-90-6 S650 Service Manual
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)
CODE DESCRIPTION CODE DESCRIPTION
M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224 ACS calibration failed W3264 Pedal lock short to battery
W3231 Tilt actuator fault W3265 Sensor supply voltage out of range
W3232 Tilt actuator wiring fault W3266 Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle/pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error
W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236 Lift actuator fault W3271 Right hand drive short to battery
W3237 Lift actuator wiring fault W3274 Left joystick X-axis out of range
W3238 Lift handle wiring fault W3275 Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240 Lift handle / pedal not in neutral W3277 Remote control information error
W3241 No communication W3905 Left joystick X-axis not in neutral
W3249 Lift actuator short to ground W4005 Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral
60-100-1 S650 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Figure 60-100-1
The Bobcat Interlock Control System is an electronic
system that is used to protect the operator. The system
consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid. 
These all have indicator lights on the left panel (Items 1,
2, 3) [Figure 60-100-1] of the loader cab. 
The Press To Operate button (Items 4) [Figure 60-100-1]
activates the system and allows the operator to function
the loader.
P-85413C
1
2
3
34
60-100-2 S650 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 
(CONT'D)
Inspecting The BICS (Engine STOPPED - Key ON)
Figure 60-100-2
1. Sit in operator’s seat. Turn key to RUN or press RUN
button. Lower seat bar and disengage parking brake.
Press the PRESS TO OPERATE LOADER button
(Item 6). Two BICS™ lights (Items 1 and 2) [Figure
60-100-2] [SEAT BAR AND LIFT & TILT VALVE] on
left instrument panel must be OFF. The PRESS TO
OPERATE LOADER button will light.
2. Raise seat bar fully. All three BICS™ lights (Items 1,
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE and PARKING BRAKE] on left instrument
panel must be ON. The PRESS TO OPERATE
LOADER button light will turn OFF. 
Inspecting Deactivation Of The Auxiliary Hydraulics 
System (Engine STOPPED - Key ON)
3. Sit in operator’s seat, lower seat bar and press the
PRESS TO OPERATE LOADER button (Item 6).
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
60-100-2]. Raise the seat bar. The light must be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking
brake and fasten seat belt.
5. Start engine and operate at low idle. Press the
PRESS TO OPERATE LOADER button. While raising
the lift arms, raise the seat bar fully. The lift arms must
stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten seat belt, disengage parking brake, press the
PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
PRESS TO OPERATE LOADER button.
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
NOTE: The PARKING BRAKE light on the left
instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
brake is disengaged.
Inspecting The Lift Arm Bypass Control
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob clockwise 1/
4 turn. Pull up and hold lift arm bypass control knob
until lift arms slowly lower.
Inspecting Deactivation Of Lift And Tilt Functions 
(ACS And SJC)
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
LOADER button.
10. Raise lift arms about 2 m (6 ft) off the ground.
11. Turn key OFF or press STOP button and wait for the
engine to come to a complete stop.
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
(foot pedal, hand control or joystick) to lower the lift
arms. Lift arms must not
lower.
13. Move the control (foot pedal, hand control or joystick)
to tilt the bucket (or attachment) forward. The bucket
(or attachment) must not
tilt forward.
WARNING
AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS) must
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394
P-85413C
5
1
2
3
6
4
60-100-3 S650 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 
(CONT'D)
Troubleshooting
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.   
5. Possible low or high voltage.
60-100-4 S650 Service Manual
60-110-1 S650 Service Manual
SEAT BAR SENSOR
Description 
The seat bar sensor is part of the BICS system. The seat
bar sensor sends a signal that indicates whether the seat
bar is in the down or up position. 
The sensor is located on the left side of seat bar. 
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
60-110-2 S650 Service Manual
SEAT BAR SENSOR (CONT'D)
Testing
Figure 60-110-1
Use Sensor Tester (MEL1428) and seat bar sensor tester
adapter (MEL1567) for the following procedure:
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110-
2].
Turn the key to the ON position. DO NOT START THE
ENGINE.
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.
Figure 60-110-3
If there is no power light (Item 1) [Figure 60-110-3] on
the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Lower the seat bar. The Sensor Test light (Item 1)
[Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
sensor.
Disconnect the Sensor Tester.
Replace the Seat Bar Sensor. (See Removal And
Installation on Page 60-110-3.)
If the above test passes, run the seat bar sensor BICS
circuit test. (See Bobcat Interlock Control System (BICS)
Circuit Test on Page 60-110-4.)
P-85653
1
P-85925
1
P-4698
2
1
P-4699
1
60-110-3 S650 Service Manual
SEAT BAR SENSOR (CONT'D)
Removal And Installation
Remove the seat bar from the loader. (See Removal And
Installation on Page 50-10-1.)
Figure 60-110-5
Remove the mounting bolt (Item 1) from the seat bar
mount (Item 2) [Figure 60-110-5].
Installation: Tighten the mounting bolt to 5,6 - 7,9 N•m
(50 - 70 in-lb) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-
110-5] and nut.
Figure 60-110-6
Remove the keyed plastic bushing (Item 1) magnetic
bushing assembly (Item 2) and sensor bracket (Item 3)
[Figure 60-110-6].
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are
positioned in the slotted hole (Item 1) [Figure 60-110-6]
of the seat bar.
Inspect all parts for damage and wear and replace if
necessary.
Reverse the removal procedure to install the seat bar
sensor.
N-19219
1
2
3
N-19383
1
2
3
60-110-4 S650 Service Manual
SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test
Figure 60-110-7
Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-7].
Figure 60-110-8
Connect Sensor Tester (Item 1) [Figure 60-110-8] inline
to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE
ENGINE.
If there is no power light on the sensor tester, check the
tester or wiring harness.
When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-8] on the sensor tester to
the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-110-8]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
P-85653
1
P-4703
3
2
1
60-110-5 S650 Service Manual
SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test 
(Cont’d)
Figure 60-110-9
The BICS seat bar indicator light (Item 1) [Figure 60-110-
9] should illuminate.
Figure 60-110-10
Move the toggle switch (Item 1) [Figure 60-110-10] on
the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-9] should go
off.
If the above test fails, there is a problem with the Bobcat
controller or the wiring harness.
P-85413
1
P-4699
1
60-110-6 S650 Service Manual
60-120-1 S650 Service Manual
TRACTION LOCK
Description
The Traction Lock Control System will lock the traction
drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS).
60-120-2 S650 Service Manual
TRACTION LOCK (CONT'D)
Troubleshooting
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
SOLUTION SUGGESTIONS
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. 
(See Electrical System, Information Page 60-01.) 
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Check the brake solenoid mounting nut for correct torque.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check the flywheel RPM sensor and wiring.
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11 
60-120-3 S650 Service Manual
TRACTION LOCK (CONT'D)
Inspecting 
Figure 60-120-1
Fasten the seat belt, disengage the parking brake button,
press the PRESS TO OPERATE LOADER Button (Item
1) and raise the Seat Bar fully. Move the steering levers
slowly forward and backward. The TRACTION lock (Item
4) should be engaged. Lower the Seat Bar. Press the
PRESS TO OPERATE LOADER Button (Item 1) [Figure
60-120-1].
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: The TRACTION light on the left instrument
panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.
Figure 60-120-2
Check the wire connections at the engine speed sensor
(Item 1) [Figure 60-120-2].
Check the adjustment of the flywheel speed sensor and
replace the speed sensor if needed. (See Adjustment on
Page 60-170-2.)
NOTE: When the Traction Lock Override Button is
activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if
the engine stops.
P-85413
1
P-85923
1
60-120-4 S650 Service Manual
60-130-1 S650 Service Manual
CONTROL SYSTEM (ACS) 
Description
The ACS option allows the operator to quickly switch
between foot and hand control modes. It uses the electric
actuators to control the lift and tilt spools, foot sensors,
handle sensors and a specially designed control handle.
60-130-2 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
60-130-3 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Handle Sensor Connector Disassembly And 
Assembly
Figure 60-130-1
The wire connector (Item 1) [Figure 60-130-1] can be
removed from the handle sensor wires, use the following
procedure.
Figure 60-130-2
Remove the wedge (Item 1) [Figure 60-130-2] from the
connector.
Figure 60-130-3
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]
and pull the wire from the connector.
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
1-Terminal - Red
2-Terminal - Black
3-Terminal - Green
P16578
1
P13732
1
1
P13725
1
P13725
1
P13733
1
3
1
2
60-130-4 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Removal
Figure 60-130-4
NOTE: Switch handle can be removed and installed
while in loader.
Disconnect the harness connector (Item 1) [Figure 60-
130-4] from the handle sensor connector.
Disconnect the harness connector (Item 2) [Figure 60-
130-4] from the handle lock solenoid connector.
Figure 60-130-5
Remove the wedge (Item 1) [Figure 60-130-5] from the
harness connector (Gray) that connects to the handle
sensor connector.
Figure 60-130-6
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
Remove the wedge (Item 1) [Figure 60-130-7] from the
harness connector (Black) that connects to the handle
lock solenoid connector.
P-21879
1
2
P13732
1
P13725
1
P13735
1
3
1
2
P13732
1
P13725
1
60-130-5 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Removal (Cont'd)
Figure 60-130-8
Use a pointed tool, press down on the tab (Item 1)
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
Disconnect the right switch handle connectors (Item 1)
[Figure 60-130-9] from the loader wiring harness
connectors.
Figure 60-130-10
Disconnect the left switch handle connectors (Item 1)
[Figure 60-130-10] from the loader wiring harness
connectors.
Figure 60-130-11
Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-11] and slightly rotate the switch handle.
P13735
1
3
1
2
P-90995
1
P-90994
1
1
1
N-22783
1
2
2
60-130-6 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Removal (Cont'd)
Figure 60-130-12
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever.
Cut the wires (Item 2) [Figure 60-130-12] below the
switch handle and remove switch handle.
NOTE: Only cut the wires if the switch handle is bad
and needs replacement. If the switch handle is
good and just needs to be removed for control
handle or lever replacement, then remove the
connectors on the end of the harness and pull
switch handle up out of lever tube.
Figure 60-130-13
Pull harness (Item 1) [Figure 60-130-13] out the bottom
of the control lever tube.
Switch Handle Installation
Figure 60-130-14
When installing the new switch handle, tape the wire
terminals together.
The switch handle comes with a 6 inch piece of heat
shrink tube side on the end of the wires. Remove the
heat shrink tube from the end of the wires before routing
through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
wires for protection.
Tape half of the wires back and half forward [Figure 60-
130-14] to keep the harness small enough to route
through the control lever tube.
N-22784
1
P-24233
2
P-90996
1
P-21699
Tape back 1/2 of Wires
Tape 1/2 of Wires
60-130-7 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Installation (Cont’d)
Figure 60-130-15
Install the new switch handle and wires from the top of
the control lever.
Route wire (Item 1) [Figure 60-130-15] through the
casting, along side the handle sensor and into the control
lever tube.
NOTE: Do not pull the wire harness tight, allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
returns to neutral position.
Figure 60-130-16
Remove tape from wires for installation and install the 6
inches of heat shrink tube (Item 1) [Figure 60-130-16]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-
16] and re-bend tabs if necessary.
Install the wires into the connectors as listed below:
Right Switch Handle
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Left Switch Handle
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - Dk. Blue
C-Terminal - White
D-Terminal - Purple
E-Terminal - Yellow/Red
F-Terminal - Tan
G-Terminal - Pink
H-Terminal - Orange/Black
J-Terminal - Blank
K-Terminal - Blank
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
E-Terminal - Blank
P-21700
1
P-21695
2
1
60-130-8 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Installation (Cont'd)
Figure 60-130-17
Figure 60-130-18
Connect the handle harness connectors (Item 1) [Figure
60-130-17] and [Figure 60-130-18] to the loader harness
connectors.
Figure 60-130-19
Install the wires into the connectors as listed below:
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
Figure 60-130-20
Left and Right Control Lever Switch Handle [Figure 60-
130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
P-90995
1
P-90994
1
1
1
P13735
3
1
2
P13735
2
3
1
60-130-9 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Installation (Cont'd)
Figure 60-130-21
Connect the handle harness connectors to the sensor
and lock solenoid connectors [Figure 60-130-21].
Actuator Connector Disassembly And Assembly 
NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-22
Check the actuator wiring harness connector (Item 1)
[Figure 60-130-22] and replace if broken.
Figure 60-130-23
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Lift and Tilt Actuator
1. Terminal-Black/Green-Larger diameter wire (16
gauge)
2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
gauge)
4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)
P-21804
P-6684
2
1
N-17741
1
60-130-10 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Handle Lock Solenoid Removal And Installation
Figure 60-130-24
Disconnect the harness connector (Item 1) [Figure 60-
130-24] from the handle sensor connector.
Disconnect the harness connector (Item 2) [Figure 60-
130-24] from the handle lock solenoid connector.
Figure 60-130-25
Remove the two screws (Item 1) [Figure 60-130-25]
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38
in-lb) torque.
Remove handle lock solenoid assembly from handle.
Handle Lock Solenoid Disassembly And Assembly
Figure 60-130-26
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
Figure 60-130-27
Check the O-ring (Item 1) [Figure 60-130-27] for
damage. Replace as necessary.
P-21836
1
2
P-21832
1
P-21878A
1
2
P-21789
1
60-130-11 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Removal And Installation 
Figure 60-130-28
Remove the hairpin clip and the pin (Item 1) [Figure 60-
130-28] from the foot sensor.
Figure 60-130-29
Disconnect the wire harness (Item 1) [Figure 60-130-29]
from the foot sensor.
Figure 60-130-30
Remove the two bolts (Item 1) and the foot sensor (Item
2) [Figure 60-130-30].
Repeat for other side.
P-90979
1
1
P-90982
1
1
P-90980
1
2‘
60-130-12 S650 Service Manual
CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-130-31
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor.
Installation: Tighten the bolts to 10,2 N•m (90 in-lb)
torque. Apply Loctite® #242 to the threads.
Figure 60-130-32
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130-
32].
NOTE: Do not disassemble the sensor assembly
(Item 5) [Figure 60-130-32]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.
Foot Sensor Lock Solenoid Removal And Installation
Figure 60-130-33
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Apply a drop of oil on the solenoid threads
and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-34
Check the O-ring (Item 1) [Figure 60-130-34] for
damage. Replace as necessary.
P-24269
1
1
P-24270
5
4
3
2
1
P-90992
1
2
P-21790
1
60-140-1 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS
Identification Chart
REF. NO. DESCRIPTION
1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 ENGINE SPEED CONTROL
6 STEERING LEVERS
7 LIFT ARM PEDAL
8TILT PEDAL
9 LIFT ARM BYPASS CONTROL
10 ATTACHMENT FUNCTION CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS
B-15781F / NA1014A / B-15781E
1
2 3
7 8
4
13
12
11
10
9
5
6
60-140-2 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin
connector to communicate between the loader and the
attachment. 
Attachments with a 14 pin connector use four different
groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for
more detailed information.
60-140-3 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Identification Chart ACD Group 0
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
B-16447
10, 11, 
12, 13, 
14
----- K No Jumpers
B-16448
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-140-4 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Identification Chart ACD Group 1
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
61111 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
B-16447
10, 11, 
12, 13, 
14
----- K Jumpers K,L
B-16448
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-140-5 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Identification Chart ACD Group 2
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
42222 K,A
5 1 1 1,7 1,7 K,A
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
B-16447
10, 11, 
12, 13, 
14
----- K Jumpers K,P
B-16448
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-140-6 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Identification Chart ACD Group 3
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
111- - K
222- - K
311- - K
4 - - - - K,A,D
5 - - - - K,A,C
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
B-16447
10, 11, 
12, 13, 
14
- -- -- K Jumpers C,D
B-16448
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-141-1 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS)
Identification Chart
B-15781D / NA1164A / B-15781E
1
2 3
8
9
5
14
13
12
11
6
7
4
10
REF. NO. DESCRIPTION
1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9TILT PEDAL
10 LIFT ARM BYPASS CONTROL
11 ATTACHMENT FUNCTION CONTROL
12 FRONT AUXILIARY HYDRAULICS
13 NOT USED
14 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS
60-141-2 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin
connector to communicate between the loader and the
attachment. 
Attachments with a 14 pin connector use four different
groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for
more detailed information.
60-141-3 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Identification Chart ACD Group 0
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
P-90898
P-90900
10, 11, 
12, 13, 
14
----- K No Jumpers
P-90899
P-90900A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-141-4 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Identification Chart ACD Group 1
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
61111 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
P-90898
P-90900
10, 11, 
12, 13, 
14
----- K Jumpers K,L
P-90899
P-90900A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-141-5 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Identification Chart ACD Group 2
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
42222 K,A
5 1 1 1,7 1,7 K,A
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
P-90898
P-90900
10, 11, 
12, 13, 
14
----- K Jumpers K,P
P-90899
P-90900A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-141-6 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Identification Chart ACD Group 3
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
111- - K
222- - K
311- - K
4 - - - - K,A,D
5 - - - - K,A,C
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
P-90898
P-90900
10, 11, 
12, 13, 
14
- -- -- K Jumpers C,D
P-90899
P-90900A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-142-1 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
Identification Chart
B-19873A / NA1165A / B-19874A
18
9
6
3
4
2
1
5
12
11
13
14
15
16
17
7
19
8
10
REF. NO. DESCRIPTION
1 SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
3 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
5 ATTACHMENT FUNCTION CONTROL
6 SPEED MANAGEMENT
7 FRONT HORN
8 ENGINE SPEED CONTROL (HAND)
9 JOYSTICKS
10 FOOTRESTS
11 ENGINE SPEED CONTROL (FOOT)
12 LIFT ARM BYPASS CONTROL
13 ATTACHMENT FUNCTION CONTROL
14 NOT USED
15 FRONT AUXILIARY HYDRAULICS
16 NOT USED
17 TURN SIGNALS (Option)
18 FLOAT CONTROL
19 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS
60-142-2 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin
connector to communicate between the loader and the
attachment. 
Attachments with a 14 pin connector use four different
groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for
more detailed information.
60-142-3 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart ACD Group 0
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
P-24820A
P-28316A
10, 11, 
12, 13, 
14
----- K No Jumpers
P-24802A
P-28316A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-142-4 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart ACD Group 1
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
61111 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
P-24820A
P-28316A
10, 11, 
12, 13, 
14
----- K Jumpers K,L
P-24802A
P-28316A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-142-5 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart ACD Group 2
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
1 1 1 1, 7 1,7 K
22222 K
3 1 1 1, 7 1,7 K
42222 K,A
5 1 1 1,7 1,7 K,A
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
P-24820A
P-28316A
10, 11, 
12, 13, 
14
----- K Jumpers K,P
P-24802A
P-28316A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-142-6 S650 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart ACD Group 3
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve.
Front Auxiliary Pressure Release is
accomplished by manually pushing the male
and female couplers in at the front auxiliary
block. 
The High Flow Button in the left side
instrument panel must be pushed ON to
activate solenoid number seven at the gear
pump.
Left side Control 
Handle Switches
Switch 
Number
Solenoid Number 
Activated
Attachment 
Harness 
Terminal 
Activated
Attachment 
Harness 
Connector RIght Side Control 
Handle Switches
STD RH HFH RH / HFH
111- - K
222- - K
311- - K
4 - - - - K,A,D
5 - - - - K,A,C
6--- - K,E
7--- - K,F
8--- - K,G
9--- - K,H
P-24820A
P-28316A
10, 11, 
12, 13, 
14
- -- -- K Jumpers C,D
P-24802A
P-28316A
14
13
12
4
5
7
6
1
2
8
9
3
11
10
Fourteen Pin
Connector
Viewed
from front
(pin side of
connector) 
of loader.
Solenoid 
Number
Hydraulic Coupler Wiring 
Number
1 Front Male (Rod) 4330
2 Front Female (Base) 4340
3  Diverter Rear (Rod) 4430
4  Diverter Rear (Base) 4440
5 Bleed / Lock Valve (Base) 4480
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460
NA1892
1
2
5
6
7
3
4
60-150-1 S650 Service Manual
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
Figure 60-150-1
The tools listed will be needed to do the following
procedure:
MEL1563 or 7003031 - Remote Start Tool
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
NOTE: Make all connections with the key in the OFF
position.
The Service PC (Item 1) with the Remote Start Tool (Item
2) [Figure 60-150-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostics, and
upgrade software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC.
NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the Remote
Start Tool.
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
NOTE: Refer to BobcatNET for PC requirements and
the latest Service Analyzer software.
Connecting Remote Start Tool (Service Tool)
Figure 60-150-2
The tools listed will be needed to do the following
procedure:
Order from Bobcat Parts P/N: 7003031 - Remote Start
Tool (Service Tool) Kit
Kit Includes:
7003030 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness 
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
NOTE: Make all connections with the key in the OFF
position.
The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-150-2]. When
connected to the loader, the Service PC is used to
monitor, conduct diagnostics, and upgrade software.
Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 60-150-2] to the
designated serial port on the Service PC.
NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the Remote
Start Tool (Service Tool).
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and
the latest Service Analyzer software.
P16119
3
1
2
P-76450
3
1
2
60-150-2 S650 Service Manual
60-160-1 S650 Service Manual
CALIBRATION 
Description 
Calibration procedures must be followed when replacing
a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC. The
Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator. 
NOTE: The Actuator Test should be used as the
preferred method of actuator and valve spool
calibration. 
The Lift and Tilt Calibration (ACS) provides set points to
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (ACS) should be used if reduced
performance codes are present or when replacing a
controller or actuator.
The Lift and Tilt Calibration (SJC) provides set points to
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced
performance codes are present or when replacing a
controller or actuator.
The Hydrostatic Pump Calibration (SJC) provides set
points to the Drive controller to actuate the hydrostatic
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a
desired travel path cannot be attained or replacing the
hydrostatic pump, hydrostatic motor, or controller. After
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the
hydrostatic pump control.
For more information on Steering Drift Compensation
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a
Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC). 
Actuator Testing 
Figure 60-160-1
[Figure 60-160-1] Excessive actuator loading can occur
if the actuator and valve spool components are
misaligned. Misalignment may reduce spool stroke
performance and reduce the life of the actuator. Starting
with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
valve spool misalignment.
Connect the Service PC. (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
If a Service PC is not available, (See Lift And Tilt
Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
Calibration (ACS) on Page 60-160-11.).
NOTE: Warm the hydraulic oil to room temperature
22°C (72°F), stop the engine and clear all
active service codes before running the test.
Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
Service PC (Laptop) monitor.
P-54336
CONTROL VALVE ACTUATORS
60-160-2 S650 Service Manual
CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
This test will engage both actuators to fully stroke the
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to
move the spools just past the neutral points then allow
the centering springs to return the spools to neutral.
When complete, the Actuator Test will show a pass mode
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a
combination of three problems below. 
• Actuator slow return to neutral. The spool returns to
neutral too slowly.
• Actuator did not fully extend / retract. During the test,
the spool was not able to fully stroke in both
directions.
• Actuator out of neutral. The spool did not return to the
neutral window during the test.
NOTE: A time out will occur if the test cannot be
completed within 8 seconds. If this happens,
retry the test.
Figure 60-160-2
[Figure 60-160-2] If the initial Actuator Test results in a
fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause. 
If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
or side / side.
Rerun the Actuator Test, if the test passes, check the
following probable causes in Column 1 [Figure 60-160-
2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
Re-run the test to verify.
NOTE: Actuator and spool misalignment. Re-tighten
the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
both bolts are tight.
If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
60-160-2], check the following probable causes in
Column 2 [Figure 60-160-2].
• Contamination in the spool.
• The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• The wire harness or connectors may have an
intermittent short. Check the connections and wire
harnesses.
• The controller may be defective, replace the
controller.
Run Actuator Test
Pass
Fail
Retest With Warm Hydraulic Oil
Loosen Actuator
Pass
Fail
Pass
Fail
• Misaligned Assembly
• Pin
• Contamination in Spool
• Actuator
• End Cap / Center Spring
• Wire Harness
• Controller
Probable Cause
Probable Cause
Column 1 Column 2
• Contamination in Spool
60-160-3 S650 Service Manual
CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator
did not fully extend / retract, check the following.
• The actuator connectors may be reversed between
the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.
• The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator
out of neutral, check the following.
• The actuator may be defective, replace the actuator.
• The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.
60-160-4 S650 Service Manual
CALIBRATION (CONT’D)
Lift And Tilt Calibration (SJC) 
The controller uses a calibration sequence to optimize
the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to
calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed
when replacing the hydraulic control valve, lift
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
Figure 60-160-3
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure
60-160-3] in the ISO position.
Figure 60-160-4
Move the right joystick to the forward-right corner position
[Figure 60-160-4] and hold in position.
P-85307
SJC
1
P-85958
P-85958
60-160-5 S650 Service Manual
CALIBRATION (CONT’D)
Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
With the seat bar down, turn the ignition key ON [Figure
60-160-5].
NOTE: Do not start the engine.
Figure 60-160-6
The loader Control Pattern Switch (Item 1) [Figure 60-
160-6] will start flashing and will continue to flash until the
calibration procedure is completed.
Figure 60-160-7
At the left panel, press the PRESS TO OPERATE Button
(Item 1) [Figure 60-160-7] while holding the right joystick
in position.
Release the joystick.
NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
complete, code W3224 (Calibration
Performed) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-85493A
P-85307
SJC
1
P-85413C
1
60-160-6 S650 Service Manual
CALIBRATION (CONT’D)
Hydrostatic Pump Calibration (SJC) 
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
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Operator must be in the seat and the seat bar down.
Figure 60-160-8
Close the cab door. (If loader is so equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure
60-160-8] in the ISO position.
Verify the parking brake.
Figure 60-160-9
With the seat bar down, turn the ignition key ON [Figure
60-160-9].
NOTE: Do not start the engine.
Figure 60-160-10
The Control Pattern ISO Switch (Item 1) [Figure 60-160-
10] will start flashing.
P-85307
SJC
1
P-85493A
P-85307
SJC
1
60-160-7 S650 Service Manual
CALIBRATION (CONT'D)
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-11
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
Press the PRESS TO OPERATE LOADER Button (Item
1)  [Figure 60-160-12] while holding the left joystick in
position.
Three audible beeps will sound. 
Figure 60-160-13
Move the left joystick to the reverse-right corner position
[Figure 60-160-13] and hold in position.
Figure 60-160-14
Press the PRESS TO OPERATE LOADER Button (Item
1)  [Figure 60-160-14] while holding the left joystick in
position.
Three audible beeps will sound. 
B-19873
P-85959
P-85413C
1
B-19873
P-85960
P-85413C
1
60-160-8 S650 Service Manual
CALIBRATION (CONT'D)
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-15
Allow the left joystick to go to the neutral position [Figure
60-160-15].
Figure 60-160-16
Press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 60-160-16].
Three audible beeps will sound. 
Start the engine from the RUN, RUN / ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
Figure 60-160-17
The Control Pattern ISO Switch (Item 1) [Figure 60-160-
17] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Figure 60-160-18
Move the throttle (Item 1) [Figure 60-160-18] to high idle.
NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
neutral position.
The calibration procedure will stop.
To  return  to  calibration  mode,  the  operator
must start the complete procedure from the
beginning.
P-85961
P-85413C
1
P-85307
SJC
1
P-85760A
1
60-160-9 S650 Service Manual
CALIBRATION (CONT'D)
Hydrostatic Pump Calibration (SJC) (Cont'd)
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
Figure 60-160-19
Move and hold the left joystick to the forward position
[Figure 60-160-19] until the forward calibration is
completed.
Figure 60-160-20
The loader speed will “ramp up” quickly (Item 1)
[Figure 60-160-20] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)
[Figure 60-160-20] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the forward position
until the loader wheels or tracks come to a stop and an
audible beep is heard. 
Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in
Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
B-19873
P-85962
P-64321
1
2
60-160-10 S650 Service Manual
CALIBRATION (CONT'D)
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-21
Move and hold the left joystick to the reverse position
[Figure 60-160-21] until the reverse calibration is
completed.
Figure 60-160-22
The loader speed will “ramp up” quickly (Item 1)
[Figure 60-160-22] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)
[Figure 60-160-22] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position
until the loader wheels or tracks come to a stop and an
audible beep is heard. 
Reverse calibration is complete.
NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
There will be an audible beep, the PRESS TO OPERATE
LOADER button light will remain on. The TRACTION
light will illuminate, the SEAT BAR, and LIFT AND TILT
lights will be off. The D7598 error code will clear. There
should be no other codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering
Drift Compensation values will be reset to [S----] or
neutral.
Press the PRESS TO OPERATE LOADER button. Move
the left joystick to forward position [Figure 60-160-19]
and check for normal forward wheel or track rotation.
Move the left joystick to the reverse position [Figure 60-
160-21] and check for normal reverse wheel or track
rotation.
Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
If loader does not maintain a desired travel path with
Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-1.)
or (See Troubleshooting on Page 60-10-8.) 
B-19873
P-85963
P-64321
1
2
60-160-11 S650 Service Manual
CALIBRATION (CONT’D)
Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize
the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to
calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed
when replacing a hydraulic control valve,
actuator or ACS controller. Failure to calibrate
after component replacement may result in
poor performance or reduced life of
actuator(s).
Figure 60-160-23
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-23] in
the hand control mode.
Figure 60-160-24
Close the cab door. (If loader is equipped.)
With the seat bar down, turn the ignition key ON (Deluxe
Instrumentation Panel press RUN / ENTER) (Item 1)
[Figure 60-160-24].
NOTE: Do not start the engine.
Figure 60-160-25
Push the PRESS TO OPERATE button (Item 1) [Figure
60-160-25] to unlock the hand controls.
P-85307B
ACS
1
P-85493A
P-85413C
1
60-160-12 S650 Service Manual
CALIBRATION (CONT’D)
Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-26
Fully stroke both control handles in toward the center of
the cab and hold the handles [Figure 60-160-26].
Lift the seat bar, high enough for the PRESS TO
OPERATE light (Item 1) [Figure 60-160-27] to go OFF.
Lower the seat bar.
Figure 60-160-27
Push the PRESS TO OPERATE button (Item 1) [Figure
60-160-27] to begin calibration.
NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
complete, code W3224 (Calibration
Performed) will be generated.
Release the control handles.
Calibration is complete.
B-16628
Stroke Both Handles Fully In and Hold Them
P-85413C
1
60-161-1 S650 Service Manual
STEERING DRIFT COMPENSATION
Steering Drift Compensation is available on SJC
equipped machines.
Description
Steering Drift Compensation can be used to reduce
steering drift to maintain a desired travel path in both
forward and reverse directions.
Examples of applications where this feature can be used:
• To compensate for normal variations such as tire
inflation pressure, track tension, tire wear and track
wear.
• Using side shift attachments such as trenchers,
planers and silt fence installers.
• Driving on uneven terrain such as crowned road
surfaces.
Figure 60-161-1
Steering drift compensation contains a total of 21
settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].
Operation
NOTE: Changes CANNOT be performed until the seat
bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
pressed to activate the BICS.
Perform pre-starting and starting procedures:
1. Fasten seat belt.
2. Lower seat bar.
3. Place joysticks in neutral position.
4. Start the engine.
5. Press the PRESS TO OPERATE LOADER button.
6. Current drive response setting will be displayed briefly
in the data display.
NOTE: Raising the seat bar or changing control
mode (ISO / H) will cause the machine to
disengage from steering drift compensation.
The last displayed setting will remain in effect
until the machine is turned OFF.
B-23580C
STEERING DRIFT COMPENSATION
60-161-2 S650 Service Manual
STEERING DRIFT COMPENSATION (CONT’D)
Operation (Cont’d)
Figure 60-161-2
Press and hold the PRESS TO OPERATE LOADER
button (Item 1) for three seconds to enter the drive
response adjustment menu. Press the PRESS TO
OPERATE LOADER button (Item 1) again to adjust the
loader’s steering drift compensation setting. The current
steering drift compensation setting will appear in the data
display (Item 2) [Figure 60-161-2]. 
Press the upper left button (Item 6) on the left joystick to
adjust the machine left. [S-L01] (Item 3) through a
maximum of [S-L10] will appear in the data display (Item
2) [Figure 60-161-2]. The number will increase by one
each time you press the button. The higher the number,
the greater the amount of steering drift compensation to
the left. Adjustments to steering drift compensation will
be effective immediately.
Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
to appear in the data display (Item 2) [Figure 60-161-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-161-3
Saving The Steering Drift Compensation Setting:
The current steering drift compensation setting can be
saved by pressing and holding the PRESS TO OPERATE
LOADER button (Item 1) for three seconds. [SET] (Item
3) will appear in the data display (Item 2) [Figure 60-161-
3] and the machine will exit from the steering drift
compensation adjustment menu.
OR
Press the PRESS TO OPERATE LOADER button to exit
from the steering drift compensation adjustment menu
without saving the current setting. [DONE] (Item 4) will
appear in the data display (Item 2) [Figure 60-161-3] and
the upper left and upper right buttons on the left joystick
will no longer make changes to steering drift
compensation.
NOTE: The last displayed steering drift
compensation setting will remain in effect
until the machine is turned OFF. The machine
will revert back to the last saved setting the
next time it is started.
P-24820C
6
7
Left Joystick
Right Joystick
P-24802C
1
2
NA1011
P-76461L
P-76461N
P-76461M
4
5
3
1
2
NA1011
P-76461K
P-76461O
4
3
60-170-1 S650 Service Manual
FLYWHEEL RPM SENSOR
Description
The flywheel rpm sensor has a magnet located on the
end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
controller which registers the rpm of the engine.
The flywheel rpm sensor is located just above the starter
on the left side of the engine.
60-170-2 S650 Service Manual
FLYWHEEL RPM SENSOR (CONT’D)
Adjustment
Figure 60-170-1
When reinstalling the rpm sensor, turn the rpm sensor
(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-170-1] until it
contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the rpm sensor when the
sensor is turned back out for adjustment.
Figure 60-170-2
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 1,27 mm (0.050 in) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Remove the feeler gauge.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 16 - 23
N•m (12 - 17 ft-lb) torque.
NOTE: New rpm sensors have a plastic tip which is
used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
P-85922
1
2
P-85921
1
2
60-180-1 S650 Service Manual
CONTROL PANEL SETUP
Right Panel Setup (Deluxe Instrumentation Panel)
Icon Identification
Figure 60-180-1
Example
Languages
Figure 60-180-2
ICON DESCRIPTION
DATE / TIME
USER / HOURMETER
CURRENT JOB HOURS
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
LEFT SCROLL button
RIGHT SCROLL button
ENTER button
NA3025
P-90385 / NA3025 / NA3012 / NA302
3
Press a scroll butto
n
(Item 1) repeatedly unt
il
the Display screen ico
n
(Inset) is highlighted.
1 1
Select
[2. LANGUAGES].
Select the desire
d
language.
60-180-2 S650 Service Manual
CONTROL PANEL SETUP (CONT’D)
Right Panel Setup (Deluxe Instrumentation Panel) 
(Cont’d)
More Examples
Clocks
Select …
DISPLAY screen icon
[1. CLOCKS]
SET TIME AND DATE
Select [1. TIME]
Use the keypad to enter date.
Press ENTER to continue.
Use the keypad to enter time.
Select AM / PM / 24hr.
Press ENTER to continue.
RESET JOB CLOCK
(Owner password required if Job Clock is locked.)
Select [2. JOB CLOCK]
Press [4] to cycle between lock and unlock.
Press [9] to reset.
SET ALARM
Select [3. ALARM CLOCK]
Select alarm 1, 2 or 3.
Press [1] to cycle between ON and OFF.
Press [2] and use the keypad to enter alarm time.
Select AM / PM / 24hr.
Press ENTER to continue.
Press  [3] to cycle between ONCE, DAILY and
WEEKLY.
Selecting WEEKLY will prompt for a day selection
using number [4].
Press ENTER to continue.
Vitals
(Monitor the engine, hydraulic / hydrostatic,
electrical functions when engine is running.)
Select …
VITALS screen icon
Press [6] to cycle between METRIC or ENGLISH (M /
E) readouts.
You can monitor real-time readouts of:
Engine Speed
Engine Oil Pressure
Engine Coolant Temperature
System Voltage
Hydraulic Charge Pressure
Hydraulic Oil Temperature
The Deluxe Instrumentation Panel is easy to use.
Continue to set your own preferences for running /
monitoring your Bobcat loader.
60-190-1 S650 Service Manual
PASSWORD SETUP (DELUXE INSTRUMENTATION 
PANEL)
Password Setup is available on machines with a Deluxe
Instrumentation Panel.
Password Description
All new machines with a Deluxe Instrumentation Panel
arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start
the engine.
For security purposes, your dealer may change the
password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password:
A permanent, randomly selected password set at the
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password.
Owner Password:
Allows for full use of the loader and to setup the
Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner
or user passwords. Owner should change the
password as soon as possible for security of the
loader.
User Password:
Allows starting and operating the loader; cannot
change password or any of the other setup features.
For the procedures to change passwords (See Changing
The Owner Password on Page 60-190-1.) and (See
Changing The User Passwords on Page 60-190-2.)
Changing The Owner Password
Figure 60-190-1
P-90399/NA3025/NA3016/NA3031/NA3033/NA3028/NA3015/NA3027
Press a scroll button (Item
1) repeatedly until th
e
Security screen ico
n
(Inset) is highlighted.
1 1
Enter owner password an
d
press [ENTER].
Select  [1. USER
SETTINGS].
Select [1. OWNER].
Select  [2. CHANG
E
PASSWORD].
Enter new owne
r
password and pres
s
[ENTER].
You will be prompted t
o
reenter the new owne
r
password.
Press [ENTER].
60-190-2 S650 Service Manual
PASSWORD SETUP (DELUXE INSTRUMENTATION 
PANEL) (CONT’D)
Changing The User Passwords
Figure 60-190-2
Password Lockout Feature
This feature allows the owner to unlock the password
feature so that a password does not need to be used
every time the engine is started.
Figure 60-190-3
NOTE: The procedure above can be followed to reset
the machine lock so that the machine requires
a password to start the engine.
P-90399/NA3025/NA3016/NA3031/NA3033/NA3026/NA3010/NA3027
Press a scroll button (Item
2) repeatedly until th
e
Security screen ico
n
(Inset) is highlighted.
1 1
Enter owner password an
d
press [ENTER].
Select  [1. USER
SETTINGS].
Select user.
Select  [2. CHANG
E
PASSWORD].
Enter new user passwor
d
and press [ENTER].
Press [ENTER].
P-90399 / NA3025 / NA3016 / NA3031
Press a scroll butto
n
(Item 2) repeatedly unt
il
the Security screen ico
n
(Inset) is highlighted.
1 1
Enter owner passwor
d
and press [ENTER].
Select  [2. MACHIN
E
LOCK].
60-191-1 S650 Service Manual
PASSWORD SETUP (KEYLESS START PANEL)
Password Description
Master Password:
A permanent, randomly selected password set at the
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password.
Owner Password:
Allows for full use of the loader. It must be used to
change the owner password.
Changing The Owner Password
Press the RUN button to turn on the loaders electrical
system.
Enter the five digit owner password using the number
keys (1 through 0) if locked.
Figure 60-191-1
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds.
The lock key red light will flash and the left panel display
screen will show [ENTER].
Enter a new five digit password using the number keys (1
through 0). An asterisk will show in the left panel display
screen for each key press.
The left panel display screen will show [AGAIN].
Enter the new five digit password again.
The lock key red light will become solid.
Password Lockout Feature
This feature allows the owner to unlock the password
feature so that a password does not need to be used
every time the engine is started.
Press the RUN button to turn on the loaders electrical
system.
Enter the five digit owner password using the number
keys (1 through 0).
Figure 60-191-2
Press the unlock key (Item 2) [Figure 60-191-2].
The left panel display screen will show [CODE].
Enter the five digit owner password using the number
keys (1 through 0). The unlock key green light will flash,
then become solid.
The loader can now be started without using a password.
NOTE: Use the following procedure to reset the
machine lock so that the loader requires a
password to start the engine.
Press the RUN button to turn on the loaders electrical
system.
Press the lock key (Item 1) [Figure 60-191-2].
The lock key red light will flash and the left panel display
screen will show [CODE].
Enter the five digit owner password using the number
keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
You must now enter the password every time to start the
loader.
P-90805
1
2
P-90805
1
2
60-191-2 S650 Service Manual
60-200-1 S650 Service Manual
MAINTENANCE CLOCK
Description
The Maintenance Clock alerts the operator when the next
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-200-1
During machine operation, a two beep alarm will sound
when there are less than 10 hours until the next planned
maintenance.
The remaining hours before maintenance is required will
appear in the data display (Item 1) for five seconds while
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-200-1] flash.
NOTE: The display will show negative numbers after
counting down to zero.
The display will then revert back to the previous display
and will appear for five seconds every time the machine
is started until the maintenance clock is reset.
Figure 60-200-2
The Deluxe Instrumentation Panel, if equipped, will
display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.
This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
maintenance clock is reset.
Figure 60-200-3
The Deluxe Instrumentation Panel, if equipped, will
display a bar (Item 1) [Figure 60-200-3] showing time
remaining until next service. This bar will turn red when
service is past due. NEXT MAINTENANCE DUE will
change to MAINTENANCE PAST DUE and display the
number of hours past due.
Keys  [4] and [9] can be used to adjust the service
interval when the owner is logged in [Figure 60-200-3].
NOTE: Loaders equipped with a Standard Key Panel
or Keyless Start Panel will not display the
BobCARE PM
SM
message or NEXT
MAINTENANCE TYPE on the right panel.
P-76461R
3
2
1
NA3034
1
NA3040
1
60-200-2 S650 Service Manual
MAINTENANCE CLOCK (CONT’D)
Setup
Figure 60-200-4
The first analyzer screen has an added bar for the
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to
view the next analyzer screen.
Figure 60-200-5
Click Options (Item 1) and add your dealer name and
phone number (Item 2). Click Save Options (Item 3)
[Figure 60-200-5] the information is now stored. 
Figure 60-200-6
Select Install (Item 1) [Figure 60-200-6] to begin sending
the dealer information to the controller.
Figure 60-200-7
Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to
send the dealer information to the machine controller.
NOTE: Verify that all correct option and kits are
selected before clicking SEND TO MACHINE.
P-64243A
1
P-76110
1
2
3
P-76110
1
P-76113
1
60-200-3 S650 Service Manual
MAINTENANCE CLOCK (CONT’D)
Setup (Cont’d)
Figure 60-200-8
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller.
Click Back (Item 2) [Figure 60-200-8] to return to the
Bobcat Service Analyzer screen.
Figure 60-200-9
Select Warnings (Item 1) [Figure 60-200-9].
Figure 60-200-10
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
through the tabs.
Figure 60-200-11
Click the Maintenance tab (Item 1) [Figure 60-200-11] to
view the maintenance clock screen.
Click ON/OFF (Item 2) to turn the maintenance clock on
or off [Figure 60-200-11].
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
new interval. Click SET/RESET (Item 4) [Figure 60-200-
11] to reset and set the maintenance clock.
P-76114
1
2
P-76110
1
P-76112
1
P-76111
1
3
4
2
60-200-4 S650 Service Manual
MAINTENANCE CLOCK (CONT’D)
Setup (Cont’d)
Figure 60-200-12
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
Figure 60-200-13
Select Back (Item 1) [Figure 60-200-13] to return to the
main menu.
Figure 60-200-14
Select Program / Update (Item 1) [Figure 60-200-14] to
view the maintenance clock.
Figure 60-200-15
After the maintenance clock has been activated, the first
analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
the interval, the number will reflect negative hours. 
P-76111
1
2
P-76111
1
P-76110
1
P-64244A
1
60-200-5 S650 Service Manual
MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
Press the information button (Item 2) until the display
screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.
Press and hold the information button (Item 2) for seven
seconds until [RESET] (Inset) appears in the display
screen (Item 1) [Figure 60-200-16].
P-76455H
2
1
60-200-6 S650 Service Manual
60-210-1 S650 Service Manual
BACK-UP ALARM SYSTEM
Description
The back-up alarm will sound when the operator moves
both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
Inspecting
Figure 60-210-1
Inspect for damaged or missing back-up alarm decal
(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse
position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear
door.
Figure 60-210-2
Inspect the back-up alarm electrical connections (Item 1)
[Figure 60-210-2], wire harness (Item 2) [Figure 60-210-
2] and back-up alarm switches (if equipped) (Item 1)
[Figure 60-210-3] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See
Adjusting Switch Position on Page 60-210-2.)
P-85994
1
P-90531A
1
2
60-210-2 S650 Service Manual
BACK-UP ALARM SYSTEM (CONT’D)
Adjusting Switch Position
NOTE: Joystick equipped machines do not have
back-up alarm switches and cannot be
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Place the steering levers in the neutral position.
Figure 60-210-3
The back-up alarm switches (Item 1) [Figure 60-210-3]
are located alongside the steering bellcranks. Both
switches must be adjusted properly for the back-up alarm
to operate correctly.
Figure 60-210-4
Loosen the screws (Item 3) [Figure 60-210-4] securing
the back-up alarm switch. (Left side shown)
Position the back-up alarm switch so that the roller (Item
1) just makes contact with the bellcrank (Item 2) [Figure
60-210-4] without compressing the switch spring.
Torque the screws (Item 3) [Figure 60-210-4] securing
the switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Repeat adjustment procedure for the other switch.
Lower the operator cab. (See Lowering on Page 10-30-
3.)
Inspect back-up alarm system for proper function. (See
Inspecting on Page 60-210-1.)
P-85722
1
P-85723A
3
1
2
60-210-3 S650 Service Manual
BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard And ACS)
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.
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
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 
reverse position.
1, 2, 3, 4, 5, 6, 7
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7 
KEY TO CORRECT THE CAUSE
1. The ground connection is not making a good contact.
2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The back-up alarm or switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.
60-210-4 S650 Service Manual
BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Joystick)
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.
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
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 
position.
1, 2, 3, 4, 5, 6
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6 
KEY TO CORRECT THE CAUSE
1. The ground connection is not making a good contact.
2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.
60-210-5 S650 Service Manual
BACK-UP ALARM SYSTEM (CONT’D)
Alarm Removal And Installation
Stop the engine and open the rear door.
Figure 60-210-5
Disconnect the alarm connector (Item 1) [Figure 60-210-
5] from the alarm.
Remove the two nuts (Item 2) [Figure 60-210-5].
Remove the alarm and bracket from the loader.
Switch Removal And Installation
NOTE: Joystick equipped machines do not have
back-up alarm switches.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-6
Place the steering levers in the neutral position.
Loosen the screws (Item 1) securing the back-up alarm
switches. Slide the switch (Item 2) [Figure 60-210-6] off
the mounting bracket.
Mark the wires for ease of assembly and disconnect
them from the switch.
Repeat for other side.
Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjust the switches (See
Adjusting Switch Position on Page 60-210-2.) and
inspect back-up alarm operation (See Inspecting on
Page 60-210-1.) are required. 
P-85280
1
2
P-85723A
2
1
60-210-6 S650 Service Manual
60-220-1 S650 Service Manual
FRONT HORN
Removal And Installation
NOTE: Two different style horns are used.
Remove the left side lower panel. (See Removal And
Installation on Page 50-160-1.)
Figure 60-220-1
Figure 60-220-2
Disconnect wire harness (Item 1) [Figure 60-220-1] and
[Figure 60-220-2] from the front horn.
Remove the two bolts and nuts (Item 2) [Figure 60-220-
1] and [Figure 60-220-2].
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].
Figure 60-220-3
Remove the two bolts and nuts (Item 1) [Figure 60-220-
3].
Remove the front horn from the bracket.
P-90901
1
2
3
P-90885
2
1
1
P-90902
2
3
1
P-90903
2
3
P-90886
1
60-220-2 S650 Service Manual
70-01 S650 Service Manual
ENGINE SERVICE
ENGINE INFORMATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-1
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-5
Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-5
Engine Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-7
Engine Mount Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-14
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-10-15
ENGINE SPEED CONTROL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-20-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-20-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-20-1
Cable Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-20-2
ENGINE SPEED CONTROL (SJC) S/N A3NV12469 AND BELOW & S/N A3NW11130 AND 
BELOW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-21-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-21-2
ENGINE SPEED CONTROL (SJC) S/N A3NV12470 AND ABOVE & S/N A3NW11131 AND 
ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-22-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-22-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-22-2
MUFFLER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-30-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-40-1
Housing Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-40-1
Housing Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-40-2
ENGINE COOLING SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-1
Radiator Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-3
Hydraulic Fan Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-4
Lower Fan Duct Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-5
Blower Housing Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-5
Hydraulic Fan Motor Assembly Removal And Installation  . . . . . . . . . . . . . . . . . . . .  70-50-6
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-6
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-7
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-8
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-8
Thermostat Housing Removal And Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-9
Thermostat - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-50-10
70-02 S650 Service Manual
LUBRICATION SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-1
Oil Pump Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-1
Relief Valve - Testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-2
Oil Pump Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-2
Oil Filter Cooler Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-3
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-60-4
FUEL SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-1
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-1
Fuel Injection Pump - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-2
Fuel Injection Pump Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . .  70-70-3
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-6
Governor Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-8
Fuel Camshaft Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-10
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-12
Fuel Injection Pump - Timing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-14
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-15
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-17
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-18
Valve Seat Tightness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-70-18
CYLINDER HEAD  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-1
Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-1
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-3
Cylinder Head Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-4
Cylinder Head Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-8
Valve Guide - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-8
Valve Guide Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-9
Reconditioning The Valve And Valve Seat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-9
Valve Spring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-80-11
Valve Tappets  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-12
Rocker Arm And Shaft - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-13
Bridge Arm And Bridge Arm Shaft - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-13
Bridge Arm Shaft - Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-14
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-80-15
CRANKSHAFT AND PISTONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-1
Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .  70-90-1
Piston And Connecting Rod - Servicing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-2
Cylinder Bore - Checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-6
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-6
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-7
Crankshaft And Bearings - Servicing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-90-9
70-03 S650 Service Manual
CAMSHAFT AND TIMING GEARS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-1
Timing Gearcase Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-1
Timing Gearcase Cover Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-2
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-5
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .  70-100-5
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-6
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-100-7
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-2
FLYWHEEL AND HOUSING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-120-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-120-3
Housing Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-120-3
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .  70-130-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-130-2
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-130-5
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70-130-6
70-04 S650 Service Manual
70-10-1 S650 Service Manual
ENGINE INFORMATION
Description
The S650 has a Kubota direct injected V3307-DI-T turbo
diesel engine with a displacement of 3,3 L (203 in
3
). The
engine is rated at an SAE Gross 55,4 kW (74.3 hp) and
has a closed breather system [Figure 70-10-1].
The engine has 4 cylinders and the rotation is counter-
clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts. 
To meet emission regulations it is also equipped with an
Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and
is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts. 
The engine is liquid cooled with a propylene glycol/water
mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic/hydrostatic
fluid temperature sensor.
Figure 70-10-1
P-85028
70-10-2 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Specifications
All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Free Length (Intake and Exhaust) 35,1 - 35,6 (1.39 - 1.40)
Allowable Limit 34,6(1.36)
Fitted Length (Intake and Exhaust) 31,5 (1.24)
Setting Load/ Setting Length (Intake and Exhaust) 63,5 N/31,5mm (14.3 lb./1.24in)
Allowable Limit 45,9 N/31,5mm (10.3 lb./1.24in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 (0.039)
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 40 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 14 degrees A.T.D.C.
O.D. of Rocker Arm Shaft 14,973 - 14,984 (0.58949 - 0.58992)
I.D. of Rocker Arm Bushings 15,000 - 15,018 (0.59056 - 0.59125)
Oil Clearance Between Rocker Arm & Bushing 0,016 - 0,045 (0.00063 - 0.0017)
Allowable Limit 0,15 (0.0059)
Journal O.D. 1 34.934 - 34,950 (1.3754 - 1.3759)
Bearing I.D. 1 35,0 - 35,025 (1.3780 - 1.3789)
Journal O.D. 2 43,934 - 43,950 (1.7297 - 1.7303)
Bearing I.D. 2 44,000 - 44,025 (1.7323 - 1.7332)
Oil Clearance 0,050 - 0,091 (0.002 - 0.0035)
Allowable Limit 0,15 (0.0059)
Alignment Allowable Limit 0,01 (0.0004)
Cam Lobe Height (Intake) 37,50 (1.476)
Allowable Limit (Intake) 37,00 (1.457)
Cam Lobe Height (Exhaust) 37,90 (1.492)
Allowable Limit (Exhaust) 37,40 (1.472)
Side Clearance Allowable Limit 0,10 (0.0039)
Oil Clearance Between Tappet & Guide 0,020 - 0,050 (0.0079 - 0.0019)
Allowable Limit 0,07 (0.003)
Tappet O.D. 9,965 - 9,980 (0.3924 - 0.3929)
Tappet Guide I.D. 10,000 - 10,015 (0.39370 - 0.39429)
70-10-3 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Specifications (Cont’d)
All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Cylinder Liner
Piston Rings
Pistons
Connecting Rod
Oil Pump
Cylinder Bore I.D. 94,000 - 94,022 (3.7008 - 3.7016)
Allowable Limit 87,15 (3.431)
Oversized Cylinder Liner (Bore) I.D. 94,500 - 94,522 (3.7205 - 3.7213)
Allowable Limit 94,65 (3.726)
Ring Gap (Top Ring) 0,25 - 0,40 (0.0099 - 0.015)
Allowable Limit 1,25 (0.0492)
Ring Gap (2nd Ring) 0,30 - 0,45 (0.012 - 0.017)
Allowable Limit 1,25 (0.0492)
Ring Gap (Oil Ring) 0,25 - 0,45 (0.0099 - 0.017)
Allowable Limit 1,25 (0.0492)
Side Clearance of Ring Groove:
Top Ring 0,050 - 0,090 (0.0020 - 0.0035)
Allowable Limit 0,15 (0.0059)
Second Ring 0,090 - 0,12 (0.0035 - 0.0047)
Allowable Limit 0,0079 (0.20)
Oil Ring 0,020 - 0,060 (0.00079 - 0.0023)
Allowable Limit 0,15 (0.0059)
Piston Pin Bore 28,000 - 28,013 (1.1024 - 1.1028)
Allowable Limit 28,05 (0.0059)
Piston Pin O.D. 28,006 - 28,011 (1.1026 - 1.1027)
Small End Bushing I.D. 28,031 - 28,046 (1.1036 - 1.1041)
Oil Clearance Between Piston Pin & Small End Bushing 0,020 - 0,040 (0.00079 - 0.0015)
Allowable Limit 0,15 (0.0059)
Connecting Rod Alignment Allowable Limit 0,05 (0.002)
Oil Pressure Rated RPM 193,1 - 393,0 kPa (1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (0,48 bar) (7 psi)
Clearance Between Inner Rotor & Outer Rotor 0,030 - 0,090 (0.002 - 0.003)
Clearance Between Outer Rotor & Pump Body 0,100 - 0,184 (0.00394 - 0.00724)
End Clearance Between Inner Rotor & Cover 0,025 - 0,075 (0.00099 - 0.0029)
70-10-4 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Specifications (Cont’d)
All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Crankshaft
Timing Gear
Thermostat
Crankshaft Alignment Limit Permitted 0,02 (0.0008)
Oil Clearance Between Journal & Bearing  0,030 - 0,073 (0.0012 - 0.0028)
Limit Permitted 0,020 (0.0079)
Journal O.D. 79,977 - 79,990 (3.1487 - 3.1492)
Oil Clearance Between Crank Pin & Bearing 0,017 - 0,048 (0.00067 - 0.0018)
Limit Permitted 0,20 (0.0079)
Crank Pin O.D. 49,980 - 49,991 (1.9678 - 1.9681)
Crank Pin I.D. (Blue) 53,010 - 53,020 (2.0870 - 2.0874)
Crank Pin I.D. (No Color) 53,000 - 53,010 (2.0867 - 2.0870)
Crankshaft Side Clearance 0,15 - 0,35 (0.0059 - 0.013)
Limit Permitted 0,50 (0.020)
Timing Gear Backlash:
Crank Gear-Cam Gear 0,0410 - 0,139 (0.00162 - 0.00547)
Allowable Limit 0,22 (0.0087)
Idle Gear-Cam Gear 0,0410 - 0,134 (0.00162 - 0.00527)
Allowable Limit 0,22 (0.0087)
Idle Gear-Injection Pump Gear 0,0410 - 0,134 (0.00162 - 0.00527)
Allowable Limit 0,22 (0.0087)
Oil Clearance Between Idle Gear Shaft & Idle Gear Bushing: 0,050 - 0,091 (0.0020 - 0.0035)
Idle Gear Bushing I.D. 35,025 - 35,050 (1.3790 - 1.3799)
Idle Gear Shaft O.D. 34,959 - 34,975 (1.3764 - 1.3769)
Idle Gear Side Clearance  0,15 - 0,25 (0.0059 - 0.0098)
Allowable Limit 0,90 (0.035)
Valve Opening Temperature 74,5 - 78,5°C (166.1 - 173°F)
Valve Fully Open 90°C (194°F)
70-10-5 S650 Service Manual
ENGINE INFORMATION (CONT’D)
All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Torque Values
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.
Thread Size
(Dia. x Pitch)
Material
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m
(6 - 7 ft-lb)
8 - 12 N•m
(6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m
(6 - 9 ft-lb)
15 - 22 N•m
(11 - 16 ft-lb)
24 - 34 N•m
(18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m
(13 - 18 ft-lb)
30 - 41 N•m
(22 - 30 ft-lb)
49 - 68 N•m
(36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m
(22 - 30 ft-lb)
54 - 73 N•m
(40 - 54 ft-lb)
94 - 118 N•m
(69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m
(36 - 50 ft-lb)
79 - 108 N•m
(58 - 80 ft-lb)
157 - 186 N•m
(116 - 137 ft-lb)
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11
70-10-6 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Troubleshooting (Cont’d)
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner.  37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery
70-10-7 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation
DANGER
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
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
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.)
Disconnect the steering linkage. 
Remove the battery from the loader. (See Removal And
Installation on Page 60-20-1.)
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-3.)
Remove the air cleaner. (See Housing Removal And
Installation on Page 70-40-1.)
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Figure 70-10-2
Loosen the engine speed control cable adjustment nuts
(Item 1) and remove the engine speed control cable from
the ball pivot (Item 2). [Figure 70-10-2].
Figure 70-10-3
Disconnect engine ground cable (Item 1) and chassis
ground cable (Item 2) [Figure 70-10-3].
P-90575
1
2
P-85852
1
2
70-10-8 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation (Cont'd)
Figure 70-10-4
Disconnect engine oil pressure sender connector (Item 1)
[Figure 70-10-4].
Disconnect the alternator wiring (Item 2) [Figure 70-10-
4].
Disconnect the engine ground cable (Item 3) [Figure 70-
10-4].
Disconnect fuel shut-off solenoid connector (Item 4)
[Figure 70-10-4].
Cut cable tie (Item 5) [Figure 70-10-4].
Figure 70-10-5
Disconnect glow plug wiring (Item 1) [Figure 70-10-5].
Figure 70-10-6
Disconnect flywheel rpm sensor (Item 1) [Figure 70-10-
6].
Cut cable ties (Item 2) [Figure 70-10-6].
Disconnect the engine starter positive cable (Item 3)
[Figure 70-10-6].
Disconnect the starter wiring harness connector (Item 4)
[Figure 70-10-6].
Figure 70-10-7
Disconnect fuel line (Item 1) [Figure 70-10-10] for lift
pump and plug.
P-85849
1
3
4
2
5
P-85853
1
P-85857
3
1
4
2
P-85854
1
70-10-9 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation (Cont'd)
Figure 70-10-8
Disconnect and plug fuel return line (Item 1) [Figure 70-
10-8].
Figure 70-10-9
Disconnect coolant return line (Item 1) [Figure 70-10-
13].
Figure 70-10-10
Disconnect radiator hose (Item 1) [Figure 70-10-10].
Figure 70-10-11
Disconnect radiator hose (Item 1) [Figure 70-10-11] from
the thermostat housing.
P-85855
1
P-85895
1
P-85894
1
P-85892
1
70-10-10 S650 Service Manual
ENGINE INFORMATION (CONT’D)                  
Engine Removal And Installation (Cont'd)
Figure 70-10-12
Disconnect coolant temperature connector (Item 1)
[Figure 70-10-12] from thermostat housing.
Cap or plug all hoses and fittings.
Figure 70-10-13
Remove and cap fan inlet hose (Item 1) [Figure 70-10-
13].
Remove and cap fan outlet hose (Item 2) [Figure 70-10-
13].
Figure 70-10-14
Mark and disconnect the drive motor hoses (Item 1)
[Figure 70-10-14].
Disconnect the tandem pump case drain hose (Item 2)
[Figure 70-10-14].
Cap or plug all hoses and fittings.
NOTE: The hydraulic fittings (Item 1) [Figure 70-10-
17] on the hydrostatic pump must be
tightened to 156 - 170 N•m (115 - 125 ft-lb)
torque.
Figure 70-10-15
Disconnect tandem pump suction hoses (Item 1) [Figure
70-10-15].
Disconnect the charge pump inlet hose (Item 2) [Figure
70-10-15].
Cap or plug all hoses and fittings.
P-85893
1
P-85897
1
2
P-85909
1
1
2
P-85907
1
1
2
70-10-11 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation (Cont'd)
Figure 70-10-16
Disconnect hydraulic control valve inlet hose (Item 1)
[Figure 70-10-16].
Cap or plug all hoses and fittings.
Figure 70-10-17
Remove rear engine mounting bolt (Item 1) [Figure 70-
10-17].
Installation: Tighten the mounting bolt to 135 N•m (100
ft-lb) torque.
Figure 70-10-18
Remove the mounting bolt (Item 1) [Figure 70-10-18]
from the left engine mount.
Installation: Tighten the mounting bolt (Item 1) [Figure
70-10-18] to 135 N•m (100 ft-lb) torque.
Figure 70-10-19
Remove the mounting bolt (Item 1) [Figure 70-10-19]
from the right engine mount.
Installation: Tighten the mounting bolt to 135 N•m (100
ft-lb) torque.
P-85908
1
P-85876
1
P-85911
P-85910
70-10-12 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation (Cont'd)
Figure 70-10-20
Use the engine removal tool (MEL 1653-1) [Figure 70-
10-20] and the attachment (MEL 1653-5) [Figure 70-10-
21] to aid in the removal and installation of the engine.
Figure 70-10-21
Install the engine removal attachment (MEL1653-5)
[Figure 70-10-21] on the engine.
Figure 70-10-22
Install the engine removal attachment (Item 1) on the left
hand muffler support bracket (Item 2) [Figure 70-10-22].
Installation: Use 9,525 x 38,1mm (0.375 x 1.5 in) bolts
and nuts grade 5 minimum.
Tighten the all bolts and nuts that hold the engine
removal attachment onto the engine.
P-76872
P-85912
P-85920
1
2
70-10-13 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Removal And Installation (Cont'd)
Figure 70-10-23
Install the engine removal attachment (Item 1) on the
right hand muffler support bracket (Item 2) [Figure 70-
10-22].
Figure 70-10-24
Install the engine removal tool (Item 1) into the
attachment (Item 2) and insert the pin (Item 3) [Figure
70-10-24].
Install the chain hoist on the eyelet [Figure 70-10-24] of
the removal tool.
Remove the engine/hydrostatic pump assembly from the
loader.
P-85918
2
1
P-85919
2
3
1
70-10-14 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Mount Replacement
Figure 70-10-25
Use the following procedure to install new rear engine
mount:
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all three engine mounts one rear and two sides.
Use the parts shown to install the new engine mounts
[Figure 70-10-25]:
Hex Nut - (Item 1) 
Washer - (Item 2)
Cup Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Engine Mount - (Item 6)
Cup Washer - (Item 7)
Mounting Bolt - (Item 8)
Figure 70-10-26
Install the new engine mount as shown in the cut away
side view [Figure 70-10-27].
Tighten the mounting bolts to 135 N•m (100 f.-lb) torque.
Figure 70-10-27
Use the parts shown to install the new side engine
mounts [Figure 70-10-25].
Mounting Bolt - (Item 1) 
Cup Washer - (Item 2)
Engine Mount - (Item 3)
Tube Spacer - (Item 4)
Engine Mount - (Item 5)
Cup Washer - (Item 6)
Retaining Nut - (Item 7)
P-85989
1
2
3
4
5
6
7
8
P-90300
Washer
Engine
Mounting
Bracket
Spacer
Engine
Mount
Snubbing
Washer
Loader
Frame
P-85990A
1
2
3
4
5
6
7
70-10-15 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Engine Mount Replacement (Cont’d)
Figure 70-10-28
Install the new engine mount as shown in the cut away
side view [Figure 70-10-27].
Tighten the mounting bolts to 135 N•m (100 ft-lb) torque.
Compression - Checking
Figure 70-10-29
The tools listed will be needed to do the following
procedure:
MEL10630 - Engine Compression Kit
MEL1655 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See CYLINDER HEAD on
Page 70-80-1.)
Install the correct compression adapter (Item 1) [Figure
70-10-29] into the cylinder head.
P-85987
Washer
Engine
Mounting
Bracket
Spacer
Engine
Mount
Snubbing
Washer
Loader
Frame
P-85940
1
70-10-16 S650 Service Manual
ENGINE INFORMATION (CONT’D)
Compression - Checking (Cont’d)
Figure 70-10-30
Connect the compression gauge to the adapter [Figure
70-10-30].
Make sure the engine speed control is fully backward
(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter cranking rpm.
If the measurement is below the allowable limit, check
the cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 3,9 MPa (39,2 bar)
(569 psi)
Allowable Limit (minimum) is 2,9 MPa (29,0 bar) (421 psi)
No more than 10% variance among cylinders.
Figure 70-10-31
Push the button on the compression gauge to release
pressure [Figure 70-10-31].
Connect the fuel stop solenoid.
P-85941
P-85939
70-20-1 S650 Service Manual
ENGINE SPEED CONTROL
Removal And Installation
Figure 70-20-1
Remove the two nuts (Item 1) [Figure 70-20-1].
Figure 70-20-2
The speed control cable (Item 1) is connected to the
speed control handle (Item 2) by a ball and socket end
[Figure 70-20-2].
Disconnect the speed control cable (Item 1) from the
speed control handle (Item 2) [Figure 70-20-2].
Loosen the jam nut (Item 3) [Figure 70-20-2] from the
speed control cable.
Remove the cable from the speed control handle.
Disassembly And Assembly
Figure 70-20-3
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the handle (Item 3) [Figure 70-20-3].
Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].
Installation: Tighten the nut (Item 1) [Figure 70-20-3]
until the speed control lever moves backward and
forward at a comfortable tension.
Figure 70-20-4
Inspect and replaced any damaged parts [Figure 70-20-
4].
P-85789
2
1
P-85790
1
2
3
P-85791
2
1
3
P-85792
70-20-2 S650 Service Manual
ENGINE SPEED CONTROL (CONT’D)
Cable Removal And Installation
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the speed control lever. (See Removal And
Installation on Page 70-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 70-20-5
Remove the bolt (Item 1) [Figure 70-20-5] from the
clamp that secures the cable.
Figure 70-20-6
Remove the three bolts (Item 1) [Figure 70-20-6] from
the clamps that secure the cable.
Figure 70-20-7
Remove the bolt (Item 1) [Figure 70-20-7] from the
clamp that secures the cable.
Figure 70-20-8
The speed control cable is connected to the linkage by a
ball and socket end [Figure 70-20-8].
Loosen the jam nut (Item 1) [Figure 70-20-8] from the
speed control cable.
Disconnect the speed control cable (Item 2) from the
linkage (Item 3) by rolling the cable away from the engine
[Figure 70-20-8].
Remove the speed control cable.
P-85806
1
P-85801
1
P-85801
P-85805
1
P-90575
1
2
3
70-21-1 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12469 
AND BELOW & S/N A3NW11130 AND BELOW
Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 70-21-1
Remove the two mounting nuts (Item 1) [Figure 70-21-1]
from the right side foot rest.
Remove the foot rest from the loader.
Figure 70-21-2
Loosen the clamping bolt (Item 1) and remove the engine
speed control foot pedal (Item 2) [Figure 70-21-2].
Installation: Install the engine speed foot pedal (Item 2)
but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-21-2].
Figure 70-21-3
Remove the four bolts (Item 1) and washer (Item 2)
[Figure 70-21-3].
Lay the assembly down.
Figure 70-21-4
Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
Remove panel assembly from the loader.
P-90733
1
P-90734
1
2
P-90735
1
1
1
2
P-90754
1
1
2
2
70-21-2 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12469 
AND BELOW & S/N A3NW11130 AND BELOW 
(CONT'D)
Disassembly And Assembly 
Figure 70-21-5
Remove the spring (Item 1) from the engine speed
control foot pedal pivot assembly (Item 2) and the engine
speed control hand throttle bracket (Item 3) [Figure 70-
21-5]
Figure 70-21-6
Remove the two bolts (Item 1) [Figure 70-21-6] from the
engine speed control hand assembly.
Figure 70-21-7
Remove the nut (Item 1) and pivot bolt (Item 2) from the
engine speed control hand bracket assembly (Item 3)
[Figure 70-21-7].
Remove the engine speed control hand throttle cam lever
(Item 4) [Figure 70-21-7].
Figure 70-21-8
The pivot assembly shown disassembled [Figure 70-21-
8].
NOTE:  No lubrication is necessary or recommended
on the engine speed control.
P-90756
1
2
3
P-90755
1
P-90769
1
2
34
P-90767
70-21-3 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12469 
AND BELOW & S/N A3NW11130 AND BELOW 
(CONT'D)
Disassembly And Assembly (Cont’d)
Figure 70-21-9
Remove the snap ring (Item 1) [Figure 70-21-9] from the
engine speed control foot pedal pivot.
Figure 70-21-10
The engine speed control foot pedal pivot assembly
shown disassembled, [Figure 70-21-10] replace worn
parts as needed.
NOTE:  No lubrication is necessary or recommended
on the engine speed control.
Figure 70-21-11
The engine speed control foot pedal pivot assembly roller
bearing [Figure 70-21-11] shown disassembled.
P-90736
1
P-90771
P-90773
70-21-4 S650 Service Manual
70-22-1 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12470 
AND ABOVE & S/N A3NW11131 AND ABOVE
Removal And Installation
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 70-22-1
Remove the two mounting nuts (Item 1) [Figure 70-22-1]
from the right side foot rest.
Remove the foot rest from the loader.
Figure 70-22-2
Loosen the clamping bolt (Item 1) and remove the engine
speed control foot pedal (Item 2) [Figure 70-22-2].
Installation: Install the engine speed foot pedal (Item 2)
but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-22-2].
Figure 70-22-3
Remove the four bolts (Item 1) and washer (Item 2)
[Figure 70-22-3].
Lay the assembly down.
Figure 70-22-4
Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-22-4].
Remove panel assembly from the loader.
P-90733
1
P-90734
1
2
P-90735
1
1
1
2
P100359
1
2
2
1
70-22-2 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12470 
AND ABOVE & S/N A3NW11131 AND ABOVE 
(CONT'D)
Disassembly And Assembly 
Figure 70-22-5
Remove the spring (Item 1) from the engine speed
control foot pedal pivot assembly (Item 2) and the engine
speed control hand throttle bracket (Item 3) [Figure 70-
22-5]
Figure 70-22-6
Remove the two bolts (Item 1) [Figure 70-22-6] from the
engine speed control hand assembly.
Figure 70-22-7
Remove the nuts (Item 1) and pivot bolts (Item 2) from
the engine speed control hand bracket assembly (Item 3)
[Figure 70-22-7].
Remove the engine speed control hand throttle cam lever
(Item 4) and engine throttle cable lever Item 5) [Figure
70-22-7].
Figure 70-22-8
The pivot assemblies shown disassembled [Figure 70-
22-8].
NOTE:  No lubrication is necessary or recommended
on the engine speed control.
P100382
1
2
3
P-90755
1
P100381
3
4
1
2
5
P100380
70-22-3 S650 Service Manual
ENGINE SPEED CONTROL (SJC) S/N A3NV12470 
AND ABOVE & S/N A3NW11131 AND ABOVE 
(CONT'D)
Disassembly And Assembly (Cont’d)
Figure 70-22-9
Remove the snap ring (Item 1) [Figure 70-22-9] from the
engine speed control foot pedal pivot.
Figure 70-22-10
The engine speed control foot pedal pivot assembly
shown disassembled, [Figure 70-22-10] replace worn
parts as needed.
NOTE:  No lubrication is necessary or recommended
on the engine speed control.
Figure 70-22-11
The engine speed control foot pedal pivot assembly roller
bearing [Figure 70-22-11] shown disassembled.
P-90736
1
P100376
P100375
70-22-4 S650 Service Manual
70-30-1 S650 Service Manual
MUFFLER
Removal And Installation
Figure 70-30-1
Open the rear door and remove the rear grille and side
panels. (See Removal And Installation on Page 50-60-1.)
Remove the bolts (Item 1) from the engine cover (Item 2)
[Figure 70-30-1] and remove engine cover.
Remove the muffler mounting bolts (Item 3) [Figure 70-
30-1].
Remove exhaust manifold to muffler mounting bolts (Item
4) [Figure 70-30-1].
Remove the muffler from the loader.
Installation: Tighten the muffler mounting bolts to 43 - 47
N•m (32 - 35 ft-lb) torque.
P-85843
1
1
1
2
3
3
4
70-30-2 S650 Service Manual
70-40-1 S650 Service Manual
AIR CLEANER
Housing Removal And Installation
Open the rear door.
Figure 70-40-1
Remove the top two mounting bolts (Item 1) [Figure 70-
40-1] from the air cleaner mount bracket.
Figure 70-40-2
Remove the bottom mounting bolt (Item 1) [Figure 70-
40-2] from the air cleaner mount bracket.
Figure 70-40-3
Disconnect the wire connector (Item 1) [Figure 70-40-3]
from the air cleaner sender.
Loosen the hose clamp (Item 2) and disconnect the hose
(Items 3) [Figure 70-40-3] from the air cleaner.
NOTE: Disconnect the scavenger hose (Item 4)
[Figure 70-40-3] if equipped.
Remove the air cleaner from the loader.
P-85689
1
P-85688
1
P-85694
1
2
3
4
70-40-2 S650 Service Manual
AIR CLEANER (CONT’D)
Housing Bracket Removal And Installation
Figure 70-40-4
Remove the three bolts (Item 1) and remove the air
cleaner bracket (Item 2) [Figure 70-40-4].
P-85691
1
2
70-50-1 S650 Service Manual
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Stop the engine and open the rear door.
Remove the rear grille and side panels. (See Removal
And Installation on Page 50-60-1.)
Remove the oil cooler. (See Removal And Installation on
Page 20-90-1.)
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
Figure 70-50-1
Loosen the radiator cap (Item 1) from the pressurized
expansion tank. Disconnect and plug radiator air bleed
hose (Item 2) [Figure 70-50-1].
Figure 70-50-2
Remove hose (Item 1) [Figure 70-50-2] on the engine oil
cooler and drain the coolant into a container. 
Figure 70-50-3
Disconnect the pressurized expansion tank fill hose (Item
1), disconnect the coolant air bleed hose (Item 2) and the
radiator hose (Item 3) [Figure 70-50-3].
Remove the radiator hold down bolt (Item 4) [Figure 70-
50-3].
P-90574
2
1
P-85606
1
P-85949
1
2
3
4
70-50-2 S650 Service Manual
ENGINE COOLING SYSTEM (CONT'D)
Radiator Removal And Installation (Cont'd)
Figure 70-50-4
Disconnect the radiator hose (Item 1) and remove the
radiator hold down bolt (Item 2) [Figure 70-50-4].
Figure 70-50-5
Remove radiator hold down bolt (Item 1) [Figure 70-50-
5].
Figure 70-50-6
Remove radiator hold down bolt (Item 1) [Figure 70-50-
6].
Remove the radiator (Item 2) [Figure 70-50-6].
Lift the radiator up and remove it from the loader.
NOTE: Coolant recovery tank removed for photo
clarity
P-90555
2
1
P-85952
1
P-85954
1
2
70-50-3 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Hydraulic Fan Description
The proportioning valve meters the flow through the fan
motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors. 
The hydraulic fan is used to cool the engine and
hydraulic / hydrostatic systems. The hydraulic fan
consists of a fan and hydraulic motor that is controlled by
a proportioning valve.
NOTE: The proportioning valve is factory set and can
not be adjusted accurately in the field due to
the adjustment being tamper proof.
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpms)
can range from 0 - 4000 rpms.
The hydraulic fan speed at cold engine startup will range
from 0 to 500 rpms until the engine coolant and the
hydraulic fluid reach normal operating temperatures.
During normal operating temperatures the fan speed may
range from approximately 1900 - 3500 rpms.
70-50-4 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Hydraulic Fan Disassembly And Assembly
Figure 70-50-7
NOTE: The mounting gasket (Item 1), proportioning
valve, and proportioning valve O-rings, back
up washer and coil mounting nut (Item 2) are
available from Bobcat Parts. The fan motor
(Item 3) [Figure 70-50-7] must be replaced as
an assembly if damaged.
Remove the filter cover (Item 4) [Figure 70-50-7].
Installation: Tighten filter cover (Item 4) [Figure 70-50-
7] to 47,5 - 54 N•m (35 - 40 ft-lb) torque.
Figure 70-50-8
Remove coil mounting nut (Item 1), the coil (Item 2), and
the coil valve stem (Item 3) [Figure 70-50-8].
NOTE:  Coil mounting nut must be replaced each time
it is removed. Coil mounting nuts are
available from Bobcat Parts.
Installation: Install coil mounting nut with the
counterbored space (Item 4) [Figure 70-50-8] facing
towards the coil and tighten securely by hand. 
Installation: Tighten coil valve stem (Item 3) [Figure 70-
50-8] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Figure 70-50-9
Inspect and replace O-rings (Item 1) and back up washer
(Item 2) [Figure 70-50-9] if necessary.
Figure 70-50-10
Remove the pressure transducer (Item 1) [Figure 70-50-
10].
Installation: Tighten the pressure transducer (Item 1)
[Figure 70-50-10] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.
P-76714A
3
2
1
4
P-76716A
1
2
3
4
P-76637
1
2
P-76717
1
70-50-5 S650 Service Manual
ENGINE COOLING SYSTEM (CONT'D)
Hydraulic Fan Disassembly And Assembly (Cont’d)
Figure 70-50-11
Inspect and replace the O-ring (Item 1) [Figure 70-50-11]
if necessary.
Lower Fan Duct Removal And Installation
Figure 70-50-12
Unhook the rubber straps (Item 1) [Figure 70-50-11] and
remove lower fan duct.
Blower Housing Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Remove the air conditioning condenser if equipped. (See
Removal And Installation on Page 80-60-1.)
Remove the oil cooler. (See Removal And Installation on
Page 20-90-1.)
Remove the radiator. (See Radiator Removal And
Installation on Page 70-50-1.)
Figure 70-50-13
Remove the four bolts (Item 1)[Figure 70-50-13].
Remove the blower housing (Item 2)[Figure 70-50-13]
from the loader.
NOTE: Engine and hydraulic fan assembly removed
for photo clarity.
NOTE: Line up the bushings and bolts thru the fan
shroud 
P-76726
1
P-85470
1
P-90063
1
1
2
70-50-6 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Hydraulic Fan Motor Assembly Removal And 
Installation
Figure 70-50-14
Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-50-14].
Remove the fan case drain hose (Item 3) [Figure 70-50-
14].
Remove the charge pressure hose (Item 4) [Figure 70-
50-14].
Cap and plug all hose’s.
Disconnect the electrical connectors (Item 5) [Figure 70-
50-14].
Figure 70-50-15
Remove the four bolts (Item 1) [Figure 70-50-15].
Remove fan assembly (Item 2) [Figure 70-50-15].
Fan Removal And Installation
Figure 70-50-16
Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-16].
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
torque.
Figure 70-50-17
Remove the nut (Item 1) [Figure 70-50-17] and washer
from the motor shaft.
Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)
torque.
P-85897
1
2
5
3
5
4
P-90268
1
1
P-90313
1
1
2
P-90065
1
70-50-7 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Hydraulic Fan Motor Removal And Installation
Figure 70-50-18
Remove and discard the two nuts and cotter pins (Item 1)
[Figure 70-50-18].
Remove the two washers (Item 2) [Figure 70-50-18].
Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb)
torque.
Figure 70-50-19
Remove and discard the two bolts (Item 1) [Figure 70-
50-19] then remove motor.
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
torque.
NOTE: Always install new bolts, nuts, cotter pins,
and rubber gasket when installing the fan
motor.
Figure 70-50-20
Use the following procedure to remove the fan hub from
the fan motor shaft:
Install a bushing (Item 1) [Figure 70-50-20] in the hub to
protect the fan motor shaft and threads during removal.
Use two bolts to position a puller (Item 2) on the bushing
(Item 1) as shown [Figure 70-50-20].
NOTE: If a puller is not available one can be made if
needed to remove the hub from the shaft.
Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.
P-90069
1
2
2
P-90076
1
P-90062
70-50-8 S650 Service Manual
ENGINE COOLING SYSTEM (CONT'D)
Water Pump Removal And Installation
Drain the cooling system.
Remove the alternator belt.
Remove the water pump bolts.
Figure 70-50-21
Remove the water pump (Item 1) [Figure 70-50-21].
Installation: Always use a new gasket (Item 2) [Figure
70-50-21] when installing the water pump.
Water Pump Disassembly And Assembly
Figure 70-50-22
Remove the flange (Item 1) [Figure 70-50-22].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-
50-22] out the impeller side of the water pump.
Remove the impeller (Item 3) [Figure 70-50-22] from the
shaft.
Remove the seal (Item 4) [Figure 70-50-22].
Install a new seal (Item 4) [Figure 70-50-22] when
assembling the water pump.
P-90018
1
2
P-90019
1
2
3
4
70-50-9 S650 Service Manual
ENGINE COOLING SYSTEM (CONT'D)
Thermostat Housing Removal And Installation 
Figure 70-50-23
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-23].
Remove bolts (Item 5), housing (Item 6), and gasket
(Item 7) from the cylinder head [Figure 70-50-23].
P-90166
1
2
3
4
5
7
6
70-50-10 S650 Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Checking
Figure 70-50-24
Push down the thermostat valve and insert a string
between the valve and the valve seat.
Place the thermostat and a thermometer in a container
with water and gradually heat the water [Figure 70-50-
24].
Hold the string to suspend the thermostat in the water.
When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature
when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the
thermostat.
Thermostat’s valve 
opening tempera-
ture
Factory spec. 74,5 - 78,5°C
166.1 - 173°F
Temperature at 
which thermostat 
completely opens
Factory spec. 90°C
194°F
P-37172
70-60-1 S650 Service Manual
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Remove the engine and hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-7.)
The engine will have to be on an engine stand or
suspended in the air safely to remove the oil pan.
Figure 70-60-1
Remove oil pan bolts (Item 1) securing oil pan (Item 2)
[Figure 70-60-2]. Slightly tapping on the oil pan with a
soft mallet will break loose the oil pan from the engine
block.
Installation: Use a liquid gasket adhesive to the oil pan
side of the oil pan gasket. Tighten oil pan bolts to 39 - 75
N•m (29 - 33 ft-lb) torque.
Figure 70-60-2
Remove the oil strainer (Item 1) and O-ring (Item 2)
[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.
Oil Pump Removal And Installation
Figure 70-60-3
Remove the bolts from the front cover / oil pump (Item 1)
[Figure 70-60-3].
Installation: Use a liquid gasket adhesive.Tighten the
front cover / oil pump mounting bolts to 24 - 27 N•m (18 -
20 ft-lb) torque.
P-85062
1
2
P-85056
1
2
P-85061
1
70-60-2 S650 Service Manual
LUBRICATION SYSTEM (CONT’D)
Relief Valve - Testing
Figure 70-60-4
Remove the relief valve retaining screw (Item 1) from the
front cover / oil pump (Item 2) and remove the relief valve
spring (Item 3) and relief valve (Item 4) [Figure 70-60-4].
Measure free length of relief valve spring (Item 3) [Figure
70-60-4] and check the entire surface of spring for any
scratches. Replace if out of spec or any scratches.
Installation: Tighten relief valve retaining screw (Item 1)
[Figure 70-60-4] 69 - 78 N•m (51 - 57 ft-lb) torque.
Oil Pump Inspection
Figure 70-60-5
Remove oil pump cover screws. Measure the clearance
between the lobes of the inner rotor and outer rotor
[Figure 70-60-5].
Installation: Tighten cover screws to 7,9 - 9,3 N•m (5.8 -
6.8 ft-lb)
If the clearance exceeds the allowable limit, replace the
oil pump.
Figure 70-60-6
Measure the clearance between the outer rotor and
pump body [Figure 70-60-6].
If the clearance exceeds the allowable limit, replace the
oil pump.
Free Length 60,0 - 60,5 mm
(2.37 - 2.38 in)
Allowable Limit 55,0 mm (2.17 in)
P-85057
1
2
4
3
P-85058
Clearance 
Between Inner & 
Outer Rotor
0,030 - 0,090 mm
(0.0012 - 0.0035 in)
Allowable limit 0,30 mm (0.012 in.)
Clearance 
Between Outer 
Rotor & Body
0,100 - 0,184 mm
(0.00394 - 0.00724 in)
Allowable limit 0,30 mm (0.012 in)
P-85059
70-60-3 S650 Service Manual
LUBRICATION SYSTEM (CONT’D)
Oil Pump Inspection (Cont’d)
Figure 70-60-7
Put a piece of press gauge on the rotor face [Figure 70-
60-7].
Install the cover and tighten the bolts.
Remove the cover carefully. Measure the width of the
press gauge [Figure 70-60-7].
If the clearance exceeds the allowable limit replace the
oil pump.
Oil Filter Cooler Removal And Installation
Figure 70-60-8
Remove the cooling hose’s (Item 1) [Figure 70-60-8].
Remove oil filter cartridge (Item 2) and the oil cooler joint
screw (Item 3) [Figure 70-60-8].
Remove oil cooler (Item 4) [Figure 70-60-8].
Installation: Tighten oil cooler joint screw (Item 3)
[Figure 70-60-8] 64 - 73 N•m (47 - 54 ft-lb) torque.
End Clearance 0,25 - 0,75 mm
(0.00099 - 0.0029 in)
Allowable limit 0,225 mm (0.00886 in)
P-85060
P-85072
1
2
3
4
70-60-4 S650 Service Manual
LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-9
Install a pressure gauge [Figure 70-60-9].
Start the engine and run until it is at operating
temperature.
If the oil pressure is less than the allowable limit, check
the following items:
* Engine Oil Level Low
* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable 
Limit 
48,3 kPa (0.49 bar) (7 psi)
At Rated Speed 193,0 - 393,0 kPa 
(1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit         144,8 kPa (1,4 bar) (21 psi)
PI-10010
70-70-1 S650 Service Manual
FUEL SYSTEM
Fuel Shutoff Solenoid - Checking
Figure 70-70-1
Stop the engine and open the rear door [Figure 70-70-1].
Disconnect the connector (Item 1) [Figure 70-70-1] from
the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2
The reading between electrical connector terminal C and
terminal A must be between approximately 0.33 ohm
[Figure 70-70-2].
The reading between electrical connector terminal C and
terminal B must be between approximately 24.5 ohm.
Fuel Shutoff Solenoid Removal And Installation
Figure 70-70-3
Stop the engine and open the rear door.
Disconnect the connector (Item 1) [Figure 70-70-3].
Figure 70-70-4
Remove the mounting screws (Item 1) [Figure 70-70-4]
of the fuel shutoff solenoid.
Reverse the above procedure to install the fuel shutoff
solenoid.
P-85956
1
P-85955
P-85956
1
P-85957
1
70-70-2 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump - Checking
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on
the performance of the engine.
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
The tools listed will be needed to do the following
procedure:
MEL 1237 - Adapter Fuel Line
MEL 1173-1 Pressure Gauge
To check the discharge pressure at the fuel injection
pump, use the following procedure:
Disconnect a high pressure fuel line from the injection
pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 70-70-5
Connect the adapter fuel line (Item 1) to the fitting and
connect the pressure gauge (Item 2) [Figure 70-70-5].
Move the speed control lever to the high engine idle
position.
Turn the flywheel to increase the pressure. If the
pressure can not reach the allowable limit, replace the
injection pump assembly.
With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 18,6
MPa (186,3 bar) (2702 psi).
Turn the flywheel back approximately one-half turn. Keep
the flywheel at this position, and measure the time it
takes the pressure to decrease from 17,7 MPa (176,5
bar) (2560 psi).
B-8235
2
1
Fuel Tightness of Pump 
Element Allowable Limit
18,6 MPa
(186,3 bar) (2702 psi)
Fuel Tightness of Delivery 
Valve Allowable Limit
5 Seconds
70-70-3 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump Assembly Removal And 
Installation 
Remove the alternator. (See Removal And Installation on
Page 60-30-5.)
Figure 70-70-6
Clean the area around the injection pump thoroughly.
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-6] from the fuel injectors.
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-7
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-7] from the injection pump
vent.
Cap the inlets on the injection pump vent where the
hoses were removed [Figure 70-70-7].
.
Figure 70-70-8
Remove the high pressure fuel lines (Item 1) [Figure 70-
70-8] from the injection pump.
Remove the engine speed control linkage (Item 2)
[Figure 70-70-8].
P-85085
1
1
P-85082
1
2
P-85082
1
2
70-70-4 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump Assembly Removal And 
Installation (Cont'd)
Figure 70-70-9
Remove the window cover for the fuel injection pump
assembly (Item 1) [Figure 70-70-9] from the flywheel
housing.
Figure 70-70-10
Place the number four piston at top dead center on the
compression stroke and lock the flywheel in place using
the flywheel stopper tool as described below.
Look for the alignment mark on the idler gear and
injection pump gear (Item 1)[Figure 70-70-10] then using
a white marking pen or the like put a alignment mark to
help reassemble these gears in mesh later. 
NOTE: When the already existing marks align with
each other, there is no need to put another
alignment mark.
Figure 70-70-11
Make flywheel stop tool as shown above in [Figure 70-
70-11].
Figure 70-70-12
Construct two fuel camshaft lock screws as shown above
[Figure 70-70-12]
P-85095
1
P-85094
1
A 144 mm (5.67 in)
B 104 mm (4.09 in)
C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
E 12,0 mm dia. (0.472 in dia.)
F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
I 16,0 mm (0.630 in)
P-85215
P-85091
M8 X 1.25
5,0mm 
(0.20 in) dia
0,79 rad
1
0mm (0.39 in)
5,0mm (0.20 in)
4,0mm (0.16 in)
45mm (1.8 in)
70-70-5 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump Assembly Removal And 
Installation (Cont'd)
Figure 70-70-13
Remove the two plugs (Item 1) [Figure 70-70-13].
Installation: Tighten the plugs to 9,81 - 11,2 N•m (7.24 -
8.31 ft-lb) torque.
Figure 70-70-14
Install one lock tool in the upper plug opening (Item 1)
and tighten until it comes in contact with the fuel
camshaft. Make sure the fuel camshaft is not moving.
Install second lock tool in lower opening (Item 1) [Figure
70-70-14] and repeat the process. 
NOTE: Do not over tighten the lock screws after they
have contacted the fuel camshaft. Otherwise
the injection pump may become damaged.
Figure 70-70-15
Remove the lubricating oil pipe (Item 1) [Figure 70-70-
15].
Remove the three injection pump mounting nuts (Item 2)
[Figure 70-70-15]
Installation: Tighten the lubricating oil pipe to 16 - 19
N•m (12 - 14 ft-lb) torque.
Installation: Tighten the injection pump mounting nuts to
18 - 20 N•m (13 - 15 ft-lb) torque.
Figure 70-70-16
Remove injection pump support (Item 1) [Figure 70-70-
16].
Remove injection pump assembly (Item 2) [Figure 70-
70-16].
P-85095
1
P-85090
1
P-85093
1
2
P-85095
1
2
70-70-6 S650 Service Manual
FUEL SYSTEM (CONT'D)
Governor Housing Disassembly And Assembly
The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the engine load.
Disassemble and assemble the governor and fuel
camshaft as shown in figure.
Check all the parts for wear or damage and replace as
needed.
Figure 70-70-17
Jig for Governor Connecting Rod
Application: Use this tool for connecting the governor
connecting rod to the rack pin of the fuel injection pump
assembly.
Make the tool as shown in figure [Figure 70-70-17] or
purchase part number below to connect the governor
connecting rod to the rack pin of the fuel injection pump.
MEL1667 - Jig for Governor Connecting Rod
(Item 1) [Figure 70-70-17] Material: S43C-D
(Item 2) [Figure 70-70-17] Permanent Magnet: 8 mm
dia. (0.31 in dia.) Thickness: 3 mm (0.12 in)
A 0,50 mm (0.020 in)
B 12,7 - 13,0 mm (0.500 - 0.511 in)
C 8,70 - 9,00 mm (0.343 - 0.354 in)
D 39 mm dia (1.54 in dia.)
E 10,0 ‘mm (0.394 in)
F 7,0 mm (0.28 in)
G 6,0 mm (0.24 in)
H 80,0 mm (3.15 in)
I 27,95 - 28,05 mm (1.101 - 1.104 in)
J 5,0 mm (0.20 in)
K 3,000 - 3,010 mm dia, 6,0 mm depth
(0.1182 - 0.1185 in dia, 0.24 in depth)
L 9,0 mm (0.35 in)
M 5,0 mm (0.020 in)
N 14,45 - 14,55 mm (0.5689 - 0.5728 in)
O 5,0 mm (0.020 in)
P 4,0 mm (0.16 in)
P-85182
Q 2,955 - 2,965 mm dia.
(0.1164 - 0.1167 in dia.)
R 3,020 - 3,030 mm dia.
(0.1189 - 0.1192 in dia.)
S Ra = 1.6a
AA Governor housing side
BB Press in side
a 0,60 mm radius (0.024 in radius)
b 1,0 mm radius (0.039 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.4 Chamfer 0,40 mm (0.016 in)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in)
C2 Chamfer 2,0 mm (0.079 in)
70-70-7 S650 Service Manual
FUEL SYSTEM (CONT’D)
Governor Housing Disassembly And Assembly 
(Cont’d)
Figure 70-70-18
Remove the fuel injection pump assembly. (See Fuel
Injection Pump Assembly Removal And Installation on
Page 70-70-3.)
Remove the governor lubricating pipe (Item 1) [Figure
70-70-18].
Remove the stop solenoid (Item 2) [Figure 70-70-18].
Remove the sight cover (Item 3) [Figure 70-70-18] from
the injection pump unit.
Figure 70-70-19
Unhook the start spring (Item 1) from the rack pin (Item
2) [Figure 70-70-19] of injection pump assembly.
Remove the nut (Item 3) [Figure 70-70-19].
Installation: Reverse procedure to install. Tighten the
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: Be careful not to drop the nut inside.
NOTE: (See Fuel Injection Pump Removal And
Installation on Page 70-70-12.) for proper
alignment of the governor connection rod
procedure. The procedure will require a
special tool as shown on page 70-70-6.
Figure 70-70-20
Slide off the governor connecting rod (Item 1) [Figure 70-
70-19] from the rack pin of injection pump assembly.
For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod.
Remove the governor housing mounting bolts.
Installation: Tighten the governor housing bolts to 9,81 -
11,2 N•m (7.24 - 8.31 ft-lb) torque.
Figure 70-70-21
Remove the governor housing assembly (Item 1) [Figure
70-70-21] from the injection pump unit.
NOTE: The injection pump unit is lubricated with
engine oil. Oil will leak when the governor
housing is removed from the injection pump.
P-85095
3
2
1
P-85099
1
2
3
P-85100
1
P-85097
1
70-70-8 S650 Service Manual
FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly
Figure 70-70-22
Remove the governor fork shaft lever (Item 1) using a
bolt 4 mm dia. (0.16 in dia.), pitch 0,7 mm (0.03 in) at
least a inch long (Item 2) [Figure 70-70-22].
NOTE: When assembling the inside parts, lightly put
oil on each inside part.
Figure 70-70-23
Unhook the governor spring (Item 1) at the fork lever
(Item 2) [Figure 70-70-23].
Figure 70-70-24
Remove the governor fork lever assembly (Item 1) from
the housing [Figure 70-70-24].
Figure 70-70-25
Remove the spring pin (Item 1), then remove speed
control lever (Item 2) and the return spring (Item 3)
[Figure 70-70-25].
P-85101
1
2
P-85188
1
2
P-85189
1
P-8519
0
1
2
3
70-70-9 S650 Service Manual
FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly (Cont’d)
Figure 70-70-26
Remove the start spring (Item 1) [Figure 70-70-26] from
the governor housing.
After reassembling the governor housing assembly,
check the movement of the governor fork lever (Item 2),
the speed control lever, stop lever, governor spring (Item
3) and governor fork lever shaft (item 4) [Figure 70-70-
26].
NOTE: When assembling the inside parts, lightly put
oil on each inside part.
NOTE: Be careful not to deform the start spring.
.
P-85192
1
70-70-10 S650 Service Manual
FUEL SYSTEM (CONT’D)
Fuel Camshaft Removal And Installation
Remove the fuel injection pump assembly. (See Fuel
Injection Pump Assembly Removal And Installation on
Page 70-70-3.)
Remove the fuel injection pump unit. (See Fuel Injection
Pump Assembly Removal And Installation on Page 70-
70-3.)
WARNING
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and
clothing. Failure to wear eye and body protection can
result in serious injury.
W-2009-1285
Figure 70-70-27
To remove and replace the fuel camshaft, make the tool
as shown in figure [Figure 70-70-27] or purchase part
number below.
MEL1666  - Injection Pump Gear Puller 
P-85123
A M35 x P1.5, 6,0 mm depth (0.24 in depth)
B 35,0 mm dia.,12,0 mm depth
(1.38 in dia., 0.472 in depth)
C 30,0 mm dia.,27,5 mm depth
(1.18 in dia., 1.08 in depth)
D 40,00 - 40,20 mm dia. (1.575 - 1.582 in dia.)
E 35,90 - 36,10 mm dia. (1.414 - 1.421 in dia.)
F 2.09 rad (120 degrees)
GM8 x P1.25
H 9,0 mm dia (0.35 in dia.)
I 19,0 mm dia. (0.748 in dia.)
J 12,0 mm (0.472 in)
K 15,0 mm (0.591 in)
L 27,5 mm (1.08 in)
M 31,0 mm (1.22 in)
N 2.26 in. (57,5 mm)
O 3.94 in. (100 mm)
P 3,75 - 4,00 mm (0.148 - 0.157 in)
Q 16,17 mm (0.6366 in)
a 5,0 mm radius (0.20 in radius)
b 0,40 mm radius (0.016 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.5 Chamfer 0,50 mm (0.020 in)
70-70-11 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Camshaft Removal And Installation (Cont’d)
Figure 70-70-28
Remove the governor sleeve (Item 1) and remove the
two fuel camshaft lock allen screws (Item 2) [Figure 70-
70-28].
NOTE: Do not use the fuel camshaft locks screws
when removing governor weight, otherwise
damage may occur to the allen screws or the
governor housing.
Figure 70-70-29
Make flywheel stop tool as shown above in [Figure 70-
70-29].
Figure 70-70-30
Install injection pump housing to the engine and tighten.
Fix the flywheel with the flywheel stop tool (Item 1)
[Figure 70-70-32].
Loosen the injection pump gear mounting nut (Item 2)
[Figure 70-70-32].
Installation: Tighten injection pump gear mounting nut to
138 - 156 N•m (102 - 115 ft-lb).
NOTE: The injection pump gear mounting nut is a left
hand thread to loosen turn towards B and to
tighten turn towards A as seen from the
flywheel side
Figure 70-70-31
Remove the fuel injection pump gear (Item 1) using the
tool (Item 2) [Figure 70-70-31].
A 144 mm (5.67 in)
B 104 mm (4.09 in)
C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
E 12,0 mm dia. (0.472 in dia.)
P-85186A
1
2
P-85215
F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
I 16,0 mm (0.630 in)
P-85183
1
2
P-85121
2
1
70-70-12 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Camshaft Removal And Installation (Cont’d)
Figure 70-70-32
Loosen fuel camshaft stopper mounting bolts (Item 1)
and remove camshaft stopper (Item 2) [Figure 70-70-
32].
Installation: Tighten fuel camshaft stopper mounting
bolts to 9,81 - 11,2 N•m (7.24 - 8.37 ft-lb).
NOTE: When reassembling fuel camshaft stopper
make sure the oil path hole (Item 3) [Figure 70-
70-32] is the proper alignment. 
Figure 70-70-33
Remove fuel camshaft (Item 1), then remove fuel
camshaft stopper bearing screws (Item 2) [Figure 70-70-
33].
If replacing the fuel camshaft bearings tighten the fuel
camshaft stopper bearing plate screws (item 2) [Figure
70-70-33] to 3,9 - 4,2 N•m (2.9 - 3.1 ft-lb) torque.
Fuel Injection Pump Removal And Installation 
Figure 70-70-34
Remove all injection pipes (Item 1) [Figure 70-70-34].
Remove overflow hose (Item 2) [Figure 70-70-34].
Remove fuel stop solenoid (Item 3) [Figure 70-70-34].
Remove sight cover from housing (Item 4) [Figure 70-
70-34].
NOTE: The injection pump can be removed and
installed with the crankshaft at any position.
Figure 70-70-35
Unhook the start spring (Item 1) from the rack pin (Item 2)
[Figure 70-70-35] of injection pump assembly.
Remove the nut (Item 3) [Figure 70-70-35].
Installation: Reverse procedure to install. Tighten the
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: Be careful not to drop the nut inside.
P-85122
2
1
3
P-85120
1
2
P-85199
1
1
1
2
P-85099
1
2
3
70-70-13 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump Removal And Installation 
(Cont’d)
Figure 70-70-36
Slide off the governor connecting rod (Item 1) [Figure 70-
70-36] from the rack pin of injection pump assembly.
For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod.
Figure 70-70-37
Remove all of the mounting bolts and nuts (Item 1)
[Figure 70-70-37] from the fuel injection pump.
Figure 70-70-38
Remove the fuel injection pump (Item 1) [Figure 70-70-
38].
Installation: Reverse procedure to install. Tighten the
bolts to 24 - 27 N•m (18 - 20 ft-lb) torque.Tighten nuts to
18 - 20 N•m (13 - 15 ft-lb)
Remove top cover (Item 2) [Figure 70-70-38] for
adjusting the governor connecting rod.
Figure 70-70-39
Hook the governor connecting rod (Item 1) to the rack pin
(Item 2) and hand tighten the nut (Item 3) [Figure 70-70-
39].
Place service jig (Item 4) (Refer to page 70-70-6) in place
of top cover and make sure the magnet is contacting the
governor connecting rod (Item 1) [Figure 70-70-39].
Holding down the service jig tighten the nut to specified
torque. 
Hook starter spring (Item 5) to rack pin (Item 2) [Figure
70-70-39].
Installation: Tighten the nut (Item 3) [Figure 70-70-39]
to 2,9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: A = 27,95 - 28,05 mm (1.100 - 1.104 in)
P-85100
1
P-85198
1
P-85200
1
2
P-85203
1
2
3
4
5
70-70-14 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injection Pump - Timing 
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Remove fuel injection high pressure lines.
Remove the fuel shutoff solenoid. (See Fuel Shutoff
Solenoid Removal And Installation on Page 70-70-1.)
Figure 70-70-40
Align timing mark between the injection pump assembly
and the flywheel housing (Item 1) [Figure 70-70-40].
NOTE: Timing the injection pump is done by rotating
the injection pump assembly up for advance,
down for retard.
Figure 70-70-41
Rotate the flywheel counterclockwise (viewed from the
flywheel side) until fuel fills up the hole of the delivery
valve holder for the number one cylinder as shown in
[Figure 70-70-41] below.
Figure 70-70-42
After fuel fills up the hole of the number one cylinder
delivery valve holder (Item 1) [Figure 70-70-42] turn
back the flywheel clockwise 1,6 rad (90°) then turn
counterclockwise to 0,17 rad (10°) before top dead
center.
Slowly turn the flywheel counterclockwise and stop
turning when the fuel begins to come up to get the
present injection timing (Item 1) [Figure 70-70-42].
P-85102
1
P-85104
P-85098
70-70-15 S650 Service Manual
FUEL SYSTEM (CONT'D)
Injection Pump - Timing (Cont’d)
Figure 70-70-43
Check to see the degree marks on the flywheel (Item 1)
[Figure 70-70-43]. The flywheel has a 1TC mark for the
crank angle before the top dead center of cylinder
number one. 
NOTE: If the injection pump timing is not within the
specification, then rotate the injection pump
assembly upwards for advancing, downwards
for retarding injection pump timing. 
The injection timing is 0,00960 - 0,0357 rad. (0.550 -
2.05°) before T.D.C.
Fuel Injector Removal And Installation
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
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
P-85103
1
70-70-16 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injector Removal And Installation (Cont’d)
Figure 70-70-44
The following are some problems caused by faulty
injectors:
-Engine is hard to start or will not start
-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-44] from the fuel injectors and from the injection
pump.
Remove the high pressure fuel lines from the engine.
Remove the glow plugs. (See Glow Plugs Removal And
Installation on Page 70-80-1.)
Remove the cylinder head valve cover (See Cylinder
Head Removal And Installation on Page 70-80-4.)
Figure 70-70-45
Remove the overflow pipe (Item 1) [Figure 70-70-45].
Installation: Tighten the overflow pipe assembly
retaining screws to 9,81 - 11,2 N•m (7.24 - 8.31 ft-lb)
torque.
Figure 70-70-46
Remove the nozzle holder clamps (Item 1) [Figure 70-
70-46].
Installation: Tighten the nozzle holder clamp screws to
24 - 27 N•m (18 - 20 ft-lb) torque.
P-85085
1
P-85117
1
P-85118
1
70-70-17 S650 Service Manual
FUEL SYSTEM (CONT'D)
Fuel Injector Removal And Installation (Cont’d)
Figure 70-70-47
Remove the injector nozzle (Item 1) [Figure 70-70-47]
from the cylinder head.
Pull on the injector nozzle to remove the injector nozzle
from the cylinder head.
Figure 70-70-48
[Figure 70-70-48] shows the injector nozzle removed
from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)
and the nozzle washer (Item 2) before installing new or
used injectors. [Figure 70-70-48]. 
Fuel Injector Nozzle Pressure - Checking
The tool listed will be needed to do the following
procedure:
OEM1064 - Injector Nozzle Tester
Figure 70-70-49
Set the injection nozzle to the nozzle tester.
Slowly move the tester handle to measure the pressure
at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory
specifications, replace or repair the injection nozzle
assembly.
NOTE: Injection nozzle gasket must be replaced
when the injection nozzle is removed for
checking.
P-85119
1
P-37583
2
1
Injection 
pressure
Factory 
spec.
18,6 -19,6 MPa
(186,4 - 96 bar)
(2703 - 2844 psi)
3EEABAC1P012A
70-70-18 S650 Service Manual
FUEL SYSTEM (CONT'D)
Nozzle Spray Condition
The tool listed will be needed to do the following
procedure:
OEM1064 - Injector Nozzle Tester
Figure 70-70-50
Set the injection nozzle to a nozzle tester, and check the
nozzle spraying condition.
If the spraying condition is defective, replace or repair the
injection nozzle assembly. 
Valve Seat Tightness
The tool listed will be needed to do the following
procedure:
OEM1064 - Injector Nozzle Tester
Figure 70-70-51
Set the injection nozzle to a nozzle tester.
Raise the fuel pressure, and keep at 16,7 MPa (166,7
bar) (2418 psi) for 10 seconds.
If any fuel leak is found, replace or repair the injection
nozzle assembly.
3EEABAC1P013A
Correc
t
Incorrec
t
Valve seat tightness Factory spec No fuel leak at 
16,7 MPa 
(166,7 bar) 
(2418 psi)
3EEABAC1P014A
70-80-1 S650 Service Manual
CYLINDER HEAD
Glow Plugs - Testing
Figure 70-80-1
Disconnect the glow plug nuts (Item 1), remove glow plug
connecting strap (Item 2) and glow plugs (Item 3) [Figure
70-80-1].
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Figure 70-80-2
Touch one probe to the end of the glow plug (Item 1) and
the other probe to the body of glow plug (Item 2) [Figure
70-80-2].
Use an ohmmeter to check the glow plugs.The
resistance should be approximately one ohm.
Repeat the procedure for each glow plug.
NOTE: Adjust the direction of the ditch (Item 3)
[Figure 70-80-2] to the terminal side when the
seal is installed on the glow plug.
Glow Plugs Removal And Installation
Figure 70-80-3
Disconnect the glow plug nuts (Item 1),remove glow plug
connecting strap (Item 2) and glow plugs (Item 3) [Figure
70-80-3].
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Figure 70-80-4
NOTE: Adjust the direction of the ditch (Item 1)
[Figure 70-80-4] to the terminal side when the
seal is installed on the glow plug.
P-85178
1
2
3
P-85179
1
2
3
P-85178
1
2
3
P-85179
1
70-80-2 S650 Service Manual
CYLINDER HEAD (CONT'D)
Glow Plugs Removal And Installation (Cont’d)
Figure 70-80-5
Photo  [Figure 70-80-5] shows the glow plug removed
from the engine. Inspect the glow plugs and replace
when necessary.
Valve Clearance Adjustment
Figure 70-80-6
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 70-80-6].
Turn the adjustment screw (Item 2) [Figure 70-80-6] until
the correct clearance is obtained.
NOTE: The clearance is measured between the
rocker arm and bridge head (Item 3) [Figure
70-80-6].
P-48708
P-85181
2
1
3
70-80-3 S650 Service Manual
CYLINDER HEAD (CONT'D)
Valve Clearance Adjustment (Cont’d) 
Figure 70-80-7
NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Figure 70-80-8
Adjust the valve clearance cold as follows:
0,13 - 0,17 mm (0.0052 - 0.0068 in) Intake & Exhaust
Use the following sequence to set the valves [Figure 70-
80-7] & [Figure 70-80-8]:
1. With the No. 1 cylinder set at compression top dead
center set valves 1,2,3 and 6.
2. With the No. 1 cylinder at overlap position set valves
4,5,7 and 8.
Valve Timing - Checking
Figure 70-80-9
Stop the engine and open the rear door.
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
70-10-7.)
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-120-1.)
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
Make sure timing marks are in correct alignment [Figure
70-80-9].
Injection Pump Gear (Item 1) [Figure 70-80-9].
Idle Gear (Item 2) [Figure 70-80-9].
Crank Gear (Item 3) [Figure 70-80-9].
Cam Gear (Item 4) [Figure 70-80-9].
B-05569
8
7
6
5
4 3
2
1
12
3
4
B
A
III IEEE E
1
23
45 678
1234
Cylinder Number
Valve Number
Valve
I=Intake
E=Exhaust
P-85974
2
4
1
3
70-80-4 S650 Service Manual
CYLINDER HEAD (CONT'D)
Cylinder Head Removal And Installation
Figure 70-80-10
Remove the glow plug connecting strap (Item 1), glow
plugs (Item 2), and injection pipes (Item 3) [Figure 70-
80-10].
Remove the valve cover (Item 4) [Figure 70-80-10] and
gasket.
Installation:  Gradually tighten the valve cover bolts to
9,81 - 11,2 N•m (7 - 8 ft-lb) torque. Tighten center bolts
first, then work your way to the front and back of the
valve cover. 
Installation: Tighten injection pipe retaining nuts to 23 -
36 N•m (17 -    26 ft-lb) torque.
Installation: Tighten glow plugs to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Figure 70-80-11
Remove the overflow pipe (Item 1) [Figure 70-80-11].
Installation: Tighten overflow pipe to 9,81 - 11,2 N•m (7 -
8 ft-lb) torque.
Figure 70-80-12
Remove the nozzle holder clamps (Item 1) [Figure 70-
80-12].
Installation: Tighten the nozzle holder clamp bolts to 24
- 27 N•m (18 - 20 ft-lb) torque.
Figure 70-80-13
Remove the nozzle holder assembles and nozzle
gaskets (Item 1) [Figure 70-80-12].
Installation: Tighten the nozzle holder clamp bolts to 24
- 27 N•m (18 - 20 ft-lb) torque.
P-85174
2
3
4
1
P-85117
1
P-85118
1
P-85119
1
70-80-5 S650 Service Manual
CYLINDER HEAD (CONT'D)
Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-14
Remove rocker arm assembly (Item 1)[Figure 70-80-14]
as a unit.
Remove push rods (Item 2) and bridge arms (Item 3)
[Figure 70-80-14].
Figure 70-80-15
Installation: The push rod (Item 1) must be seated in the
tappet (Item 2) [Figure 70-80-15] correctly or the push
rods will be damaged.
After installing the rocker arm assembly and push rods,
the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 70-80-2.)
Figure 70-80-16
Remove the thermostat housing bolts and then remove
the housing (Item 1), gasket (Item 2) and thermostat
(Item 3) [Figure 70-80-16].
Figure 70-80-17
Remove the cylinder head bolts in order of #10 to #1
[Figure 70-80-17].
NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence in order of #1 - #10 to 187 - 196
N•m (138 - 144 ft-lb).
NOTE: It is not necessary to retighten the cylinder
head bolts after the engine has been run for 30
minutes.
P-85115
1
2
3
P-47245
1
2
P-85170
1
2
3
P-85168
70-80-6 S650 Service Manual
CYLINDER HEAD (CONT'D)
Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-18
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-18].
Figure 70-80-19
When replacing just the head gasket (Item 1), use a new
gasket that has the same mark (Item 2) [Figure 70-80-
19] as the original gasket.
When replacing the gasket after an engine rebuild, the
piston protrusion must be measured.
(See Cylinder Head Top Clearance on Page 70-80-8.)
NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Figure 70-80-20
Find the average measurement of the highest piston
protrusion and the lowest piston protrusion (recorded
earlier) for each piston (Item 1) [Figure 70-80-20].
Figure 70-80-21
When identifying which head gasket you need   [Figure
70-80-21] shows the correct number of notches and how
they should look (a) 2 notches, (b) 1 notch and (c) no
notch.
Figure 70-80-22
Select the correct gasket size (thickness) from the chart
[Figure 70-80-22].
After the gasket and cylinder head have been installed,
turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
P-85171
2
1
P-85968
A
B
1
2
P-47252
1
P-85967
a b c
Gasket Size
(Number)
Piston Protrusion
0,2500 - 0,3425 mm
0.009843 - 0.01348 in
0,0775 - 0,150 mm
0.00306 - 0.00590 in
0,150 - 0,250 mm
0.00591 - 0.00984 in
1 notch
2 notches
no notches
70-80-7 S650 Service Manual
CYLINDER HEAD (CONT'D)
Cylinder Head Disassembly And Assembly 
Figure 70-80-23
Use a valve spring compressor to compress the valve
spring [Figure 70-80-23].
Figure 70-80-24
Remove the valve cap (Item 1) and valve spring collet
(Item 2) [Figure 70-80-23] and [Figure 70-80-24].
Remove the valve spring retainer (Item 3) and the spring
(Item 4) [Figure 70-80-23] and [Figure 70-80-24].
Remove the seal (Item 6) and the valve (Item 5) [Figure
70-80-23] and [Figure 70-80-24].
Cylinder Head - Servicing
Clean the surface of the cylinder head.
Figure 70-80-25
Put a straight edge (Item 1) [Figure 70-80-25] on the
cylinder head.
NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-25] between
the straight edge and the surface of the cylinder head.
Figure 70-80-26
Put the straight edge on the cylinder head's four sides
and two diagonal as shown in figure [Figure 70-80-26].
The maximum distortion of the head surface is ± 0,05
mm (± 0.002 in). If the measurement exceeds the
specification, replace the cylinder head.
PI-9987
B-4122C
5
4
3
6
2
1
Cap
Collets
Seal
Retainer
Spring
Valve
P-51629
1
2
PI-9988
70-80-8 S650 Service Manual
CYLINDER HEAD (CONT'D)
Cylinder Head Top Clearance
Figure 70-80-27
Install the cylinder head gasket. Put the piston (Item 1)
[Figure 70-80-27] being checked at T.D.C.
Put 4 pieces of 1,5 mm (0.06 in) diameter solder (Item 2)
[Figure 70-80-27] on the top of the piston. Use grease to
hold them in position.
NOTE:  Put the solder in position so they do not touch
the valves.
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-80-4.)
Turn the crankshaft until the piston exceeds T.D.C.
Remove the cylinder head.
Figure 70-80-28
Remove the solder (Item 1) [Figure 70-80-28] and
measure it.
If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin.
Valve Guide - Checking
Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
70-80-7.)
Remove the carbon from the valve guide.
Figure 70-80-29
Measure the valve stem O.D. (Item 1) [Figure 70-80-29].
Measure the valve guide I.D. (Item 2) [Figure 70-80-29].
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
P-85172
2
1
P-85173
1
Top Clearance 0,6 - 0,8 mm (0.024 - 0.031 in)
Valve Guide I.D. 7,030 - 7,045 mm
(0.2768 - 0.2773 in)
Valve Stem O.D. 6,960 - 6,975 mm
(0.2741 - 0.2746 in)
Clearance Between 
Valve Stem and Guide
0,055 - 0,085 mm
(0.0022- 0.0033 in)
Allowable Limit 0,10 mm
(0.0039 in)
B-14335
1
2
70-80-9 S650 Service Manual
CYLINDER HEAD (CONT'D)
Valve Guide Removal And Installation 
Figure 70-80-30
To remove and replace the valve guide, make the driver
tools as shown in figure [Figure 70-80-30].
Figure 70-80-31
Press the used valve guide out of the cylinder head using
the special driver tool [Figure 70-80-31].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-31], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.
Reconditioning The Valve And Valve Seat
Figure 70-80-32
Grind the valve face to the correct angle using a valve
refacer [Figure 70-80-32].
Clean the valve seat and combustion chamber.
Figure 70-80-33
Install the valve into the guide. Measure the valve
recessing with a depth gauge [Figure 70-80-33].
MC-1364
225 mm (8.86”)
20 mm
(0.79”)
70mm (2.8”)
45 mm
(1.8”)
6,50-6,60 mm
(0.256-0.259”)
8,50-8,90 mm
(0.335-0.350 “)
20,0 mm 
(0.79”)
12,5-12,8 mm 
(0.493-0.503”)
5,0 mm
(0.2”)
6,70-7,00 mm
(0.264-0.275”)
25,0 mm
(0.98”)
11,7-11,9 mm 
(0.461-0.468”)
PI-9992
1
2
PI-9993
P-51632
70-80-10 S650 Service Manual
CYLINDER HEAD (CONT'D)
Reconditioning The Valve And Valve Seat (Cont’d)
Figure 70-80-34
If the measurement exceeds the allowable limit, replace
the valve or cylinder head [Figure 70-80-34].
Figure 70-80-35
Grind the valve seat surface in the cylinder head to the
correct angle [Figure 70-80-35].
Figure 70-80-36
Check the seat surface and valve face (Item 1) [Figure
70-80-36].
(a) identical dimensions above and below the valve seat
If the seat surface (b) needs correction, slightly correct
the seat using a 45 degree cutter and then resurface the
seat surface with a 15 degree cutter to get the correct
width (Item 2) [Figure 70-80-36].
Valve Seat Width 
Valve Seat & Face Angle
Recessing 0,65 - 0,85 mm
(0.026 - 0.33 in)
Allowable Limit (Recessing) 1,20 mm (0.0472 in.)
PI-9990
1. Cylinder Head
Surface
2. Recessing
3. Protrusion
PI-9994
45° Exhaust
45° Intake
15° Intake
15° Exhaust
Intake & Exhaust 3,3 - 3,6 mm
(0.13 - 0.14 in)
Intake 45 degrees
Exhaust 45 degrees
PI-9995
1
2
30° Exhaust
30° Intake
70-80-11 S650 Service Manual
CYLINDER HEAD (CONT'D)
Valve Spring
Figure 70-80-37
Measure the length of the valve spring. If the
measurement is less than the allowable limit, replace the
spring [Figure 70-80-37].
Put the spring on a flat surface, place a square on the
side of the spring [Figure 70-80-37].
Rotate the spring and measure the maximum tilt. If the
measurement exceeds the allowable limit, replace the
spring.
Figure 70-80-38
Put the spring on a tester and compress to specified
length [Figure 70-80-38].
Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the
spring.
Free Length 35,1 - 35,6 mm (1.39 - 1.40 in)
Allowable Limit  34,6 mm (1.36 in)
Tilt Allowable Limit 1,0 mm (0.039 in)
B-3680
Setting Length 31,5 mm (1.24 in)
Setting Load 60,8 N (14.3 lb)
Allowable Limit 45,9 N (10.3 lb)
A-2759
70-80-12 S650 Service Manual
CYLINDER HEAD (CONT'D)
Valve Tappets
Remove the oil pan and oil pump strainer. (See Oil Pan
Removal And Installation on Page 70-60-1.)
Remove the idler gear and camshaft. (See Idler Gear
And Camshaft Removal And Installation on Page 70-100-
5.)
Figure 70-80-39
Turn engine with the crankshaft facing up and remove the
valve tappets (Item 1) [Figure 70-80-39].
Figure 70-80-40
Measure the ID of the tappet bore (Item 1) [Figure 70-
80-40].
Figure 70-80-41
Measure the OD of the tappet (Item 1) [Figure 70-80-41].
If the clearance exceeds the allowable limit, replace the
tappets.
Tappet Bore ID 10,000 -10,015 mm
(0.39370 - 0.39429 in)
Clearance Between 
Tappet 
and Tappet Bore
0,020 - 0,050 mm
(0.00079 - 0.0019 in)
Allowable limit 0,07 mm (0.003 in)
P-85141
1
P-85142
1
Tappet OD 9,965 - 9,980mm
(0.3924 - 0.3929 in)
Clearance 
Between Tappet 
and Tappet 
Bore
0,020 - 0,050 mm
(0.00079 - 0.0019 in)
Allowable limit 0,07 mm (0.003 in)
P-85175
1
70-80-13 S650 Service Manual
CYLINDER HEAD (CONT'D)
Rocker Arm And Shaft - Checking
Figure 70-80-42
Measure the rocker arm I.D. (Item 1) [Figure 70-80-42]
with an inside micrometer.
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
80-42] with an outside micrometer.
If the clearance exceeds the allowable limit, replace the
bushing.
If the clearance still exceeds the allowable limit after the
bushing is replace, replace the rocker arm shaft.
Bridge Arm And Bridge Arm Shaft - Checking
Figure 70-80-43
Measure the bridge arm ID (Item 1) [Figure 70-80-43].
If the clearance exceeds the allowable limit, replace the
bridge arm (Item 1) [Figure 70-80-43].
Figure 70-80-44
Measure the bridge arm shaft OD (Item 1) [Figure 70-80-
44].
If the clearance exceeds the allowable limit, replace the
bridge arm shaft (item 1) [Figure 70-80-44].
Oil Clearance Between Rocker Arm
& Shaft 0,016 - 0,045 mm
(0.00063 - 0.0017 in)
Allowable Limit 0,15 mm
(0.0059 in)
Rocker Arm Shaft O.D. 14,973 - 14,984 mm
(0.58949 - 0.58992 in)
Rocker Arm I.D. 15,0 - 15,018 mm
(0.59056 - 0.59125 in)
B-3697
1
2
Bridge arm ID. 9,050 - 9,065 mm
(0.3170 - 0.3181 in)
Oil Clearance between 
Bridge arm and Bridge 
arm shaft.
0,018 - 0,042 mm
(0.0.00071 - 0.0016 in)
Bridge arm shaft OD. 9,023 - 9,8032 mm
(0.3553 - 0.3555 in)
Allowable Limit 0,15 mm (0.0059 in)
P-85177
1
P-85176
1
70-80-14 S650 Service Manual
CYLINDER HEAD (CONT'D)
Bridge Arm Shaft - Removal And Installation
Figure 70-80-45
Make valve bridge arm shaft replacement tool as shown
above [Figure 70-80-45].
Figure 70-80-46
Remove the used valve bridge arm shaft (Item 1), then
clean valve bridge arm shaft mounting hole. Use the
valve bridge arm replacing tool to press in new shaft
[Figure 70-80-46].
Figure 70-80-47
Install bridge arm shaft (Item 1) using the valve bridge
shaft replacing tool (Item 2) [Figure 70-80-47] to the
proper depth in [Figure 70-80-48].
A 9,50 mm (0.374 in)
B 19,0 mm (0.748 in)
C 23,2 mm (0.913 in)
D 42,00 - 42,40 mm (1.654 - 1.669 in)
E 12,5 mm dia. (0.492 in dia.) through hole
F 61,0 mm (2.40 in)
G 18,7 mm (0.736 in)
H 30,90 - 31,70 mm (1.217 - 1.248 in)
a 0,30 mm radius (0.012 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in)
C5 Chamfer 2,0 mm (0.079 in)
P-85969
P-85972
1
P-85973
2
1
70-80-15 S650 Service Manual
CYLINDER HEAD (CONT'D)
Bridge Arm Shaft - Removal And Installation (Cont’d)
Figure 70-80-48
Set the depth of the bridge arm shaft (Item 1) to 31,1 -
31,7 mm (1.23 - 1.24 in) [Figure 70-80-48].
Push Rod Alignment - Checking
Figure 70-80-49
Place the push rod on V blocks [Figure 70-80-49].
Measure the push rod alignment [Figure 70-80-49].
If the push rod exceeds the allowable limit, replace the
push rod.
P-85970
1
Push Rod 
Alignment
Allowable Limit 0,25 mm
(0.0098 in)
P-76926
70-80-16 S650 Service Manual
70-90-1 S650 Service Manual
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And 
Installation
Remove the cylinder head. (See Cylinder Head Removal
And Installation on Page 70-80-4.)
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan and oil pump strainer. (See Oil Pan
Removal And Installation on Page 70-60-1.)
Figure 70-90-1
Figure 70-90-2
Remove the tappet (Item 1) [Figure 70-90-1] from the
tappet bore (Item 2) [Figure 70-90-2] using a magnetic
tool.
Installation: Apply engine oil to the tappet during
installation.
NOTE: Mark the location of the tappets to prevent
them from becoming interchanged.
Figure 70-90-3
Remove the connecting rod bolts (Item 1) [Figure 70-90-
3].
NOTE: Mark the location of the rod bearings to
prevent them from becoming interchanged.
Installation: Tighten the connecting rod bolts to 69 - 73
N•m (51 - 54 ft-lb) torque.
Installation: Apply engine oil to the connecting rod bolts
and lightly screw in by hand.
Installation: Install the rod bearing with the centrally
lined groove towards the connecting rod, and the non
grooved side towards the cap.
Installation: Make sure the marks on the connecting rod
and bearing are aligned and facing the injection pump
when installing the bearing cap.
P-85141
1
P-85142
2
Top View of Crankcase
P-85143
1
70-90-2 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Piston And Connecting Rod Removal And 
Installation (Cont’d)
Figure 70-90-4
Use a hammer handle and push the piston / connecting
rod assembly out of the cylinder bore [Figure 70-90-4].
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
Figure 70-90-5
Installation: Make sure the marks on the connecting rod
and bearing (Item 1) [Figure 70-90-5] are aligned and
facing the injection pump when installing the bearing cap.
Repeat the procedure to remove the other piston /
connecting rod assemblies from the engine block.
Piston And Connecting Rod - Servicing
Figure 70-90-6
Installation: When reassembling, align the marks (Item
1) on the connecting rod and piston (Item 2) [Figure 70-
90-6].
NOTE: Assemble the piston to the connecting rod
with the mark (Item 2) and the connecting rod
mark (Item 1) [Figure 70-90-6] facing the
injection pump side.
P-51633
P-85144
1
P-85145
1
2
70-90-3 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-7
Remove the top ring (Item 1), the second ring (Item 2)
and the oil ring (Item 3) [Figure 70-90-7].
Remove the snap rings (Item 4) and piston pin (Item 7)
[Figure 70-90-7].
Separate the piston (Item 5) from the connecting rod
(Item 6) [Figure 70-90-7].
Installation: Heat the piston in clean engine oil to 80°C
(176°F) and tap the piston pin into position. Place the
piston rings so that there are gaps every 120 degrees
with no gap facing the piston pin in the cylinder.
NOTE: Mark the piston (Item 5) and connecting rod
(Item 6) [Figure 70-90-7] with the same
number to ensure correct installation and
proper cylinder placement.
Figure 70-90-8
Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 70-90-8].
Figure 70-90-9
Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-90-9].
If the measurement exceeds the allowable limit, replace
the piston.
P-85146
2
1
3
5
4
4
6
7
PI-10015
1
2
3
Piston Bore I.D. 28,0 - 28,013 mm
(1.1024 - 1.1028 in)
Allowable Limit 28,05 mm
(1.104 in)
P-47272
70-90-4 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-10
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-10].
Measure the I.D. of the connecting rod small end bushing
(Item 2) [Figure 70-90-10].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the connecting rod. If it still
exceeds the specifications, replace the piston pin.
Figure 70-90-11
Install a piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [Figure
70-90-11].
If the gap exceeds the allowable limit, replace the ring.
Piston Pin O.D. 28,006 - 28,011 mm
(1.1026 - 1.1027 in)
Bushing I.D. 28,031 - 28,046 mm
(1.1036 - 1.1041 in)
Oil Clearance Between 
Piston Pin & Bushing
0,020 - 0,040 mm
(0.00079 - 0.0015 in)
Allowable Limit 0,15 mm
(0.0059 in)
P-47273
1
2
Top Ring Gap 0,25 - 0,40 mm
(0.0099 - 0.015 in)
Oil Ring Gap 0,25 - 0,45 mm
(0.0099 - 0.017 in)
Allowable Limit 1,25 mm
(0.0492 in)
Second Ring Gap 0,30 - 0,45 mm
(0.012 - 0.017 in)
B-3622
70-90-5 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-12
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler
gauge [Figure 70-90-12].
If the clearance exceeds the allowable limit, replace the
ring. If the clearance still exceeds the allowable limit,
replace the piston.
Cylinder Bore - Checking
Figure 70-90-13
Use a gauge to check the inside measurement of the
cylinder bore [Figure 70-90-13].
Figure 70-90-14
Measure the six points as shown in figure [Figure 70-90-
14] to find the maximum wear.
The factory specifications are:
94 - 94,022 mm (3.7008 - 3.7016 in). 
The allowable limit is 94,15 mm (3.707 in).
If the cylinder bore is not within specifications, bore and
hone to oversize dimension.
Top Ring 0,050 - 0,090 mm
(0.0020 - 0.0035 in)
Allowable Limit 0,15 mm (0.0059 in)
Second Ring 0,090 - 0,12 mm
(0.0036 - 0.0047 in)
Allowable Limit 0,20 mm (0.0079 in)
Oil Ring 0,020 - 0,060 mm
(0.0079 - 0.0023 in)
Allowable Limit 0,15 mm (0.0059 in)
PI-10017
B-4066
P-37163
70-90-6 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Connecting Rod Alignment
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-15
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-15].
If the measurement exceeds the allowable limit, replace
the connecting rod.-
Crankshaft Gear Removal And Installation
Remove the crankshaft. (See Crankshaft And Bearings
Removal And Installation on Page 70-90-7.)
Figure 70-90-16
Remove the crankshaft sleeve (Item 1), the crankshaft
gears (Item 2), the seal (Item 3) and the key (Item 4)
[Figure 70-90-16].
Installation: Install a new seal (Item 3) when servicing
[Figure 70-90-16].
Figure 70-90-17
Installation: Heat the crankshaft sleeve (Item 1) [Figure
70-90-16] and [Figure 70-90-17] to 150 - 200°C (302 -
392°F). Install the crankshaft sleeve onto the crankshaft
using the crankshaft sleeve guide (Item 2) and the
crankshaft replacing tool (Item 3) MEL - 1660 [Figure 70-
90-17].
Installation: Install the crankshaft sleeve (Item 1) with
the chamfered surface facing outward [Figure 70-90-17].
Rod Alignment 0,05 mm (0.002 in)
B-4067
P-85149
1
2
4
3
2
P-85148
1
3
2
70-90-7 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft Gear Removal And Installation (Cont’D)
Figure 70-90-18
Installation: When installing the crankshaft sleeve
(Item 1) allow for a space (Item 2) [Figure 70-90-18]
from the end of the crankshaft to the edge of the
crankshaft sleeve.
Crankshaft And Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Page 70-90-1.)
Figure 70-90-19
Remove the crankcase mounting screws in order from Z
to A [Figure 70-90-19].
Installation: Tighten the crankcase mounting bolts from
A to J to 138 - 147 N•m (102 - 108 ft-lb)
Installation: Tighten the crankcase mounting bolts from
K to Z to 59 - 63 N•m (44 - 47 ft-lb). 
Figure 70-90-20
Remove crankcase 2 (Item 2) from crankcase 1 (Item 1)
[Figure 70-90-20].
Remove the crankshaft (Item 3) [Figure 70-90-20].
Figure 70-90-21
This tool is used for aligning the crankcase 1 and
crankcase 2. Make two of these tools.
Material (Item 1) [Figure 70-90-21]: SS400
P-85150
2
1
0,850 - 1,15 mm (0.0335 - 0.0452 in)
P-85151
A 126,6 mm (4.984 in)
B 49,1 mm (1.93 in)
C 37,5 mm (1.48 in)
D 20 mm (0.79 in)
E 14 mm dia. (0.55 in dia.)
F 14 mm dia. (0.55 in dia.)
G 14 mm dia. (0.55 in dia.)
H 17,5 mm (0.689 in)
I 17,5 mm (0.689 in)
J 35 mm (1.4 in)
K 19 mm (0.75 in)
P-85153
1
2
3
P-85995
1
70-90-8 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft And Bearings Removal And Installation 
(Cont’d)
Figure 70-90-22
NOTE: Make sure both crankcases are clean and dry
before assembling.   
Install the bearings (Item 1) into the crankcase 2 (Item 2)
[Figure 70-90-22].
Install the thrust bearings (Item 3) [Figure 70-90-22] with
the groove facing out.
Figure 70-90-23
Install the bearings (Item 2) into the crankcase 1 (Item 1)
[Figure 70-90-23].
Install the thrust bearings (Item 3) [Figure 70-90-23] with
the groove facing out.
Carefully apply liquid gasket evenly (Item 4) to the
crankcase 1 (Item 1) [Figure 70-90-23].
Figure 70-90-24
Apply oil to the thrust bearings and install the crankshaft
(Item 1) [Figure 70-90-24].
Figure 70-90-25
Align and install crankcase 2 (Item 2) to crankcase 1
(Item 1) [Figure 70-90-25].
Apply engine oil to the crankcase mounting bolts and
hand tighten from A to J and then K to Z [Figure 70-90-
19].
Install the jig (Item 3) [Figure 70-90-25] and tighten to 78
- 90 N•m (58 - 66 ft-lb)
NOTE: The jig helps to minimize the level difference
between the crankcase 1 and crankcase 2 at
the flywheel side. The gap must be 0,05 mm
(0.002 in) or smaller.
Tighten the crankcase mounting bolts from A to J to 138 -
147 N•m (102 - 108 ft-lb)
Tighten the crankcase mounting bolts from K to Z to 59 -
63 N•m (44 - 47 ft-lb). 
Remove the jig (Item 3) [Figure 70-90-25].
P-85157
3
1
2
P-85155
1
2
3
4
P-85156
1
P-85996
1
2
3
70-90-9 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft And Bearings - Servicing
Figure 70-90-26
Set a dial indicator with its tip on the end of the crankshaft
(Item 1) [Figure 70-90-26].
Measure the side clearance by moving the crankshaft
side to side (Item 2) [Figure 70-90-26].
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Figure 70-90-27
Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 70-90-26].
Turn the crankshaft at a slow rate to obtain the
misalignment (one half of the alignment measurement).
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Figure 70-90-28
Place plastigage on the crankshaft (Item 3) [Figure 70-
90-28].
Place crankcase 2 (Item 2) on crankcase 1 (Item 1)
[Figure 70-90-28] and torque the bolts.
Torque the bolts A to Z [Figure 70-90-19]. (See
Crankshaft And Bearings Removal And Installation on
Page 70-90-7.)
Remove crankcase 2 (Item 2) [Figure 70-90-28] and
measure the amount of the flattening with the scale to
determine the oil clearance.
Side clearance of 
crankshaft
Factory Spec. 0,15 - 0,35 mm
(0.0059 - 0.013 in)
Allowable limit 0,50 mm (0.020 in.)
P-85159
1
2
A-2763
Alignment 0,02 mm (0.0008 in)
Crankshaft 
Journal O.D.
Factory Spec. 79,977 - 79,990 mm
(3.1487 - 31.1492 in)
Oil clearance 
between 
crankshaft 
journal and 
crankshaft 
bearing
Factory Spec. 0,030 - 0,073 mm
(0.0012 - 0.0028 in)
Allowable limit 0,20 mm
(0.079 in)
P-85160
1
2
3
70-90-10 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-29
Reference of undersize dimensions of crankshaft journal
[Figure 70-90-29].
Figure 70-90-30
Clean the crank pin and crank pin bearing.
Put a strip of plastigage [Figure 70-90-30] on the center
of the crank pin.
NOTE: Never insert the plastigage into the crank pin
oil hole. Be sure not to move the crankshaft
while the connecting rod screws are
tightened.
Install the connecting rod cap and tighten the connecting
rod screws to the specified torque, and remove the cap
again.
Measure the amount of the flattening with the scale, and
get the oil clearance.
If the oil clearance exceeds the allowable limit, replace
the crank pin bearing.
If the same size bearing cannot be used because of the
crank pin wear, replace it with an undersized one
referring to the table.
Undersize 0,2 mm
(0.0079 in)
0,4 mm
(0.016 in)
Dimension A 2,8 - 3,2 mm 
radius
(0.11 - 0.12 in 
radius)
2,8 - 3,2 mm 
radius
(0.11 - 0.12 in 
radius)
*Dimension 
B
1,0 - 1,5 mm relief
(0.040 - 0.059 in 
relief)
1,0 - 1,5 mm 
relief
(0.040 - 0.059 in 
relief)
Dimension C 79,777 - 79,790 
mm dia.
(3.1409 - 3.1413 
in dia.)
79,577 - 79,590 
mm dia.
(3.1330 -3.1334 
in dia.)
The crankshaft journal must be fine-finished to higher 
than ————(0.8-S)
*Holes are to be de-burred and edges rounded with 
relief 
1.0 - 1.5 mm (0.040 - 0.059 in)
P-85161
Crankpin 
O.D.
Factory spec. 49,980 - 49,991 mm
(1.9678 - 1.9681 in)
Oil clear-
ance 
between 
crank pin and 
crank pin 
bearing
Factory spec. 0,011 - 0,058 mm
(0.00067 - 0.0018 in)
Allowable 
limit
0,20 mm (0.0079 in)
P-37145
70-90-11 S650 Service Manual
CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-31
NOTE: To replace it with a specific STD service part,
make sure the crank pin bearing has the same
ID color as the connecting rod [Figure 70-90-
31].
Figure 70-90-32
Undersize dimensions of crankpin.
ID 
Color
Connecting rod Crank pin bearing
Large-end in. dia. Class Center wall thick
Blue 53,010 - 53,010 
mm
(2.0870 - 2.0874 
in)
L 1,496 - 1,501 
mm
(0.05890 - 
0.05909 in)
with-
out 
Color
53,000 - 53,010 
mm
(2.0867 - 2.0870 
in)
S 1,491 - 1,496 
mm
(0.05870 - 
0.05889 in)
P-37147
1
2
3
Undersize 0,20 mm
(0.0079 in)
0,40 mm
(0.016 in)
Dimension 
A
3,3 - 3,7 mm radius
(0.13 - 0.14 in 
radius)
3,3 - 3,7 mm 
radius
(0.13 - 0.14 in 
radius)
*Dimen-
sion B
1,0 - 1,5 mm relief
(0.040 - 0.059 in 
relief)
1,0 - 1,5 mm 
relief
(0.040 - 0.059 in 
relief)
Dimension 
C
49,780 - 49,791 
mm dia.
(1.9599 - 1.9602 in 
dia.)
49,580 - 49,591 
mm dia. 
(1.9520 - 1.9524 
in dia.)
(0.8-S)
The crank pin must be fine-finished to higher than ——
——
*Holes to be de-burred and edges rounded with relief.
1,0 -1,5 mm (0.040 - 0.059 in)
P-85162
70-90-12 S650 Service Manual
70-100-1 S650 Service Manual
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-120-1.)
Remove the housing. (See Housing Removal And
Installation on Page 70-120-3.)
Figure 70-100-1
Remove the eight outside timing gearcase cover
mounting bolts (Item 1) [Figure 70-100-1].
Remove the eight inside timing gearcase cover mounting
bolts (Item 2) [Figure 70-100-1].
Remove the timing gearcase cover (Item 3) [Figure 70-
100-1].
P-90121
2
3
1
70-100-2 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation
Figure 70-100-2
Make timing gearcase cover guide tool [Figure 70-100-
2].
A 70,0 mm (2.76 in)
B 8,0 mm (0.31 in)
C 22,0 mm (0.866 in)
D 30,0 mm (1.18 in)
E 87,0 mm dia.
(3.43 in dia.)
F 82,036 - 82,071 mm dia.
(3.2298 - 3.2311 in dia.)
G 77,0 mm dia.
(3.03 in dia.)
H 57,0 mm dia. (2.24 in dia.)
I 35,0 mm dia. (1.38 in dia.)
J 30,0 mm dia. (1.18 in dia.)
K 84,0 mm (3.31 in)
L 3,5 mm (0.14 in)
M 3,0 mm (0.12 in)
N 6,60 - 6,80 mm (0.260 - 0.267 in)
O 8,0 mm (0.31 in)
P 67,0 mm dia. (2.64 in dia.)
Q 4,0 mm dia. (0.16 in) through hole
a Ra = 1.6 a
b 1,5 mm radius (0.059 in radius)
c Ra = 3.2 a
d 0,80 mm radius (0.031 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
C1.0 Chamfer 1,0 mm (0.039 in)
P-90004A
70-100-3 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-3
Make timing gearcase oil seal replacing tool [Figure 70-
100-3].
Figure 70-100-4
Make timing gearcase guide screws as shown above
[Figure 70-100-4].
Figure 70-100-5
Apply engine oil to the timing gearcase oil seal (Item 1)
[Figure 70-100-5].
Install timing gearcase guide screws (Item 2) [Figure 70-
100-5]. 
Install timing gearcase using the guide (Item 3) [Figure
70-100-5]. 
A 118 mm (4.65 in)
B 12,0 mm (0.472 in)
C 0,90 - 1,0 mm (0.36 - 0.039 in)
D 10,0,0 mm (0.394 in)
E 80,0 mm (3.15 in)
F 10,0,0 mm (0.394 in)
G 120 mm dia.
(4.72 in dia.)
H 100,90 - 101,10 mm dia.
(3.9725 - 3.9803 in dia.)
I 86,966 - 86,988 mm dia
.(3.4239 - 3.4247 in dia.)
J 79,0 mm dia. (3.11 in dia.)
K 15,0 mm dia. (0.591 in dia.)
L 30,0 mm dia. (1.18 in dia.)
M 13,0 mm (0.512 in)
N 90,00 mm (3.54 in)
O 2,50 mm (0.0984 in)
P 0,35 rad (20 degrees)
Q 0,15 - 0,25 mm (0.0059 - 0.0098 in)
a Ra = 3.2 a
P-90006
b Ra = 1.6 a
c 0,80 mm radius (0.031 in radius)
d 1,5 mm radius (0.059 in radius)
e 0,20 mm radius (0.0079 in radius)
C0.3 Chamfer 0,30 mm (0.012 in)
C1 Chamfer 1,0 mm (0.039 in)
P-85218
P-85999
1
2
3
70-100-4 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-6
Apply a liquid gasket (Three Bond 1217H) (Item 1)
[Figure 70-100-6] to the two crankcase seams.
Figure 70-100-7
Install timing gearcase oil seal using the timing gearcase
oil seal replacing tool (Item 1) [Figure 70-100-7].
Figure 70-100-8
Tighten the seven outside timing gearcase cover
mounting bolts (Item 1) [Figure 70-100-8].
Tighten the six inside timing gearcase cover mounting
bolts (Item 2) [Figure 70-100-8].
Installation: Tighten the timing gearcase cover bolts to
103 - 117N•m (76 - 86 ft-lb) [Figure 70-100-8].
P-85998
1
P-85217
1
P-85997B
1
2
70-100-5 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gears Backlash - Checking 
When the gears are installed, check the backlash of the
gears.
Figure 70-100-9
Install a dial indicator to individually check backlash for
cam gear (Item 1), idle gear (Item 2), injection pump gear
(Item 3) and crank gear (Item 4) [Figure 70-100-9].
Hold one gear while turning the other gear [Figure 70-
100-9].
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear. 
Idler Gear And Camshaft Removal And Installation
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
Remove the valve tappets. (See Valve Tappets on Page
70-80-12.)
Figure 70-100-10
Rotate entire engine with the crankshaft (Item 1) [Figure
70-100-10] facing up to remove the tappets
Remove the three camshaft set bolts (Item 2) and
remove the cam (Item 3) [Figure 70-100-10].
Remove the idle gear mounting bolts (Item 4) and
remove idle gear (Item 5) [Figure 70-100-10].
Installation: Make sure the timing marks are in correct
alignment when installing the timing gears. 
Crank Gear & Cam Gear 0,0410 - 0,139 mm
(0.00162 - 0.00547 in)
Allowable Limit 0,22 mm
(0.0087 in)
Cam Gear & Idler Gear 0,0410 - 0,134 mm
(0.00162 - 0.00527 in)
Allowable Limit 0,22 mm
(0.0087 in)
Injection Pump Gear & Idler 
Gear
0,0410 - 0,134 mm
(0.00162 - 0.00527 in)
Allowable Limit 0,22 mm
(0.0087 in)
P-85205
1
2
3
4
P-90008
2
1
3
5
4
70-100-6 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Camshaft - Servicing
Figure 70-100-11
Mount a dial indicator and check cam gear (Item 1) end
play (Item 2) [Figure 70-100-11].
Installation: Check the camshaft end play. If clearance
exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-11].
Figure 70-100-12
Measure the cylinder block bore in the engine block
[Figure 70-100-12].
Figure 70-100-13
Measure the camshaft journal (Item 1) and journal (Item
2) [Figure 70-100-13].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the camshaft.
Camshaft End Play 
Allowable Limit 
0,10 mm (0.0039 in)
P-85209
1
2
P-47263
Cylinder Block Bore 1 
I.D.
35,000 - 35,025 mm
(1.3780 - 1.3789 in)
Cylinder Block Bore 2 
I.D.
44,000 - 44,025 mm
(1.7323 - 1.7332 in)
Camshaft Journal 1 O.D. 34,934 - 34,950 mm
(1.3754 - 1.3759 in)
Camshaft Journal 2 O.D. 43,934 - 43,950 mm
(1.7297 - 1.7303 in)
Oil Clearance of Cam-
shaft Journal
0,050 - 0,091 mm
(0.0020 - 0.0035 in)
Allowable Limit 0,15 mm
(0.0059 in)
P-85212
2
1
70-100-7 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Camshaft - Servicing (Cont’d)
Figure 70-100-14
Measure the cam lobes at their highest point (Item 2)
[Figure 70-100-14].
If the measurement is less than the allowable limit,
replace the camshaft (Item 1) [Figure 70-100-14].
Figure 70-100-15
Put the camshaft (Item 1) in V-blocks. Install a dial
indicator [Figure 70-100-15].
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Idler Gear And Shaft - Servicing 
Figure 70-100-16
Mount a dial indicator and check idle gear (Item 1) end
play (Item 2) [Figure 70-100-16].
Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
collar.
Cam Lobe Height Intake 37,50 mm (1.476 in)
Cam Lobe Height Exhaust 37,90 mm (1.492 in)
Allowable Limit Intake 37,00 mm (1.457 in)
Allowable Limit Exhaust 37,40 mm (1.472 in)
P-85214
1
2
P-85213
1
Camshaft Alignment Allowable Limit 0,01 mm
(0.0004 in)
Idler Gear End Play 0,15 - 0,25 mm
(0.0059 - 0.0098 in)
Allowable Limit 0,90 mm (0.035 in)
P-85207
2
1
70-100-8 S650 Service Manual
CAMSHAFT AND TIMING GEARS (CONT’D)
Idler Gear And Shaft - Servicing (Cont’d)
Figure 70-100-17
Measure idle gear bushing ID (Item 1) and idle gear shaft
OD (Item 2) [Figure 70-100-17]. 
Installation: If the oil clearance exceeds the allowable
limit, replace the idle gear bushing.
Figure 70-100-18
Make this idle gear bushing replacing tool as shown
above [Figure 70-100-18].
Figure 70-100-19
When removing idle gear bushing, press out bushing as
shown above (item 1) [Figure 70-100-19].
When replacing idle gear bushing, press in bushing as
shown above (item 2) [Figure 70-100-19].
Idler Gear Shaft O.D. 34,959 - 34,975 mm
1.3764 - 1.3769 in)
Idler Gear Bushing I.D. 35,025 - 35,050 mm
(1.3790 - 1.3799 in)
Oil Clearance Between 
Idler Shaft & Gear Bushing
0,050 - 0,091 mm
(0.0020 - 0.0035 in)
Allowable Limit 0,10 mm
(0.0039 in)
P-85208
2
1
P-85211
A 196 mm (7.72 in)
B 25,00 mm (0.984 in)
C 150 mm (5.91 in)
D 34,5 mm dia. (1.36 in dia.)
E 38,075 - 38,100 mm dia. (1.4991 - 1.5000 in dia.)
F 20 mm dia. (0.79 in dia.)
a 0,0063 mm (0.000248 in)
b 0,0063 mm (0.000248 in)
C1 Chamfer 1,0 mm (0.039 in)
C2 Chamfer 1,0 mm (0.039 in)
P-85210
1
2
70-110-1 S650 Service Manual
TURBOCHARGER
Description
Figure 70-110-1
The turbocharger is placed between the exhaust and
intake manifolds. It is driven by hot exhaust gases and
supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The
location of the turbo is between the engine and the
blower housing.
The oil flows to the turbo by a tubeline (Item 1) and
returns to the engine block through another tubeline
(Item 2) [Figure 70-110-1].
The turbocharger internal components are not
serviceable.
Testing
Remove the turbocharger. (See Removal And Installation
on Page 70-110-2.)
Radial Clearance
Figure 70-110-2
Move the compressor / turbine wheel (up and down /
right and left) (Item 1) [Figure 70-110-2].
If the wheel contacts the housing, replace the
turbocharger assembly with a new one.
Check the oil tubelines for leaks. 
P-85976
1
2
P-76099
1
70-110-2 S650 Service Manual
TURBOCHARGER (CONT’D)
Removal And Installation
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Remove the air cleaner. (See Housing Removal And
Installation on Page 70-40-1.)
Figure 70-110-3
Disconnect the two oil pipes (Item 1) [Figure 70-110-3].
Installation: Tighten the two tubelines (Item 1) [Figure
70-110-3] to 16 - 19 N•m (12 - 14 ft-lb) torque.
Figure 70-110-4
Remove the two exhaust manifold cover bolts (Item 1)
[Figure 70-110-4].
Figure 70-110-5
Remove the eight exhaust manifold bolts (Item 1)
[Figure 70-110-4].
Installation: Tighten the eight bolts (Item 1) [Figure 70-
110-3] to 24 - 27 N•m (17.7 - 19.9 ft-lb) torque.
P-85975
1
1
P-85978
1
P-85979
1
1
70-110-3 S650 Service Manual
TURBOCHARGER (CONT’D)
Removal And Installation (Cont’d)
Figure 70-110-6
Remove the turbocharger assembly (Item 1) [Figure 70-
110-6].
Installation: During installation replace all gaskets with
new ones.
P-85127
1
70-110-4 S650 Service Manual
70-120-1 S650 Service Manual
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
70-10-7.)
Remove the drive belt shield. (See DRIVE BELT on Page
30-60-1.)
Remove the drive belt tension pulley. (See Tensioner
Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See DRIVE BELT on Page 30-
60-1.)
Figure 70-120-1
Remove the six mounting bolts (Item 1) from the pulley
(Item 2) [Figure 70-120-1].
Remove the pulley (Item 2) [Figure 70-120-1].
Installation: Tighten to 43 - 47 N•m (32 - 35 ft-lb) torque.
Figure 70-120-2
Make flywheel stop tool as shown above in [Figure 70-
120-2].
Figure 70-120-3
Make flywheel guide bolts as shown above to aid in
removal and installation of flywheel [Figure 70-120-3].
P-85138
1
2
A 144 mm (5.67 in)
B 104 mm (4.09 in)
C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
E 12,0 mm dia. (0.472 in dia.)
F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
I 16,0 mm (0.630 in)
P-85215
P-85218
70-120-2 S650 Service Manual
FLYWHEEL AND HOUSING (CONT’D)
Flywheel Removal And Installation (Cont’d)
Figure 70-120-4
Install flywheel stop tool (Item 1) [Figure 70-120-4].
Remove two flywheel bolts and replace them with the
flywheel guides bolts to aid in removal (Item 1) [Figure
70-120-3].
Remove the seven mounting bolts (Item 2)[Figure 70-
120-4] from the flywheel.
Installation: Apply engine oil to the bolts and tighten to
98,1 - 107 N•m (72.4 - 79.5 ft-lb) torque.
NOTE: Do not use a impact wrench. Serious damage
will occur. There is one positioning pin in the
crankshaft gear and it is installed in the
flywheel.
Figure 70-120-5
Install two bolts (Item 1) [Figure 70-120-5] into the
threaded holes on the flywheel and tighten to remove
flywheel.
Figure 70-120-6
Install two guide bolts (Item 1) [Figure 70-120-6] to aid in
installation of the flywheel.
P-85074
1
2
P-85140A
1
P-85140
1
70-120-3 S650 Service Manual
FLYWHEEL AND HOUSING (CONT’D)
Ring Gear Removal And Installation
Figure 70-120-7
The ring gear (Item 1) [Figure 70-120-7] on the flywheel
is an interference fit. Heat the ring gear enough to
expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.
Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Clean the new ring gear and heat it to a temperature of
232 - 260°C (450 - 500°F).
Fit the ring on the flywheel and be sure the gear is seated
correctly.
Housing Removal And Installation
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
70-10-7.)
Remove the drive belt shield. (See DRIVE BELT on Page
30-60-1.)
Remove the drive belt tension pulley. (See Tensioner
Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See DRIVE BELT on Page 30-
60-1.)
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-120-1.)
Figure 70-120-8
Remove the four mounting bolts (Item 1) and the housing
(Item 2) [Figure 70-120-8].
Installation: Tighten the mounting bolts to 80 - 84 N•m
(56 - 62 ft-lb) torque.
P-48850
1
P-85137
1
1
2
70-120-4 S650 Service Manual
70-130-1 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description 
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature. 
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold. 
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
The items listed below refer to [Figure 70-130-1].
1. Thermo Valve
2. Mechanical EGR Valve
3. Cylinder Head
4. Reed Valve
5. EGR Cooler
6. Intake Manifold 
7. Boost Pressure
8. Coolant Temperature
9. Cooled EGR Gas
10. To The Intake Manifold
11. Fresh Air
12. Cooled EGR Gas Merges With Fresh Air
13. Exhaust Gas
14. Coolant Inlet
15. Coolant Outlet
P-85105
7
1
8
10
2
9
3
4
12
11
6
5
13
14
15
2
7
1
9
70-130-2 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 
(CONT'D)
Testing
There are two tests for checking the EGR system. Both
tests will need to be performed and the coolant
temperature must be monitored through the Service
Analyzer. 
The Cold Engine Coolant Temperature Test will need to
be performed with the engine coolant below 55°C
(131°F). The Hot Engine Coolant Temperature Test will
need to be performed with the engine coolant above
70°C (158°F).
WARNING
AVOID INJURY OR DEATH
When the engine is running during service, the
steering levers or joysticks must be in neutral and
the parking brake engaged.
W-2717-0208
WARNING
MACHINE FALLING OR MOVING CAN CAUSE 
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Open the rear door.
Connect the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-150-1.)
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
Cold Engine Coolant Temperature Test
Start the engine and run at low idle.
Start Service Analyzer and select [Monitor].
Select [Engine Temperature].
WARNING
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing.
W-2716-0208
NOTE: Verify the engine temperature is below 55°C
(131°F). If the engine temperature is above
55°C (131°F), let the engine cool down and
restart the Cold Engine Coolant temperature
Test.
NOTE: Monitor the engine coolant temperature using
the Service Analyzer. 
Figure 70-130-2
Measure the surface temperature of the EGR system
(Item 1) [Figure 70-130-2] with an Infrared Thermometer.
If the engine coolant temperature is below 55°C (131°F)
and the surface temperature of the EGR system is 150°C
(302°F) or below, the EGR system is OK, Continue with
the Hot Engine Coolant temperature Test.
If the surface temperature of the EGR system reads
150°C (302°F) or above continue this Cold Engine
Coolant Temperature Test. 
P-85108
1
70-130-3 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 
(CONT'D)
Testing (Cont’d)
Figure 70-130-3
Disconnect the boost hose (Item 1) [Figure 70-130-3]
from the EGR valve.
Figure 70-130-4
Measure the surface temperature of the EGR system
(Item 1) [Figure 70-130-4] with an Infrared Thermometer.
If the surface temperature of the EGR system declines,
the thermo valve has failed.
If the surface temperature of the EGR system stays
above 150°C (302°F), the EGR valve has failed.
Hot Engine Coolant Temperature Test
Verify the engine temperature is above 70°C (158°F), if
the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
continue with the Hot Engine Coolant Temperature Test.
Figure 70-130-5
Measure the surface temperature of the EGR system
(Item 1) [Figure 70-130-5] with an Infrared Thermometer.
With the engine coolant temperature above 70°C (158°F)
and the surface temperature of the EGR system 150°C
(302°F) or above, the EGR system is OK.
If the surface temperature of the EGR system is 150°C
(302°F) or below continue this Hot Engine Coolant
Temperature Test. 
Figure 70-130-6
Disconnect the intake hose (Item 1) [Figure 70-130-6].
P-85984
1
P-85108
1
P-85108
1
P-85980
1
70-130-4 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 
(CONT'D)
Testing (Cont’d)
Figure 70-130-7
Disconnect the EGR hose (Item 1) [Figure 70-130-6].
Figure 70-130-8
Connect a hose (Item 1) directly between the intake
manifold (Item 2) and the EGR valve (Item 3) [Figure 70-
130-8].
Figure 70-130-9
Measure the surface temperature of the EGR system
(Item 1) [Figure 70-130-9] with an Infrared Thermometer.
If the surface temperature of the EGR system increases,
the thermo valve has failed.
If the surface temperature of the EGR system is 150°C
(302°F) or below, the EGR valve has failed. 
P-85984
1
P-85981
1
2
3
P-85108
1
70-130-5 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 
(CONT'D)
Removal And Installation
WARNING
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing.
W-2716-0208
Allow the engine to cool before working on the EGR
system.
Figure 70-130-10
Disconnect and cap the EGR valve coolant hoses (Item
1) [Figure 70-130-10].
Disconnect the boost pressure hose (Item 2) [Figure 70-
130-10].
Figure 70-130-11
Remove the four EGR cooler mounting bolts (Item 1) and
the EGR system assembly (Item 2) [Figure 70-130-11].
Installation: Replace the gaskets (Items 3 and 4)
[Figure 70-130-11] with new ones.
Figure 70-130-12
NOTE: The gasket (Item 3) [Figure 70-130-11] and
[Figure 70-130-12] is marked with the letter
“F” and must be installed downward.
P-85982
1
2
P-85110
3
2
1
1
1
1
4
P-85113
2
3
70-130-6 S650 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 
(CONT'D)
Disassembly And Assembly
Figure 70-130-13
Remove the two mounting bolts (Item 1) from the EGR
cooler flange (Item 2) [Figure 70-130-13].
Remove and replace the gasket (Item 3) [Figure 70-130-
13].
Remove the four bolts (Item 4) from the EGR cooler (Item
5) and the EGR valve (Item 7) [Figure 70-130-13].
Remove and replace the gasket (Item 6) [Figure 70-130-
13].
Remove the thermo valve (Item 8) [Figure 70-130-13].
Installation: When reassembling replace with new
gaskets.
NOTE: If the thermo valve is dropped it must be
replaced with a new one.
Installation: Tighten the thermo valve to 30 - 39 N•m (22
- 28 ft-lb) torque.
Figure 70-130-14
Remove the two mounting bolts (Item 1) from the EGR
valve (Item 2) and EGR valve flange (Item 6) [Figure 70-
130-14].
Remove the two mounting bolts (Item 3) from the reed
valve (Item 5) [Figure 70-130-14].
Remove and replace the gaskets (Item 4) [Figure 70-
130-14].
Installation: When reassembling replace with new
gaskets.
P-85112
1
2
3
5
6
7
4
8
P-85111
1
2
4
5
6
4
3
4
80-01 S650 Service Manual
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-10-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-10-2
Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-10-3
Safety Equipment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-1
Filters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-2
Compressor Drive Belt Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-2
Condenser  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-2
Air Conditioning Lubrication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-2
Air Conditioning Service Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . .  80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal  . . .  80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly  . . . . . . . . . . . .  80-30-1
Gauge Pressure Related Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-2
Troubleshooting Tree  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-8
Poor A/C Performance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-10
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-30-11
Electrical System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-12
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-18
Heater Valve Not Opening Or Closing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-30-19
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-40-1
Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-40-1
Reclamation And Charging With Recovery / Charging Unit  . . . . . . . . . . . . . . . . . . .  80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-50-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-50-1
Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-50-2
Oil Check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-50-3
CONDENSER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-60-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-70-1
Receiver / Drier Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-70-3
Schraeder Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-70-4
80-02 S650 Service Manual
EVAPORATOR / HEATER UNIT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-80-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-90-1
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-90-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-90-2
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-100-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-100-1
EVAPORATOR COIL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1
HEATER COIL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-120-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-120-1
BLOWER FAN  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-130-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-130-1
Disassembly And Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-130-1
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-140-1
Removal And Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-140-1
80-10-1 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.
80-10-2 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
b-16691
Thermostat
Expansion Valve
Cold Air
Evaporator
Blower
Compressor
Fan
Condenser
Sight
Glass
Pressure 
Switch
Receiver Drier
Desiccant
Evaporator
4
5
6
2
3
1
Status Of R134a_______________________________________________
High Pressure Gas
High Pressure Liquid
Low Pressure Gas
Low Pressure Liquid
80-10-3 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Components
Figure 80-10-1
Compressor: The compressor (Item 1) [Figure 80-10-1]
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is
recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2
Condenser: The condenser (Item 1) [Figure 80-10-2] is
the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
Figure 80-10-3
Receiver/Drier: The receiver / drier (Item 1) [Figure 80-
10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.
Figure 80-10-4
Pressure Relief Valve: The pressure relief valve (Item 2)
[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3,7 MPa (36,9
bar) (535 psi).
P-89538
1
P-85824
1
P-89545
2
1
N-22206
1
80-10-4 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Components (Cont'd)
Figure 80-10-5
Heater / Evaporator Unit: The heater / evaporator unit
(Item 1) [Figure 80-10-5] is located behind the loader
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower,
heat & A/C coils, thermostat and expansion valve.
Figure 80-10-6
Expansion Valve: The expansion valve (Item 1) [Figure
80-10-6] controls the amount of refrigerant entering the
evaporator coil.
Figure 80-10-7
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
10-7] cools and dehumidifies the air before it enters the
cab.
Thermostat: The thermostat (Item 2) [Figure 80-10-7]
controls the temperature of the evaporator coil. 
Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
supplies the warm air into the cab by passing air through
the coil.
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-7] is used to push air through the heater and
evaporator coils and into the cab.
P-92602
1
P-92659
1
P-89497
1
3
2
4
80-10-5 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Components (Cont'd)
Figure 80-10-8
Control Panel: The panel (Item 1) [Figure 80-10-8] has
three separate components.
Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]
will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-
10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-9
Heater Valve: The heater valve (Item 1) [Figure 80-10-9]
is used to control the amount of engine coolant that flows
to the heater coil.
Figure 80-10-10
Pressure Switch: The pressure switch (Item 1) [Figure
80-10-10] will disengage the compressor clutch at high
pressure readings over 2647,6 kPa (26,5 bar) (384 psi.)
on the high side, or at very low pressure of 193,0 kPa
(1,9 bar) (28 psi) or less on the high side, which indicates
loss of refrigerant.
P-92638
3
4
2
1
P-90353
1
P-89545
1
80-10-6 S650 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment
Figure 80-10-11
Figure 80-10-12
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR
SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
R-134a inside a canister or in an A/C system is a liquid
under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves  [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
P16398
P16399
80-20-1 S650 Service Manual
REGULAR MAINTENANCE
Filters
Fresh Air Filters
Figure 80-20-1
The fresh air filters are located behind the side windows
outside the operators cab. (Right side shown) Remove
the clamping knob (Item 1) and filter cover (Item 2)
[Figure 80-20-1].
Shake the filter (Item 3) [Figure 80-20-1] or use low
pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter,
filter cover and clamping knob.
Recirculation Filter (Earlier Models)
Figure 80-20-2
The recirculation filter is located behind the operators
seat inside the operators cab. Flip the clamps (Item 1)
holding the filter up and remove the filter (Item 2) [Figure
80-20-2].
Shake the filter or use a vacuum to clean. This can be
done several times before replacement is required.
Install the filter into the opening and flip the clamps down
to hold the filter in place.
Recirculation Filter (Later Models)
Figure 80-20-3
The recirculation filter is located behind the operator’s
seat inside the operator cab. The filter cover is held in
place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-3] to remove.
Rinse the filter elements with water or use a vacuum to
clean. Do not use solvents.
Line up the clips on the filter cover with the slots provided
and push the cover into place.
P-90492A
3
P-90489A
1
2
P-90490A
2
1
P100755
1
80-20-2 S650 Service Manual
REGULAR MAINTENANCE (CONT’D)
Compressor Drive Belt Adjustment
The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts. 
Compressor Drive Belt Replacement
Stop the engine and open the rear door.
Figure 80-20-4
NOTE: The engine is shown removed for visual
clarity.
Loosen the top air conditioning pump mounting bolts
(Item 1) [Figure 80-20-4].
Remove the bottom air conditioning pump mounting bolt
(Item 2) [Figure 80-20-4].
Move the air conditioning pump toward the engine as far
as it will go and remove the belt from the pulleys.
Inspect the pulleys for wear.
Install new belt.
Figure 80-20-5
Use a prybar at the two leverage points (Item 1) [Figure
80-20-5] to move the air conditioning pump until the
bottom air conditioning pump mounting bolt (Item 2)
[Figure 80-20-4] can be installed.
Tighten the three mounting bolts (Items 1 and 2) [Figure
80-20-4].
Close the rear door.
Condenser
The condenser should be cleaned with the oil cooler and
the radiator. 
Air Conditioning Lubrication
Run the air conditioning for about five minutes every
week to lubricate the internal components.
P-85942A
1
2
P-85993
1
80-20-3 S650 Service Manual
REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company/Phone Number:
Date:
Machine Model:        Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
80-20-4 S650 Service Manual
REGULAR MAINTENANCE (CONT’D)
Evaporator / Heater Coil
Earlier Models
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 80-20-6
Remove cover screws (Item 1) [Figure 80-20-6] and
remove the cover.
Figure 80-20-7
Use low pressure air or water to remove debris from the
heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-7].
Install the cover and lower the operator cab. (See
Lowering on Page 10-30-3.)
Later Models
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 80-20-8
Unhook cover latches (Item 1) [Figure 80-20-8] and
remove the cover.
Figure 80-20-9
Use low pressure air or water to remove debris from the
heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-9].
Install the cover and lower the operator cab. (See
Lowering on Page 10-30-3.)
P-90419A
1
P-90420A
2
1
P100756
1
P100757
2
1
80-30-1 S650 Service Manual
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Possible Cause Inspection Solution
1. Blown fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad       
connection.
Check the fan motor ground and connectors. Repair the wiring or connector.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit 
tester.
Replace Motor.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch    malfunc-
tion.
Check power into and out of the fan switch. Replace Fan Switch.
Possible Cause Inspection Solution
1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean 
evaporator fins with air or 
water.
2. Air leak. Check to make sure air ducts are properly con-
nected and seals are not damaged.
Repair or adjust.
3. Defective thermo. switch 
(frozen evaporator).
Check thermostat using a circuit tester. Replace thermostat.
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Possible Cause Inspection Solution
1. System low on refrigerant. The high side pressure will be low and bubbles 
may be present in sight glass on receive drier.
Repair any leaks and recharge 
the refrigerant to the correct 
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery 
equipment to capture excess 
refrigerant. Charge to the cor-
rect refrigerant level.
Possible Cause Inspection Solution
1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor mal-
function.
The compressor is locked up and the belt slips. Replace compressor.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch 
surface.
6. Open coil. Clutch does not engage and there is no reading 
when a circuit tester is connected between the coil 
and terminals.
Replace clutch.
7. Broken wiring or poor 
ground.
Clutch will not engage. Inspect the ground and 
connections.
Repair.
8. Wiring harness compo-
nents.
Test the conductance of the pressure switch, ther-
mostat, Relay, etc.
Check operation / thermostat 
LED status.
80-30-2 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 RPM are:
High pressure side pressure: 1447,9 - 1827,1 kPa (14,5 - 18,3 bar) (210 - 265 psi)
Low pressure side pressure: 103,4 - 227,5 (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
Possible Cause Inspection Solution
Low pressure side Too 
high.
The low pressure side pressure normally becomes too 
high when the high pressure side pressure is too high. As 
this is explained below, the following inspection is only 
used when the low pressure side is too high.
1. Expansion valve 
opens too far.
Frost is present on the suction hose. Replace expansion valve.
2. Defective compres-
sor.
The high and low pressure side gauge pressures equal-
ize when the magnetic clutch is engaged.
Replace compressor.
Low pressure side Too 
low.
1. Low refrigerant 
charge.
The high side pressure will be low and bubbles may be 
present in sight glass on receiver drier.
Repair any leaks and recharge 
the refrigerant to the correct 
level.
2. Clogged or closed 
expansion valve.
The expansion valve’s inlet side is frosted. Moisture or 
other contaminants can be the cause.
Clean or replace the expansion 
Valve.
3. Restriction between 
drier and expansion 
valve.
Frost on the line between drier and expansion valve. A 
Negative low pressure reading may be shown.
Flush system or replace hose.
4. Thermostat malfunc-
tion.
The evaporator is frozen. Adjust thermostat’s tempera-
ture setting or probe place-
ment or replace thermostat.
5. Restriction in 
receiver drier.
Excessive frost on receiver drier. Replace receiver drier.
High pressure side Too 
high.
1. Poor condenser per-
formance.
Dirty or clogged condenser fins. Condenser fans not 
operating.
Clean fins, and/or repair the 
fan.
2. Excessive refriger-
ant.
The high pressure side pressure will be high. Use refrigerant recovery equip-
ment to capture excess refrig-
erant. Charge to the correct 
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil 
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge 
back into compressor. Flush 
system with nitrogen. Replace 
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with 
refrigerant.
5. Restriction in drier, 
condenser or high pres-
sure line.
High pressure side will be high, and low pressure side 
will be low.
Evacuate and flush system 
replacing defective parts.
80-30-3 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)
Possible Cause Inspection Solution
High pressure side Too 
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and 
recharge the refrigerant to 
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump-
ing.
Equal high and low pressures. Replace compressor.
80-30-4 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Troubleshooting Tree
P-90410
80-30-5 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Troubleshooting Tree (Cont’d)
P-90411
80-30-6 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Troubleshooting Tree (Cont’d)
P-90412
80-30-7 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Troubleshooting Tree (Cont’d)
P-90413
80-30-8 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE
TEMP F PSIG TEMP F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
80-30-9 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Temperature / Pressure Chart (Cont’d)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add -13 - -12°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Conditions and pressures will vary from system to system. Check with MCC for system specifications.
Example: Ambient Temperature=90°F
90°F
+40°F
130°F condenser temperature=200 psig
80-30-10 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Poor A/C Performance
Start the loader, lock the park brake, and engage the A/C
system with the blower fan on High. Run the loader at full
throttle for approximately 15 minutes, with the loader cab
door closed.
Figure 80-30-1
Figure 80-30-2
Check the temperature at the louvers (Item 1) [Figure
80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 2,2 - 11,6°C
(45 - 53°F.) depending on the amount of humidity in the
air and ambient temperature.
If louver temperature is too high. (See Troubleshooting
Tree on Page 80-30-4.)
Check the blower for proper operation, or noise, and
replace if necessary. (See Removal And Installation on
Page 80-130-1.)
Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
60-1.)
Check the A/C evaporator coil for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
110-1.)
Check the engine coolant to see if it is bypassing the
heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-18.)
P-90356
1
N-22411
80-30-11 S650 Service Manual
TROUBLESHOOTING (CONT'D)
HVAC Repair And Leaks
Figure 80-30-3
Whenever the A/C system is opened to the atmosphere
or there has been a leak in the system, the receiver/drier
(Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or
components uncapped while working on the A/C system.
P-85954
1
80-30-12 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Electrical System
Check to see if the compressor clutch is engaging. 
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN OR press the
RUN Button, without starting the loader.
Figure 80-30-4
Push the A/C switch (Item 1) to the ON position. Turn the
blower switch (Item 2) [Figure 80-30-4] to the first ON
position.
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
If the compressor clutch does not engage, check the
HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.
Open the rear door (tailgate).
Figure 80-30-6
Locate the loader harness and the compressor clutch
wire (Item 1) [Figure 80-30-6].
Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.
Figure 80-30-7
With a multi meter, check the resistance to the
compressor clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor
clutch. 
P-92638
1
2
P-85412
1
P-90357
1
P-90358
1
80-30-13 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Electrical System (Cont'd)
Figure 80-30-8
With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8].
The voltage reading should be around 12 volts.
If there is no power at the clutch, check the wiring
harness for broken wires.
If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.
Figure 80-30-9
Disconnect the loader harness (Item 1) from the pressure
switch (Item 2) [Figure 80-30-9].
Figure 80-30-10
Using a multi meter check the loader wiring harness
(Item 1) [Figure 80-30-10] for voltage.
The voltage should be around 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 80-30-11
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, check for low refrigerant
level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
If a resistance value is seen, the pressure switch is good.
Reconnect the loader harness to the pressure switch.
P-90358
1
P-90361
1
2
P-90360
1
P-90360
1
80-30-14 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Electrical System (Cont'd)
Figure 80-30-12
Raise the operator cab. (See Raising on Page 10-30-2.)
Disconnect the thermostat wiring connector (Item 1
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
Check the loader harness (Item 1) [Figure 80-30-13] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
If there is voltage at the wiring harness, check the
thermostat (Item 2) [Figure 80-30-13] for resistance.
The resistance value of the thermostat should be 10 Ohm
at 20°C (68°F).
If there is no resistance value, replace the thermostat.
(See Removal And Installation on Page 80-90-2.)
If there is a resistance value, check the blower.
Figure 80-30-14
Disconnect the blower wiring connector (Item 1) [Figure
80-30-14] from the loader wiring harness.
Figure 80-30-15
Check the loader harness (Item 1) [Figure 80-30-15] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
If there is voltage at the wiring harness, check the
resistance to the blower at the blower wiring connector
(Item 2) [Figure 80-30-15].
If there is no resistance value replace the blower. (See
Removal And Installation on Page 80-130-1.)
If there is a resistance value check the climate controls at
the control panel inside the loader cab.
P-90363
1
P-90362
1
2
P-90363
1
P-90362
1
2
80-30-15 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Electrical System (Cont'd)
Figure 80-30-16
Remove the control panel (Item 1) [Figure 80-30-16]
from the left side lower panel.
Figure 80-30-17
Disconnect the loader wiring harness (Item 1) [Figure
80-30-17] from the blower switch.
Check the loader harness for voltage. The voltage should
be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 80-30-18
If there is voltage at the wiring harness, check the blower
switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-30-18].
With the switch in the 2 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].
With the switch in the 3 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the
blower switch.
If the above resistance tests are good, check the A/C
switch.
P-90364
1
P-90365
1
N-22288
H
C
M
B
L
80-30-16 S650 Service Manual
TROUBLESHOOTING (CONT’D)
Electrical System (Cont’d)
Figure 80-30-19
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-19] from the A/C switch.
Check the harness for voltage. The voltage should be 12
volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 80-30-20
If there is voltage at the wiring harness, check the A/C
switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no
resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be
resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-20].
If no resistance value is found, replace the A/C switch.
If a resistance value is found, check the potentiometer.
The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does
not work, check the potentiometer.
Figure 80-30-21
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-21] from the potentiometer.
Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
P-90367
1
N-22289
1
2
P-90366
1
80-30-17 S650 Service Manual
TROUBLESHOOTING (CONT’D)
Electrical System (Cont'd)
Figure 80-30-22
If there is voltage at the wiring harness, check the
potentiometer [Figure 80-30-22] for resistance.
The resistance should be 10K Ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.
Figure 80-30-24
The resistance between the wire terminal A and wire
terminal B frame [Figure 80-30-24] should be around 0 K
Ohm.
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-30-24] should be
around 10 K Ohm.
N-22290
A
B
C
P-90368
1
N-22290
A
B
C
80-30-18 S650 Service Manual
TROUBLESHOOTING (CONT’D)
Electrical System (Cont'd)
Figure 80-30-25
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-30-25]
clockwise to the full Heater position.
Figure 80-30-26
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-26] should be
around 10 K Ohm.
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-30-26] should be
around 0 K Ohm.
If the resistance is not found replace the potentiometer.
Engine Coolant Bypassing The Heater Valve
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-27
Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1, then turn the
temperature control (Item 3) [Figure 80-30-27]
counterclockwise to the full A/C position, with the loader
ignition switch OFF.
Raise the operator cab. (See Raising on Page 10-30-2.)
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
Check the heater hose (Item 1) [Figure 80-30-28] for
temperature.
If the hose is hot, the heater valve is leaking by, and
needs to be replace.
P-90369
1
N-22290
A
B
C
P-90364A
3
1
2
P-90371
1
80-30-19 S650 Service Manual
TROUBLESHOOTING (CONT'D)
Heater Valve Not Opening Or Closing
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-29
Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1 and turn the
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader ignition switch OFF.
Raise the operator cab. (See Raising on Page 10-30-2.)
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
Figure 80-30-30
NOTE: The HVAC assembly is removed for photo
clarity.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate. Place a mark on
the loader shaft.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-30-29]
to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab. 
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper
function. (See Electrical System on Page 80-30-12.)
Replace the heater valve. (See Removal And Installation
on Page 80-140-1.)
P-90364A
2
1
3
P-90370
1
80-30-20 S650 Service Manual
80-40-1 S650 Service Manual
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-40-1
NOTE: It is recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery/Recycling/Recharging
Machine.
NOTE: This test is run with the loader engine OFF,
and the A/C switch in the OFF position.
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 Refrigerant Identifier to the low pressure
hose.
Connect the Refrigerant Identifier to its power source.
Follow the steps displayed on the refrigerant identifier
screen.
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.
N-23024
1
80-40-2 S650 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation And Charging With Recovery / Charging 
Unit
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.)
Figure 80-40-2
Locate the low pressure port (Item 1), and high pressure
port (Item 2) [Figure 80-40-2].
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-40-3
IMPORTANT: Only trained technicians should
perform the reclaiming and recharging.
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
Use an approved recovery / charging unit [Figure 80-40-
3] to evacuate the system.
P-90372
1
2
N-22291
80-40-3 S650 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation And Charging With Recovery / Charging 
Unit (Cont'd)
Figure 80-40-4
Figure 80-40-5
Connect the reclaimer to the loader A/C charge ports
(Item 1) [Figure 80-40-4].
Connect the Blue hose (Item 2) [Figure 80-40-5] to the
low pressure port and open the valve.
Connect the Red hose (Item 3) [Figure 80-40-5] to the
high pressure port and open the valve.
Figure 80-40-6
Turn the reclaimer unit [Figure 80-40-6] to the ON
position and follow the on screen instructions.
NOTE: The A/C system holds 0,68 kg (1.5 lb) of
refrigerant.
Figure 80-40-7
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they may vary
slightly depending on the model and brand of
reclaimer used.
P-90374
1
P-90373
2
3
N-22292
N-22381
80-40-4 S650 Service Manual
80-50-1 S650 Service Manual
COMPRESSOR
Removal And Installation
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.)
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)
Open the rear door.
Figure 80-50-1
Disconnect the loader harness (Item 1) [Figure 80-50-1]
from the compressor clutch wire.
Figure 80-50-2
Remove the compressor mount bolt (Item 1) and the belt
(Item 2) [Figure 80-50-2].
Installation: Tighten the compressor mount bolt to 46
N•m (34 ft-lb) torque.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-50-3
Remove the compressor hoses (Item 1) [Figure 80-50-3]
from the compressor.
Installation: Tighten the compressor hoses to 29,8 N•m
(22 ft-lb) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
Figure 80-50-4
Remove the compressor mount bolts and nuts (Item 1)
[Figure 80-50-4].
Remove the compressor from the loader.
P-90357
1
P-89538
1
2
P-89543
1
P-89534
1
1
80-50-2 S650 Service Manual
COMPRESSOR (CONT'D)
Oil
Figure 80-50-5
The compressor (Item 1) [Figure 80-50-5] is factory filled
with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the
compressor oil in the following cases:
• When ever the evaporator, condenser or receiver-
drier is replaced.
• Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added
to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 100 oil should be used, and never
mix R-12 and R-134a Oils. 
The compressor oil should be checked as follows when
oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-40-1.)
Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200
RPM.
Remove the compressor from the loader. (See Removal
And Installation on Page 80-50-1.)
P-90486
1
80-50-3 S650 Service Manual
COMPRESSOR (CONT'D)
Oil Check
Figure 80-50-6
Figure 80-50-7
Remove the oil drain plug (Item 1) [Figure 80-50-6] and
drain the oil through the connectors and the oil drain hole
[Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4
- 10.8 ft-lb) torque.
Figure 80-50-8
NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
8] several times by hand.
Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor
oil, replace the complete compressor
assembly.
Figure 80-50-9
Add new compressor oil through the suction side
connector (Item 1) [Figure 80-50-9].
Installation: Add 150 - 170 cc's of PAG 100 oil.
NOTE: The suction port on the compressor is marked
with an SUC and is the larger port on the
compressor.
P-90487
1
P-16534A
P-90486
1
P-90487
1
80-50-4 S650 Service Manual
80-60-1 S650 Service Manual
CONDENSER
Removal And Installation
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.)
Remove the rear grille. (See Removal And Installation on
Page 50-60-1.)
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-2.)
Figure 80-60-1
Remove the two brackets (Item 1) [Figure 80-60-1].
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-60-2
Disconnect the hose (Item 1) [Figure 80-60-2] that
routes from the condenser to the receiver / dryer.
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-60-3
Disconnect the hose (Item 1) [Figure 80-60-3] that
routes from the condenser to the compressor.
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Remove the condenser.
P-85824
11
P-89546
1
P-89548
1
80-60-2 S650 Service Manual
80-70-1 S650 Service Manual
RECEIVER / DRIER
Receiver / Drier 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.
W-2059-0598
Remove the rear grille. (See Removal And Installation on
Page 50-60-1.)
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-2.)
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-70-1
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]
for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]
from the receiver / drier.
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
NOTE: When replacing a receiver / drier in an A/C
system 30 in
3
(1 fl oz) of PAG 100 oil must be
added to the system when recharging.
Figure 80-70-2
Note the flow direction on the receiver / drier (Item 1)
[Figure 80-70-2] for proper installation.
P-90488
1
1
P-90493
1
80-70-2 S650 Service Manual
RECEIVER / DRIER (CONT’D)
Receiver / Drier Removal And Installation (Cont’d)
Figure 80-70-3
Loosen the two clamps (Item 1) and remove the receiver
/ drier (Item 2) [Figure 80-70-3].
Figure 80-70-4
Remove the two mount bolts (Item 1) [Figure 80-70-4]
from the receiver / drier mount bracket.
Pressure Relief Valve Removal And Installation
Figure 80-70-5
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Figure 80-70-6
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
3,7 MPa (36,9 bar) (535 psi).
This will cause the A/C system to shut down, saving the
compressor.
The pressure relief valve is a secondary protection
device in the A/C system, with the pressure switch
shutting down the system at 2,6 MPa (26,5 bar) (384 psi).
NOTE:  If a pressure relief valve is found open, check
the A/C system for problems. Replace the
complete receiver / drier unit.
P-92665
1
2
P-89521
1
N-22205
1
N-22206
80-70-3 S650 Service Manual
RECEIVER / DRIER (CONT’D)
Pressure Switch Removal And Installation
Figure 80-70-7
Disconnect the loader wire harness (Item 1) [Figure 80-
70-7] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without
evacuating the A/C system.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-70-8
Remove the pressure switch (Item 1) [Figure 80-70-8]
from the A/C high pressure hose.
Remove the pressure switch from the loader.
P-90361
1
P-90488
1
80-70-4 S650 Service Manual
RECEIVER / DRIER (CONT’D)
Schraeder Valve Removal And Installation
Figure 80-70-9
The schraeder valve (Item 1) [Figure 80-70-9] is located
in the A/C high pressure hose and is located under the
pressure switch.
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-2.)
Remove the pressure switch.
With a schraeder valve removal tool, remove the valve
from the hose.
N-22166
1
80-80-1 S650 Service Manual
EVAPORATOR / HEATER UNIT
Removal And Installation
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.)
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 80-80-1
Disconnect the expansion / heater unit wiring (Item 1)
[Figure 80-80-1].
Figure 80-80-2
NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the
system.
Remove the two hoses (Item 1) [Figure 80-80-2].
Figure 80-80-3
NOTE: Support the evaporator / heater unit before
removing the mounting hardware.
Remove the two bolts (Item 1) [Figure 80-80-3].
Remove the two nuts (Item 2) [Figure 80-80-3].
Figure 80-80-4
Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)
torque.
Remove the two bolts (Item 2) [Figure 80-80-4].
Remove the two nuts (Item 3) [Figure 80-80-4].
Remove evaporator / heater unit from the loader.
P-90363
1
1
P-90423
1
P-90421
1
2
2
P-90422
3
3
2
1
80-80-2 S650 Service Manual
80-90-1 S650 Service Manual
THERMOSTAT
Description
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil
temperature and cycles the compressor clutch to
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 
NOTE: The EDT has a six second delay before start
up to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil
temperature is above 2°C (35.6°F). If the EDT does not
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator
temperature is below -2°C (28.4°F), the EDT will turn off
the clutch and status LED. 
Figure 80-90-1
When the EDT detects an open or short from the
temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground. 
NOTE: The EDT will attempt to restart every 20
seconds until the fault is repaired.
The EDT has the following protection built in:
1. Over temperature
2. Over current from clutch output
3. Voltage (Above and below operational limits or
reverse voltage)
4. Short circuit protection (Output shorted to ground)
5. Temperature sensor open and short detection
P-90576
1
MALFUNCTION
DETECTION 
INTERVAL
STATUS LED
Temperature 
sensor
Continuous 1x per second
Temperature 
sensor open and 
short detection
At A/C start up 2x per second
Compressor 
clutch short to 
battery
Continuous 3x per second
80-90-2 S650 Service Manual
THERMOSTAT (CONT’D)
Removal And Installation
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.)
NOTE: The thermostat can be changed without
evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown
removed for photo clarity.
Figure 80-90-2
Remove the nine screws (Item 1) and cover (Item 2)
[Figure 80-90-2].
Figure 80-90-3
Remove the three screws (Item 1) and left cover (Item 2)
[Figure 80-90-3].
Figure 80-90-4
Remove the thermostat probe (Item 1) [Figure 80-90-4]
from the A/C evaporator coil.
Figure 80-90-5
Remove the thermostat (Item 1) from the evaporator /
heater unit [Figure 80-90-5].
P-92606
1
2
P-92603
1
2
P-92613
1
P-92609
1
80-100-1 S650 Service Manual
EXPANSION VALVE
Removal And Installation
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.)
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-100-1
Remove the two A/C hoses (Item 1) [Figure 80-100-1]
from the expansion valve.
Installation: Tighten the two A/C hose fittings to 29,8
N•m (22 ft-lb) torque.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Figure 80-100-2
NOTE: The evaporator / heater unit is removed for
photo clarity.
Remove the four screws (Item 1) and the cover (Item 2)
[Figure 80-100-2].
Figure 80-100-3
Remove the five screws (Item 1) and the cover (Item 2)
[Figure 80-100-3].
P-92659
1
P-90416
2
1
1
1
1
P-90417
2
1
1
1
1
80-100-2 S650 Service Manual
EXPANSION VALVE (CONT'D)
Removal And Installation (Cont'd)
Figure 80-100-4
Remove the two evaporator fittings (Item 1) [Figure 80-
100-4] from the expansion valve.
Installation: Tighten the two evaporator fittings to 29,8
N•m (22 ft-lb) torque.
Remove the two mount bolts (Item 2) [Figure 80-100-4].
Remove the expansion valve from the loader.
Cap and plug the evaporator tubelines (Item 1) [Figure
80-100-4] and the expansion valve fittings with the
proper A/C caps and plugs.
Figure 80-100-5
The expansion valve [Figure 80-100-5] is replaced as a
complete unit.
P-90418
2
1
N-22085
80-110-1 S650 Service Manual
EVAPORATOR COIL
Removal And Installation
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.)
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)
NOTE: The evaporator / heater unit is removed for
photo clarity.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-110-1
NOTE: The evaporator / heater unit is removed for
photo clarity.
Remove the four screws (Item 1) and the cover (Item 2)
[Figure 80-110-1].
Figure 80-110-2
Remove the five screws (Item 1) and the cover (Item 2)
[Figure 80-110-2].
Figure 80-110-3
Disconnect the two evaporator fittings (Item 1) [Figure
80-110-3] from the expansion valve.
Installation: Tighten the two evaporator fittings to 29,8
N•m (22 ft-lb) torque.
Cap and plug the evaporator tubelines (Item 1) [Figure
80-110-3] and the expansion valve fittings with the proper
A/C caps and plugs.
P-90416
2
1
1
1
1
P-90417
2
1
1
1
1
P-90418
1
80-110-2 S650 Service Manual
EVAPORATOR COIL (CONT'D)
Removal And Installation (Cont'd)
Figure 80-110-4
Remove the thermostat probe (Item 1) [Figure 80-110-4]
from the evaporator coil.
Remove the two retaining clips (Item 2) [Figure 80-110-
4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil (Item 3) [Figure 80-110-4].
Figure 80-110-5
Inspect the evaporator coil [Figure 80-110-5] for leaks,
and replace as needed.
Clean with low pressure water or air.
P-90420A
1
2
2
3
P-90424
80-120-1 S650 Service Manual
HEATER COIL
Removal And Installation
Remove the evaporator coil (If equipped with A/C). (See
Removal And Installation on Page 80-110-1.)
Remove the heater valve. (See Removal And Installation
on Page 80-140-1.)
NOTE: The evaporator / heater unit is removed for
photo clarity.
Figure 80-120-1
Remove the nine screws (Item 1) and the cover (Item 2)
[Figure 80-120-1].
Figure 80-120-2
Remove the three screws (Item 1) and cover (Item 2)
[Figure 80-120-2].
Remove the two screws (Item 3) [Figure 80-120-2].
Figure 80-120-3
Remove the three screws (Item 1) and cover (Item 2)
[Figure 80-120-3].
Remove the tie strap and move the wire harness (Item 3)
[Figure 80-120-3] off to the side.
Figure 80-120-4
Remove the five screws (Item 1) and cover (Item 2)
[Figure 80-120-4].
P-90419A
1
2
P-90439
3
1
2
P-90440
1
3
2
P-90445
1
1
1
1
2
80-120-2 S650 Service Manual
HEATER COIL (CONT'D)
Removal And Installation (Cont'd)
Figure 80-120-5
Remove the bolt, spacer, and nut (Item 1) [Figure 80-
120-5].
Remove the heater coil from the unit.
Figure 80-120-6
The heater coil [Figure 80-120-6] can be cleaned with
low pressure air or water.
P-90441
1
P-90443
80-130-1 S650 Service Manual
BLOWER FAN
Removal And Installation
Remove the evaporator / heater unit. (See Removal And
Installation on Page 80-120-1.)
Remove the heater coil. (See Removal And Installation
on Page 80-120-1.)
Figure 80-130-1
Remove the two screws (Item 1) [Figure 80-130-1].
Remove the blower fan (Item 2) [Figure 80-130-1] from
the evaporator / heater unit.
Disassembly And Assembly
Figure 80-130-2
Remove the eight screws (Item 1) [Figure 80-130-2]
from the blower wheel cover.
Remove the two screws (Item 2) [Figure 80-130-2] from
the resistor.
Figure 80-130-3
Remove the outside rings (Item 1) and the blower wheel
cover (Item 2) [Figure 80-130-3].
Repeat for other side.
Inspect the outside rings and blower wheel covers for
wear and replace as needed [Figure 80-130-3].
P-90457
1
1
2
P-90458
1
2
2
1
P-90465
2
1
80-130-2 S650 Service Manual
BLOWER FAN (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 80-130-4
NOTE: Mark the wires for proper installation. 
Remove the two wires (Item 1) [Figure 80-130-4] from
the blower motor.
Figure 80-130-5
Remove the screw (Item 1) [Figure 80-130-5] from the
bottom side of the blower motor.
Remove the blower motor from the blower housing.
Figure 80-130-6
Check the blower housing and blower motor mount for
wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
Remove the blower wheel outside clamp (Item 1) [Figure
80-130-7] from the blower wheel.
P-90459
1
1
P-90460
1
P-90463
P-90461
1
80-130-3 S650 Service Manual
BLOWER FAN (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 80-130-8
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-
8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)
[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.
P-90462
1
3
2
4
80-130-4 S650 Service Manual
80-140-1 S650 Service Manual
HEATER VALVE
Removal And Installation
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.)
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly.
Remove any tie-straps that hold the heater hoses.
NOTE: The evaporator / heater unit is shown
removed for photo clarity.
Figure 80-140-1
NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-
1].
Remove the heater hose.
Disconnect the loader wiring harness (Item 2) [Figure
80-140-1] from the heater valve.
Remove the nut (Item 3) [Figure 80-140-1] from the
heater valve mount.
Figure 80-140-2
NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-
2].
Remove the heater hose from the heater valve.
Remove the nut (Item 2) [Figure 80-140-2] from the
heater valve mount.
Remove heater hose clamp (Item 3) and the heater valve
(Item 4) [Figure 80-140-2] from the evaporator / heater
unit.
P-90414
1
2
3
P-90415
3
1
2
4
80-140-2 S650 Service Manual
SPEC-01 S650 Service Manual
SPECIFICATIONS
(S650) LOADER SPECIFICATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tires  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General SAE Bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS  . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
SPEC-02 S650 Service Manual
SPEC-10-1 S650 Service Manual
(S650) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 74 inch Construction & Industrial bucket and may
vary with other bucket types. All dimensions are shown in millimeters. Respective imperial dimensions are given in
inches enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.
NA-1660
(72.1 in)
1832 mm
(59.3 in)
1507 mm
(82.9 in)
2106 mm
(74 in)
1880 mm
(124 in)
3149 mm
(96.3 in)
2447 mm
800 mm
(31.5 in)
42°
97°
31.1°
25.2°
(158.5 in)
4026 mm
(81.3 in)
2065 mm
(8.1 in)
207 mm
(45.3 in)
1150 mm
(108.4 in)
2753 mm
(136.8 in)
3474 mm
SPEC-10-2 S650 Service Manual
(S650) LOADER SPECIFICATIONS (CONT’D)
Performance
Engine
Drive System
Rated Operating Capacity 1220 kg (2690 lb)
with 200 Pound Frame Mounted
Counterweight Kit
1288 kg (2840 lb)
with 300 Pound Frame Mounted
Counterweight Kit
1311 kg (2890 lb)
Tipping Load 2440 kg (5380 lb)
Operating Weight 3777 kg (8327 lb)
Breakout Force - Lift 2177 kg (4800 lb)
Breakout Force - Tilt 2313 kg (5100 lb)
Push Force 2087 kg (4600 lb)
Travel Speed
- Single Speed Loader
- Two-Speed Loader (Opt.) Low/High
0 - 11,4 km/h (0 - 7.1 mph)
0 - 11,4 km/h (0 - 7.1 mph) / 0 - 19,8 km/h (0 - 12.3 mph)
Make / Model Kubota / V3307-DI-TE3 Interim Tier IV
Fuel / Cooling Diesel / Liquid
Horsepower
- ISO 9249 EEC / SAE J1349 Net
- ISO 14396 Gross
- SAE 1995 Gross
52,4 kW (70.3 hp) @ 2400 rpm
54,6 kW (73.2 hp) @ 2400 rpm
55,4 kW (74.3 hp) @ 2400 rpm
Torque
- ISO 9249 EEC / SAE J1349 Net
- SAE 1995 Gross
253,1 N•m (186.7 lb-ft) @ 1600 rpm
264,4 N•m (195.0 lb-ft) @ 1600 rpm
Low Idle RPM 1250 - 1450
High Idle RPM 2525 - 2650
Number of Cylinders 4
Displacement
3,3 L (203 in
3
)
Bore / Stroke 94 / 120 mm (3.70 / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Main Drive Fully hydrostatic, 4-wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing 
hydrostatic motors
Final Drive Pre-stressed #120 HSOC endless roller chain (no master link) and sprockets in 
sealed chaincase with oil lubrication (Chains do not require periodic 
adjustments) Two chains per side with no idler sprocket
Axle Size 68,6 mm (2.70 in), Heat treated
Wheel Bolts Eight - 9/16 in Wheel bolts fixed to axle hubs
SPEC-10-3 S650 Service Manual
(S650) LOADER SPECIFICATIONS (CONT’D)
Controls
Hydraulic System
Vehicle Steering Direction and speed controlled by two hand operated steering levers or optional 
joystick(s)
Loader Hydraulics
- Lift and Tilt
- Front Auxiliary
- Rear Auxiliary (Option)
Controlled by separate foot pedals or optional Advanced Control System (ACS) 
or optional Selectable Joystick Controls (SJC)
Controlled by electrical switch on Right Hand steering lever or joystick
Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control, additional foot operated speed control pedal with SJC 
option, key-type start switch or optional keyless start panel or optional Deluxe 
Instrumentation Panel and function error shutdown.
Starting Aid Glow plugs automatically activated as needed by Instrument Panel
Service Brake Two independent hydrostatic systems controlled by two hand operated steering 
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Mechanical disc, manually operated switch on left instrument panel
Parking Brake (Two-Speed Option) Spring applied pressure release multi-disk brake activated by manually operated 
switch on left instrument panel
Pump Type Engine driven, gear type
Pump Capacity - Standard 87,1 L/min (23.0 U.S. gpm)
Pump Capacity - High-Flow Option 115,5 L/min (30.5 U.S. gpm)
System Relief at Quick Couplers 23,8 - 24,5 MPa (237,8 - 244,7 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders
Bore Diameter:Lift Cylinder (2)
Tilt Cylinder (2)
Rod Diameter:Lift Cylinder (2)
Tilt Cylinder (2)
Stroke:Lift Cylinder (2)
Tilt Cylinder (2)
Double-acting; tilt cylinders have cushioning feature on dump and rollback
63,5 mm (2.50 in)
76,2 mm (3.00 in)
44,5 mm (1.75 in)
41,4 mm (1.63 in)
860,3 mm (33.87 in)
354,8 mm (13.97 in)
Control Valve - Standard 3-Spool, open center, manually operated with spring detent for lift float and 
electrically controlled auxiliary spool
Control Valve - ACS and SJC 3-Spool, open center with electric actuator controlled lift with float and tilt. 
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic 
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms
Lower Lift Arms
Bucket Dump
Bucket Rollback
3.4 Seconds
3.0 Seconds
2.3 Seconds
1.7 Seconds
SPEC-10-4 S650 Service Manual
(S650) LOADER SPECIFICATIONS (CONT’D)
Electrical System
Capacities
Tires
Alternator Belt driven, 90 amps, open frame
Battery 12 volts, 950 cold cranking amps @ -18°C (0°F),
180 Minute reserve capacity @ 25 amps
Starter 12 volts, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction, 
Hydraulic System Malfunction, General Warning.
Indicators:
BICS Functions, Two-Speed, 3-Point Shoulder Belt, Turn Signals, Engine 
Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock 
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown, 
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure; 
System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, 
Attachment Control Information, Password Lockout, Multi-language Display, 
Help Screens, Diagnostic Capability and Engine / Hydraulic Systems Shutdown 
Function.
Fuel 103,1 L (27.2 U.S. gal)
Engine Oil with Filter Change 11,4 L (12.0 qt.)
Engine Cooling System
with Heater
without Heater
11,4 L (3.0 U.S. gal)
11,7 L (3.1 U.S. gal)
Hydraulic / Hydrostatic Reservoir 10,2 L (2.7 U.S. gal)
Hydraulic / Hydrostatic System 45,0 L (11.9 U.S. gal)
Chaincase Reservoir 39,2 L (10.35 U.S. gal)
Heavy Duty (Standard) 12.00 x 16.5, 12 Ply Rating
Heavy Duty Offset (Option) 12.00 x 16.5, 12 Ply Rating
Heavy Duty Poly Fill (Option) 12.00 x 16.5, 12 Ply Rating
Severe Duty (Option) 12.00 x 16.5, 12 Ply Rating
Severe Duty Poly Fill (Option) 12.00 x 16.5, 12 Ply Rating
Solidflex (Option) 33 x 6 x 11
Super Float Offset (Option) 33 x 15.50 - 16.5, 12 Ply Rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT 
mix brands of tires used on the same loader.
SPEC-20-1 S650 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
Thread
size
sae grade 5 sae grade 8
N•m
(in-lb)
0.250 9,0 - 10,2
(80 - 90)
12,4 - 13,6
(110 - 120)
0.3125 20,3 - 22,6
(180 - 200)
24,2 - 27,1
(215 - 240)
N•m
(ft-lb)
0.375 34 - 38
(25 - 28)
47 - 54
(35 - 40)
0.4375 54 - 61
(40 - 45)
81 - 88
(60 - 65)
0.500 88 - 95
(65 - 70)
122 - 136
(90 - 100)
0.5625 122 - 136
(90 - 100)
170 - 190
(125 - 140)
0.625 170 - 190
(125 - 140)
240 - 260
(175 - 190)
0.750 300 - 330
(220 - 245)
410 - 450
(300 - 330)
0.875 450 - 490
(330 - 360)
645 - 710
(475 - 525)
1.000 645 - 710
(475 - 525)
985 - 1085
(725 - 800)
1.125 880 - 975
(650 - 720)
1425 - 1600
(1050 - 1175)
1.250 1200 - 1360
(900 - 1000)
2000 - 2200
(1475 - 1625)
1.375 1630 - 1830
(1200 - 1350)
2720 - 2980
(2000 - 2200)
1.500 2040 - 2240
(1500 - 1650)
3530 - 3870
(2600 - 2850)
1.625 2720 - 2980
(2000 - 2800)
4680 - 5150
(3450 - 3800)
1.750 3390 - 3730
(2500 - 2750)
5830 - 6500
(4300 - 4800)
1.875 4270 - 4750
(3150 - 3500)
7450 - 8300
(5500 - 6100)
2.000 5150 - 5700
(3800 - 4200)
8800 - 9800
(6500 - 7200)
SPEC-20-2 S650 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE
(DIA. X PITCH)
MATERIAL
HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m
(6 - 7 ft-lb)
8 - 12 N•m
(6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m
(6 - 9 ft-lb)
15 - 22 N•m
(11 - 16 ft-lb)
24 - 34 N•m
(18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m
(13 - 18 f.-lb)
30 - 41 N•m
(22 - 30 ft-lb)
49 - 68 N•m
(36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m
(22 - 30 ft-lb)
54 - 73 N•m
(40 - 54 ft-lb.
94 - 118 N•m
(69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m
(36 - 50 ft-lb)
79 - 108 N•m
(58 - 80 ft-lb)
157 - 186 N•m
(116 - 137 ft-lb)
SPEC-30-1 S650 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-30-1
Lubricate the O-ring before installing the fitting. Loosen
the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-30-
1].
Figure SPEC-30-2
O-ring Boss
Tightening Torque
x
x
Thread Size
TORQUE
N•m
(ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)
A-1852
Nut
Washer
O-ring
Nut
Washer
O-ring
SPEC-30-2 S650 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS 
(CONT’D)
Flare Fitting
Figure SPEC-30-3
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-30-4] to find the correct
tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-30-4
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will
restrict flow and cause heat.
Replace hoses which show signs of wear, damage or
weather cracked rubber.
Always use two wrenches when loosening and tightening
hose or tubeline fittings.
Flare Fitting Tightening Torque
Tubeline
Outside
Diameter
x
x
Thread Size
TORQUE
N•m
(ft.-lb.)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)
P-85926
SPEC-40-1 S650 Service Manual
HYDRAULIC / HYDROSTATIC FLUID 
SPECIFICATIONS
Specifications
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
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.)
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
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
When temperatures below -18°C (0°F) are common, the
loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.
WARNING
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the
hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
SPEC-40-2 S650 Service Manual
SPEC-50-1 S650 Service Manual
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SPEC-50-2 S650 Service Manual
INDEX-01 S650 Service Manual
ALPHABETICAL INDEX
(S650) LOADER SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
ACCESS PANEL (INSIDE) (SJC)  . . .50-121-1
ACCESS PANEL (INSIDE) . . . . . . . . .50-120-1
AIR CLEANER SERVICE . . . . . . . . . . .10-80-1
AIR CLEANER . . . . . . . . . . . . . . . . . . .70-40-1
AIR CONDITIONING SYSTEM FLOW .80-10-1
ALTERNATOR  . . . . . . . . . . . . . . . . . . .60-30-1
ARMREST  . . . . . . . . . . . . . . . . . . . . .50-150-1
BACK-UP ALARM SYSTEM  . . . . . . .60-210-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . .60-20-1
BLOWER FAN  . . . . . . . . . . . . . . . . . .80-130-1
BOBCAT CONTROLLER (ACS)  . . . . .60-71-1
BOBCAT CONTROLLER (SJC) (DRIVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-72-1
BOBCAT CONTROLLERS (GATEWAY AND 
AUXILIARY) . . . . . . . . . . . . . . . . . . . . .60-70-1
BOBCAT INTERLOCK CONTROL SYSTEM 
(BICS) . . . . . . . . . . . . . . . . . . . . . . . . .60-100-1
BOB-TACH (HAND LEVER) . . . . . . . .10-140-1
BOB-TACH (HAND LEVER) . . . . . . . . .50-40-1
BOB-TACH (POWER) BLOCK . . . . . .20-120-1
BOB-TACH (POWER)  . . . . . . . . . . . .10-141-1
BOB-TACH (POWER)  . . . . . . . . . . . . .50-41-1
BRAKE (SINGLE SPEED) . . . . . . . . . .40-10-1
BRAKE (TWO-SPEED)  . . . . . . . . . . . . 40-11-1
BUCKET POSITION VALVE  . . . . . . .20-100-1
CAB DOOR  . . . . . . . . . . . . . . . . . . . .50-140-1
CALIBRATION  . . . . . . . . . . . . . . . . . .60-160-1
CAMSHAFT AND TIMING GEARS  . .70-100-1
CHAINCASE  . . . . . . . . . . . . . . . . . . . .40-30-1
CHARGE PRESSURE . . . . . . . . . . . . .30-40-1
COMPRESSOR . . . . . . . . . . . . . . . . . .80-50-1
CONDENSER  . . . . . . . . . . . . . . . . . . .80-60-1
CONTROL HANDLE / LEVER (ACS) . 50-111-1
CONTROL HANDLE / LEVER (SJC) . 50-112-1
CONTROL HANDLE / LEVER . . . . . . 50-110-1
CONTROL PANEL (SJC) . . . . . . . . . .50-101-1
CONTROL PANEL SETUP  . . . . . . . .60-180-1
CONTROL PANEL . . . . . . . . . . . . . . .50-100-1
CONTROL PEDALS AND LINKAGES (ACS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-91-1
CONTROL PEDALS AND LINKAGES .50-90-1
CONTROL SYSTEM (ACS) . . . . . . . .60-130-1
CONVERSIONS . . . . . . . . . . . . . . .SPEC-50-1
CRANKSHAFT AND PISTONS  . . . . . .70-90-1
CYLINDER (BOB-TACH)  . . . . . . . . . . .20-22-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
CYLINDER HEAD  . . . . . . . . . . . . . . . .70-80-1
DELIVERY REPORT  . . . . . . . . . . . . . . . . 1-15
DIAGNOSTIC SERVICE CODES . . . . .60-90-1
DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-80-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-60-1
DRIVE COMPONENTS  . . . . . . . . . . . .40-20-1
ELECTRICAL / HYDRAULIC CONTROLS 
(ACS)  . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
ELECTRICAL / HYDRAULIC CONTROLS 
(SJC)  . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
ELECTRICAL / HYDRAULIC CONTROLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
ELECTRICAL SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
EMERGENCY EXIT . . . . . . . . . . . . . .10-210-1
ENGINE COOLING SYSTEM  . . . . . . .10-90-1
ENGINE COOLING SYSTEM  . . . . . . .70-50-1
ENGINE INFORMATION  . . . . . . . . . . .70-10-1
ENGINE LUBRICATION SYSTEM . . .10-110-1
ENGINE SPEED CONTROL (SJC) S/N 
A3NV12469 AND BELOW & S/N A3NW11130 
AND BELOW  . . . . . . . . . . . . . . . . . . . .70-21-1
ENGINE SPEED CONTROL (SJC) S/N 
A3NV12470 AND ABOVE & S/N A3NW11131 
AND ABOVE . . . . . . . . . . . . . . . . . . . . .70-22-1
ENGINE SPEED CONTROL  . . . . . . . .70-20-1
EVAPORATOR / HEATER UNIT . . . . . .80-80-1
EVAPORATOR COIL  . . . . . . . . . . . . .80-110-1
EXHAUST GAS RECIRCULATION (EGR) 
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
FINAL DRIVE TRANSMISSION 
(CHAINCASE)  . . . . . . . . . . . . . . . . . .10-130-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
FLYWHEEL AND HOUSING  . . . . . . .70-120-1
FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
FOREWORD  . . . . . . . . . . . . . . . . . . . . . . . 1-7
FRONT AUXILIARY HYDRAULIC COUPLER 
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
INDEX-02 S650 Service Manual
FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1
FUEL SYSTEM  . . . . . . . . . . . . . . . . .10-100-1
FUEL SYSTEM  . . . . . . . . . . . . . . . . . .70-70-1
FUEL TANK  . . . . . . . . . . . . . . . . . . . . .50-80-1
HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1
HEATER COIL  . . . . . . . . . . . . . . . . . .80-120-1
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1
HYDRAULIC / HYDROSTATIC FILTERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
HYDRAULIC / HYDROSTATIC FLUID 
SPECIFICATIONS  . . . . . . . . . . . . .SPEC-40-1
HYDRAULIC CONNECTION 
SPECIFICATIONS  . . . . . . . . . . . . .SPEC-30-1
HYDRAULIC CONTROL VALVE (ACS) OR 
(SJC)  . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
HYDRAULIC CONTROL VALVE (STANDARD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1
HYDRAULIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
HYDRAULIC/HYDROSTATIC SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
HYDROSTATIC DRIVE MOTOR (TWO-
SPEED)  . . . . . . . . . . . . . . . . . . . . . . . .30-21-1
HYDROSTATIC DRIVE MOTOR  . . . . .30-20-1
HYDROSTATIC MOTOR CARRIER (SJC)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31-1
HYDROSTATIC MOTOR CARRIER . . .30-30-1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-51-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1
HYDROSTATIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1
LEFT SIDE LOWER PANEL  . . . . . . .50-160-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1
LIFT ARM SUPPORT DEVICE  . . . . . .10-20-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1
LIFTING AND BLOCKING THE LOADER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
LIGHTS  . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16
LOADER STORAGE AND RETURN TO 
SERVICE  . . . . . . . . . . . . . . . . . . . . . .10-190-1
LUBRICATING THE LOADER . . . . . .10-150-1
LUBRICATION SYSTEM  . . . . . . . . . . .70-60-1
MAIN RELIEF VALVE . . . . . . . . . . . . .  20-30-1
MAINTENANCE CLOCK  . . . . . . . . .  60-200-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . 1-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .  70-30-1
OIL COOLER  . . . . . . . . . . . . . . . . . . .  20-90-1
OPERATOR CAB . . . . . . . . . . . . . . . .  10-30-1
OPERATOR CAB . . . . . . . . . . . . . . . .  50-20-1
OPERATOR SEAT (SUSPENSION) . .  50-31-1
OPERATOR SEAT  . . . . . . . . . . . . . . .  50-30-1
PASSWORD SETUP (DELUXE 
INSTRUMENTATION PANEL)  . . . . .  60-190-1
PASSWORD SETUP (KEYLESS START 
PANEL) . . . . . . . . . . . . . . . . . . . . . . .  60-191-1
PIVOT PINS  . . . . . . . . . . . . . . . . . . .  10-180-1
REAR AUXILIARY DIVERTER VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
REAR DOOR (TAILGATE)  . . . . . . . . .  50-70-1
REAR GRILLE  . . . . . . . . . . . . . . . . . .  50-60-1
RECEIVER / DRIER . . . . . . . . . . . . . .  80-70-1
REGULAR MAINTENANCE . . . . . . . .  80-20-1
REMOTE START TOOL (SERVICE TOOL) KIT 
- 7003031  . . . . . . . . . . . . . . . . . . . . . .  10-61-1
REMOTE START TOOL KIT-MEL1563 10-60-1
RIGHT SIDE LOWER PANEL  . . . . .  50-170-1
SAFETY INSTRUCTIONS  . . . . . . . . . . . . 1-10
SEAT BAR SENSOR  . . . . . . . . . . . . .60-110-1
SEAT BAR  . . . . . . . . . . . . . . . . . . . . .  50-10-1
SEAT BELT . . . . . . . . . . . . . . . . . . . .  10-220-1
SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
SERVICE MANUAL REVISION  . . . . . . SMR-1
SERVICE PC (LAPTOP COMPUTER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60-150-1
SERVICE SCHEDULE . . . . . . . . . . . .  10-70-1
SPARK ARRESTOR MUFFLER . . . .  10-170-1
SPEED SENSORS (SJC) . . . . . . . . . .  60-80-1
STARTER . . . . . . . . . . . . . . . . . . . . . .  60-40-1
STEERING DRIFT COMPENSATION 60-161-1
STOPPING THE ENGINE AND LEAVING THE 
LOADER . . . . . . . . . . . . . . . . . . . . . .  10-200-1
SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80-40-1
THERMOSTAT . . . . . . . . . . . . . . . . . .  80-90-1
TIRE MAINTENANCE  . . . . . . . . . . .  10-160-1
TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
TOWING THE LOADER . . . . . . . . . . .  10-50-1
INDEX-03 S650 Service Manual
TRACTION LOCK  . . . . . . . . . . . . . . .60-120-1
TRANSPORTING LOADER ON A TRAILER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1
TROUBLESHOOTING . . . . . . . . . . . . .80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-110-1
TWO-SPEED / BRAKE VALVE  . . . . . .30-70-1
WINDOW (REAR)  . . . . . . . . . . . . . . .50-130-1
WINDOW (SIDE)  . . . . . . . . . . . . . . . .50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . .50-131-1
INDEX-04 S650 Service Manual
SMR-1 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 1
Date: 15 July 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (7-09)
The following Sections are a revision to the above Service Manual.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
COVER
70-10
Insert This Sheet With The Below Listed Manual For Future Reference
.
NOTICE
SMR-2 S650 Service Manual
SMR-3 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 2
Date: 15 August 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (8-09)
S630 Service Manual (P/N 6987168) Dated 8-09 contains updated service information which replaces the previous
S630 Service Manual (P/N 6987168) Dated 7-09.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference
.
NOTICE
SMR-4 S650 Service Manual
SMR-5 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 3
Date: 15 September 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (9-09)
The following Sections are a revision to the above Service Manual.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
COVER
20-10
20-20
30-10
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.
NOTICE
SMR-6 S650 Service Manual
SMR-7 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 4
Date: 15 October 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (10-09)
The following Sections are a revision to the above Service Manual.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
COVER 60-01
FORWARD 60-50
60-90
10-30 60-130
10-150 60-140
10-200 60-141
10-210 60-142
60-150
20-80 60-160
60-190
50-01 60-191
50-20 60-200
50-80 60-220
50-150
50-160 70-40
50-170
50-180 SPEC-10
ALPHABETICAL INDEX
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.
NOTICE
SMR-8 S650 Service Manual
SMR-9 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 5
Date: 15 December 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (12-09)
The following Sections are a revision to the above Service Manual.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
COVER
10-100
20-120
30-20
30-21
50-70
50-91
50-120
60-50
60-60
60-130
70-20
70-21 ADDED
70-70
SPEC-10
SPEC-40
ALPHABETICAL INDEX
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.
NOTICE
SMR-10 S650 Service Manual
SMR-11 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 6
Date: 15 June 2010
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (6-10)
The following Sections are a revision to the above Service Manual.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
FRONT COVER
10-20 60-10
10-40 60-20
10-80 60-90
10-90
10-110 70-90
10-120
10-130 SPEC-40
10-170
20-21
20-61
30-30
30-31
50-01
50-20
50-30
50-60
50-112
Insert This Sheet With The Below Listed Manual For Future Reference
.
NOTICE
SMR-12 S650 Service Manual
SMR-13 S650 Service Manual
SERVICE MANUAL 
REVISION
Revision No: S650 - 7
Date: 15 October 2010
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (10-10)
S630 Service Manual (P/N 6987168) Dated 10-10 contains updated service information which replaces the
previous 
S630 Service Manual (P/N 6987168) Dated 6-10.
ROUTE TO 
ATTENTION
PARTS MANAGER
SERVICE MANAGER    X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference
.
NOTICE
SMR-14 S650 Service Manual